2007 Annual Report 1a.Objectives (from AD-416) The thrust of this project is twofold: . 1)conduct research that will overcome material handling challenges with distillers grains, and. 2)through collaborative efforts with our customers and partners, develop value-added feeds, foods, and industrial materials from these coproducts. Attaining these objectives will provide ethanol processors with new and refined methods for storing and handling distillers grains. Additionally, new market opportunities for these coproducts will be identified and developed. Thus, this project will improve manufacturing economics as well as augment the viability of the fuel ethanol industry. 1b.Approach (from AD-416) Three specific research activities include: . 1)identify, characterize, and quantify specific physical and chemical properties of distillers grains that affect storability and flowability behavior of these coproducts;. 2)develop and evaluate improved processes for converting distillers grains into value-added feed materials;. 3)develop and evaluate processes for converting distillers grains into value-added industrial and food products. 3.Progress Report The studies undertaken this year were aimed at developing new processing and storage methods for fuel ethanol byproducts (primarily DDGS), as well as converting these byproducts into value-added co-products, such as livestock and aquaculture feeds, human foods, and industrial composites, which will thus improve the overall economics of ethanol processing. Research into DDGS flowability has proceeded. The ability of DDGS to dynamically adsorb water, as well as ultimate equilibrium moisture conditions, have been determined for DDGS with a range of soluble levels (10, 15, 20, and 25% db) at several temperatures (10, 20, 30, and 40oC), and relative humidity levels (60, 70, 80, and 90%). Additionally, flowability characteristics have been determined at these conditions. Results indicate that increased soluble levels and moisture contents can decrease flowability behavior, depending on the temperature and humidity conditions used. Research has proceeded, both on a laboratory-scale and on a pilot scale, toward developing extrusion processing methods to produce DDGS-based rations for aquaculture diets, primarily Nile tilapia. More details are provided in the Accomplishments section. Fractionation studies have been conducted with DDGS, including physical separation (sieving) and air classification, in order to determine the feasibility of concentrating nutrients (i.e., protein, fiber, or fat) in specific fractions. Neither of these methods was able to concentrate nutrients according to size or density. Aqueous extraction techniques, however, were successfully used to remove corn oil from the DDGS (reducing crude fat levels from approximately 12% db to less than 2% db), and thus concentrate protein and fiber. The ability to produce DDGS with differing nutritional and chemical characteristics will provide greater opportunities for livestock feed as well as human foods, and will be further developed in subsequent studies. Progress was made in developing new external cooperative agreements. The collaboration with MBI International (Lansing, MI) was renewed. It focuses on developing new technologies to enhance the value of ethanol processing byproducts, with particular emphasis on products with animal feed value that can be developed from DDGS, and on developing processing technologies for biomass materials (such as corn fiber) which could become feedstocks for fermentation as lignocellulosic biorefineries become commercialized. The collaboration with South Dakota State University (Brookings, SD) was also renewed. It focuses on research to examine the digestibility and feeding value of ethanol byproduct streams (primarily DDGS, but also DWG) for beef and dairy cattle. The collaboration with Northern Illinois University (DeKalb, IL) continues to focus on compression molding blends of DDGS with various resins to develop biodegradable composites. Additionally, a new research partner has been added, the Technology and Management Department at SDSU, which is helping to develop composites using DDGS as a base material, but is focusing on rapid prototyping applications. 4.Accomplishments Adding Value to DDGS by Pelleting. Densifying, or pelleting, is one of the easiest ways to add value and increase the market potential for DDGS (Distillers Dried Grains with Solubles), but to date has not been pursued commercially due to lack of information in industry. A series of experiments were conducted to develop DDGS pellets, both on a laboratory scale and on a commercial scale. We were able to produce high quality pellets without the use of binders, using traditional feed milling equipment; and, we did not find detrimental effects on the resulting nutrient compositions of these pellets. Additionally, bulk density increased (9.1 to 20.1%), and angle of repose decreased (18.3 to 19.2%) versus unmodified DDGS. Thus, pelleted DDGS offers the possibility of alleviating flowability issues during storage and transport, and also offers the possibility of expanding DDGS use beyond the feedlot, into rangeland settings, which could have implications for cattle producers throughout the U.S., as well as throughout the entire livestock industry. This accomplishment addresses NP 307 Component I. Ethanol – Coproduct Development; NP 306 Action Plan’s Component 2, Problem Area 2b, New Uses for Agricultural By-Products – Cereals, Oilseeds, and Novel Crops; and NP 306 Component 2, Problem Area 2c, New and Improved Processes and Feedstocks – Cereals, Oilseeds, and Novel Crops. Adding Value to DDGS by Developing Aquaculture Feed. Distillers Dried Grains with Solubles (DDGS) has potential to be used as an alternative protein source for aquaculture feed production, especially in the north central area of the U.S., but to date has seen limited use because of its difficult functionality, which is due to the high protein and fiber contents and lack of starch. A series of experiments was conducted to overcome these processing challenges, both on a laboratory scale and on a pilot scale, aimed at developing balanced rations for Nile tilapia species, using DDGS as the primary protein source. Feed rations were successfully developed using DDGS at rates of up to 60% of the diet, and these pelleted feeds had excellent nutritional and physical properties. Moreover, these feed pellets had excellent floatability, which is a key to producing aquaculture feeds. Because functionality challenges have been overcome, and because DDGS offers the potential to displace fish meal as a protein source, a feeding trial is currently underway at South Dakota State University to test the efficacy in a production setting, and is the next stage in commercializing this technology. This accomplishment addresses NP 307 Component I. Ethanol – Coproduct Development; NP 306 Action Plan’s Component 2, Problem Area 2b, New Uses for Agricultural By-Products – Cereals, Oilseeds, and Novel Crops; and NP 306 Component 2, Problem Area 2c, New and Improved Processes and Feedstocks – Cereals, Oilseeds, and Novel Crops. 5.Significant Activities that Support Special Target Populations None. 6.Technology Transfer Number of web sites managed 1 Number of non-peer reviewed presentations and proceedings 18 Number of newspaper articles and other presentations for non-science audiences 10 Review Publications Rosentrater, K.A., Ganesan, V., Muthukumarappan, K. 2006. Methodology to determine soluble content in dry grind ethanol coproduct streams. Applied Engineering in Agriculture. 22(6):899-903. Rosentrater, K.A., Al-Kalaani, Y. 2006. Renewable energy alternatives - a growing opportunity for engineering & technology education. Technology Interface. 6(1):1-12. Rosentrater, K.A., Muthukumarappan, K. 2006. Corn ethanol coproducts: generation, properties, and future prospects. International Sugar Journal. 108(1295):648-657. Rosentrater, K.A., Balamuralikrishna, R. 2007. The growing importance of emerging bio-based industries to engineering and technology. International Journal of Applied Management and Technology. 5(2):167-184. Tatara, R., Suraparaju, S., Rosentrater, K.A. 2007. Compression Molding of Phenolic Resin / Corn-based DDGS Blends. Polymers and the Environment. 15(2):89-95.