David B. Johnston

Comparison of modified dry-grind corn processes for fermentation characteristics and DDGS composition.

ABSTRACT Three different modified dry-grind corn processes, quick germ (QG), quick germ and quick fiber (QGQF), and enzymatic milling (E-Mill) were compared with the conventional dry-grind corn process for fermentation characteristics and distillers dried grains with solubles (DDGS) composition. Significant effects were observed on fermentation characteristics and DDGS composition with these modified dry-grind processes. The QG, QGQF, and E-Mill processes increased ethanol concentration by 8–27% relative to the conventional dry-grind process. These process modifications reduced the fiber content of DDGS from 11 to 2% and increased the protein content of DDGS from 28 to 58%.

Comparison of Enzymatic (E-Mill) and Conventional Dry-Grind Corn Processes Using a Granular Starch Hydrolyzing Enzyme

ABSTRACT A new low temperature liquefaction and saccharification enzyme STARGEN 001 (Genencor International, Palo Alto, CA) with high granular starch hydrolyzing activity was used in enzymatic dry-grind corn process to improve recovery of germ and pericarp fiber before fermentation. Enzymatic dry-grind corn process was compared with conventional dry-grind corn process using STARGEN 001 with same process parameters of dry solid content, pH, temperature, enzyme and yeast usage, and time. Sugar, ethanol, glycerol and organic acid profiles, fermentation rate, ethanol and coproducts yields were investigated. Final ethanol concentration of enzymatic dry-grind corn process was 15.5 ± 0.2% (v/v), which was 9.2% higher than conventional process. Fermentation rate was also higher for enzymatic dry-grind corn process. Ethanol yields of enzymatic and conventional dry-grind corn processes were 0.395 ± 0.006 and 0.417 ± 0.002 L/kg (2.65 ± 0.04 and 2.80 ± 0.01 gal/bu), respectively. Three additional coproducts, germ 8.0...

Comparison of Raw Starch Hydrolyzing Enzyme with Conventional Liquefaction and Saccharification Enzymes in Dry-Grind Corn Processing

ABSTRACT In a conventional dry-grind corn process, starch is converted into dextrins using liquefaction enzymes at high temperatures (90–120°C) during a liquefaction step. Dextrins are hydrolyzed into sugars using saccharification enzymes during a simultaneous saccharification and fermentation (SSF) step. Recently, a raw starch hydrolyzing enzyme (RSH), Stargen 001, was developed that converts starch into dextrins at low temperatures (<48°C) and hydrolyzes dextrins into sugars during SSF. In this study, a dry-grind corn process using RSH enzyme was compared with two combinations (DG1 and DG2) of commercial liquefaction and saccharification enzymes. Dry-grind corn processes for all enzyme treatments were performed at the same process conditions except for the liquefaction step. For RSH and DG1 and DG2 treatments, ethanol concentrations at 72 hr of fermentation were 14.1–14.2% (v/v). All three enzyme treatments resulted in comparable ethanol conversion efficiencies, ethanol yields, and DDGS yields. Sugar pr...

Use of Proteases to Reduce Steep Time and SO2 Requirements in a Corn Wet-Milling Process

ABSTRACT To eliminate the diffusion barriers associated with enzyme addition during conventional steeping, we have developed a two-stage milling procedure to evaluate the effects of enzyme addition on corn wet milling. The current study compares the effects of the addition of commercially available enzyme preparations during conventional steeping to their comparable addition in the two-stage procedure. Results are presented in terms of yields of fiber, starch, germ, and gluten. The results demonstrate that the application of enzymes to the normal steeping step of wet milling is not an effective means of decreasing the steeping time or sulfur dioxide usage. Only when specific enzymes are added to the hydrated ground corn, using the modified two-stage procedure, are enzymes effective in decreasing the steeping time and sulfur dioxide requirements. The overall steeping time with the two-stage modified procedure ranges from 6 to 8 hr, representing a 67–83% reduction over the conventional process. The modified...

Production of ethanol from winter barley by the EDGE (enhanced dry grind enzymatic) process

BackgroundUS legislation requires the use of advanced biofuels to be made from non-food feedstocks. However, commercialization of lignocellulosic ethanol technology is more complex than expected and is therefore running behind schedule. This is creating a demand for non-food, but more easily converted, starch-based feedstocks other than corn that can fill the gap until the second generation technologies are commercially viable. Winter barley is such a feedstock but its mash has very high viscosity due to its high content of β-glucans. This fact, along with a lower starch content than corn, makes ethanol production at the commercial scale a real challenge.ResultsA new fermentation process for ethanol production from Thoroughbred, a winter barley variety with a high starch content, was developed. The new process was designated the EDGE (enhanced dry grind enzymatic) process. In this process, in addition to the normal starch-converting enzymes, two accessory enzymes were used to solve the β-glucan problem. First, β-glucanases were used to hydrolyze the β-glucans to oligomeric fractions, thus significantly reducing the viscosity to allow good mixing for the distribution of the yeast and nutrients. Next, β-glucosidase was used to complete the β-glucan hydrolysis and to generate glucose, which was subsequently fermented in order to produce additional ethanol. While β-glucanases have been previously used to improve barley ethanol production by lowering viscosity, this is the first full report on the benefits of adding β-glucosidases to increase the ethanol yield.ConclusionsIn the EDGE process, 30% of total dry solids could be used to produce 15% v/v ethanol. Under optimum conditions an ethanol yield of 402 L/MT (dry basis) or 2.17 gallons/53 lb bushel of barley with 15% moisture was achieved. The distillers dried grains with solubles (DDGS) co-product had extremely low β-glucan (below 0.2%) making it suitable for use in both ruminant and mono-gastric animal feeds.

Effects of ground corn particle size on ethanol yield and thin stillage soluble solids.

ABSTRACT The effects of ground corn particle size on ethanol yield and soluble solids in thin stillage was evaluated using a 2-L laboratory dry-grind procedure. The procedure was optimized for grinding, liquefaction, sacchari-fication, and fermentation parameters. The optimized procedure was reproducible with a coefficient of variation of 3.6% in ethanol yield. Five particle size distributions of ground corn were obtained using a cross-beater mill equipped with five screens (0.5, 2, 3, 4, and 5 mm). Particle size had an effect on ethanol yield and on soluble solids concentration in thin stillage. The highest ethanol yield of 12.6 mL/100 mL of beer was achieved using a 0.5-mm screen in the cross-beater mill. Treatment using the 0.5-mm mill screen resulted in soluble solids concentration of 25.1 g/L and was higher than soluble solids concentrations obtained with other screens. No differences in soluble solid concentrations were observed in samples of thin stillage obtained from 2, 3, 4, and 5-mm screens whi...

Evaluation and strategies to improve fermentation characteristics of modified dry-grind corn processes.

ABSTRACT New corn fractionation technologies that produce higher value coproducts from dry-grind processing have been developed. Wet fractionation technologies involve a short soaking of corn followed by milling to recover germ and pericarp fiber in an aqueous medium before fermentation of degermed defibered slurry. In dry fractionation technologies, a dry degerm defiber (3D) process (similar to conventional corn dry-milling) is used to separate germ and pericarp fiber before fermentation of the endosperm fraction. The effect of dry and wet fractionation technologies on the fermentation rates and ethanol yields were studied and compared with the conventional dry-grind process. The wet process had the highest fermentation rate. The endosperm fraction obtained from 3D process had lowest fermentation rate and highest residual sugars at the end of fermentation. Strategies to improve the fermentation characteristics of endosperm fraction from 3D process were evaluated using two saccharification and fermentatio...

Fermentation of "Quick Fiber" Produced from a Modified Corn-Milling Process into Ethanol and Recovery of Corn Fiber Oil

Approximately 9% of the 9.7 billion bushels of corn harvested in the United States was used for fuel ethanol production in 2002, half of which was prepared for fermentation by dry grinding. The University of Illinois has developed a modified dry grind process that allows recovery of the fiber fractions prior to fermentation. We report here on conversion of this fiber (Quick Fiber [QF]) to ethanol. QF was analyzed and found to contain 32%wt glucans and 65%wt total carbohydrates. QF was pretreated with dilute acid and converted into ethanol using either ethanologenic Escherichia coli strain FBR5 or Saccharomyces cerevisiae. For the bacterial fermentation the liquid fraction was fermented, and for the yeast fermentation both liquid and solids were fermented. For the bacterial fermentation, the final ethanol concentration was 30 g/L, a yield of 0.44 g ethanol/g of sugar(s) initially present in the hydrolysate, which is 85% of the theoretical yield. The ethanol yield with yeast was 0.096 gal/bu of processed corn assuming a QF yield of 3.04 lb/bu. The residuals from the fermentations were also evaluated as a source of corn fiber oil, which has value as a nutraceutical. Corn fiber oil yields were 8.28%wt for solids recovered following prtetreatment.

Enzymatic corn wet milling: engineering process and cost model

BackgroundEnzymatic corn wet milling (E-milling) is a process derived from conventional wet milling for the recovery and purification of starch and co-products using proteases to eliminate the need for sulfites and decrease the steeping time. In 2006, the total starch production in USA by conventional wet milling equaled 23 billion kilograms, including modified starches and starches used for sweeteners and ethanol production [1]. Process engineering and cost models for an E-milling process have been developed for a processing plant with a capacity of 2.54 million kg of corn per day (100,000 bu/day). These models are based on the previously published models for a traditional wet milling plant with the same capacity. The E-milling process includes grain cleaning, pretreatment, enzymatic treatment, germ separation and recovery, fiber separation and recovery, gluten separation and recovery and starch separation. Information for the development of the conventional models was obtained from a variety of technical sources including commercial wet milling companies, industry experts and equipment suppliers. Additional information for the present models was obtained from our own experience with the development of the E-milling process and trials in the laboratory and at the pilot plant scale. The models were developed using process and cost simulation software (SuperPro Designer®) and include processing information such as composition and flow rates of the various process streams, descriptions of the various unit operations and detailed breakdowns of the operating and capital cost of the facility.ResultsBased on the information from the model, we can estimate the cost of production per kilogram of starch using the input prices for corn, enzyme and other wet milling co-products. The work presented here describes the E-milling process and compares the process, the operation and costs with the conventional process.ConclusionThe E-milling process was found to be cost competitive with the conventional process during periods of high corn feedstock costs since the enzymatic process enhances the yields of the products in a corn wet milling process. This model is available upon request from the authors for educational, research and non-commercial uses.

Fractionation, characterization, and study of the emulsifying properties of corn fiber gum.

Corn fiber gum (CFG) has been fractionated by hydrophobic interaction chromatography on Amberlite XAD-1180 resin using ionic, acidic, basic, and hydrophobic solvents of different polarities. Characterization, including determination of total carbohydrate, acidic sugar, and protein content, has been done for each fraction together with measurements of molar mass, polydispersity, radius of gyration, Mark-Houwink exponent, and intrinsic viscosity using multiangle laser light scattering and online viscosity measurements. Emulsification properties of all fractions in an oil-in-water emulsion system with 20:1 oil to gum ratio were studied by measuring turbidity over 14 days. The results indicate that CFG consists of different components differing in their molecular weights and carbohydrate and protein contents. The main fraction eluted with NaCl, although low in protein content, has the highest average molecular weight and was determined to be a better emulsifier than the other fractions. The unfractionated CFG, which contains different molecular species, is the best emulsifier.