Corn DDGS

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CornDDGS
More than Meets the Eye
Using Coproducts for Food
Kurt A. Rosentrater, Ph.D. Lead Scientist,
Bioprocess Engineer North Central Agricultural
Research Laboratory USDA ARS Brookings, South
Dakota, USA
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Presentation Outline

• Fuel, feed, food, and more
• DDGS characteristics
• Review of previous work
• ARS research and development
• Future needs work
• Issues of concern
• Conclusions final thoughts

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Disclaimers

• All assumptions, data, and projections regarding
  results, performance, costs, expenses, etc., are
  for ILLUSTRATIVE PURPOSES ONLY. The assumptions,
  methods, equipment, and process settings
  utilized, and the resulting performance may not
  be appropriate for every situation or for every
  DDGS source. Actual results could vary
  significantly. USDA-ARS makes no warranties,
  expressed or implied.
• Mention of a trade name, propriety product, or
  specific equipment does not constitute a
  guarantee or warranty by the United States
  Department of Agriculture, and does not imply
  approval of a product to the exclusion of others
  that may be suitable.

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May 21
May 28
May 30
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Have you noticed..

• DDGS are never mentioned?
• Distillers grains are the industrys hidden
  treasure!
• Feed
• What about food?
• Challenges
• Opportunities

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DDGS Characteristics
( db)

• Compositional properties influence potential end
  use
• Good for humans or not?

Rosentrater Muthukumarappan, 2006
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What Have Others Done?Using DDGS in Human Foods

• Many research studies
• Focused on livestock utilization
• How much how best do you feed DDGS?
• Source of most chemical / nutritional data
• Much work over the years
• Examined use as functional ingredients
• For human food products
• Reviewed and summarized in Rosentrater Krishnan
  (2006)

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What Have Others Done?Using DDGS in Human Foods

• Compilation of data
• Examined 7 categories from the literature
• Ethanol feedstock used
• Corn, wheat, barley, rye, sorghum, oat
• Food product applications
• Residue used
• DDG, DDGS, WS
• Inclusion (substitution) rate
• 0 to 100
• Resulting functionality
• Resulting taste panel results
• Citation information
• 32 studies over last 25 years

Rosentrater Krishnan, 2006
62 products
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What Have Others Done?Using DDGS in Human Foods
Rosentrater Krishnan, 2006
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What Have Others Done?Using DDGS in Human Foods

• Several insights / common themes
• Many food products have been examined
• Most studies
• Breads and cookies
• Lesser extent
• Pastas, blended ingredients, extruded products

Rosentrater Krishnan, 2006
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What Have Others Done?Using DDGS in Human Foods

• Several insights / common themes
• Organoleptic and functional quality impacts
• As inclusion of coproducts increased
• Darker appearance
• Decreased functionality
• Volume / expansion during baking
• Moisture absorption
• Texture
• Mouthfeel
• Flavor impact
• Ranged from marginally acceptable to not
  acceptable

Rosentrater Krishnan, 2006
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What Have Others Done?Using DDGS in Human Foods

• As a result of energy crises of 1970s
• Ethanol industry began steady growth in US
• Spurred research in utilization of
  residues/coproducts
• Industry has continued to grow
• But food utilization research has not
• 1980s 23 studies 47 food products
• 1990s 8 studies 10 food products
• 2000s 1 study 5 food products
• Lack of recent research
• Hindrance to value-added uses
• Coproducts have changed with technology

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What Have Others Done?Using DDGS in Human Foods

• As the industry continues to expand
• Interest in food grade residues beginning to
  grow
• Especially large processors economies of scale
• To expand utilization avenues beyond livestock
  feed
• Current industry needs
• Improve
• Flavor
• Odor
• Color
• Functionality
• Considerable product development with new
  coproducts

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Product Development Work

• Because of nutritional properties
• Diabetics
• Celiacs disease
• Taking a proof of concept approach
• Cookies
• Breads
• Will move into other baked products as well

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Product Development WorkPreliminary Work with
SDSU

• Food grade DDGS
• Laboratory procedures
• Ethanol washed (5 times, 5 min.)
• Water washed (5 times, 5 min.)
• Freeze dried
• Milled into flour
• Sterilized (bottled autoclave)
• Resulting DDGS flour product
• Odor-neutral
• Flavor-neutral
• Color-neutral

Low-fat DDGS
Rosentrater Krishnan, 2006
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Product Development WorkPreliminary Work with
SDSU

• Cookies
• Baked products rely on chemical leavening
  agents
• Low-fat DDGS up to 40 substitution
• Smaller batter spread
• Color, taste, texture were acceptable

Rosentrater Krishnan, 2006
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Product Development Work
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Product Development Work
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Product Development Work

• Will DDGS produce a lower glycemic effect after
  ingestion?

8 participants Ingested 20-g samples Blood drawn
at 0, 30, 60, 90 min Glucose analysis
Blood glucose levels over time. Error bars
represent standard error of the mean.
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Future Needs / Work

• Other factors to consider
• DDGS particle size
• Conditioning agents (oxidizers, reducing agents,
  emulsifiers, enzymes many proprietary products)
• What about new fractionated products?
• High fiber (bran) meal
• Corn germ meal
• High protein DDGS
• Low fat DDGS

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Future Needs / Work

• Minimal processing steps
• Is food grade treatment necessary?
• Scale-up
• Properties of food grade DDGS
• Sensory profiles
• Functionality profiles
• Recommended optimal substitution levels
• Depends upon food products
• What else (besides breads and cookies)?
  Multitude of grain-based foods
• Other food products
• Ethnic foods Indian, African, Mexican
  grain-based products
• Other constituents their benefits
• Yeast cells metabolites (proteins vitamin E)
• Carotenoids xanthophylls (antioxidants)

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Issues of Concern

• Food grade issues (dependent upon each plant)
• All materials that impact DDGS must be food
  grade, declared, and approved
• Incoming grain
• GMO grains
• Heavy metals
• Pesticides
• Dioxin
• Mycotoxins
• Processing Aids
• Enzymes
• Yeast
• Urea/ammonia
• pH adjusters
• Anti-fouling agents
• Defoamers
• Antibiotics

• Other issues
• Water quality
• Anaerobic digesters
• Recycling process water
• Cleaning agents
• Sodium hydroxide
• Sulfuric acid
• Sulfur
• Salt

• Key information
• 21CFR
• Section 171
• www.cfsan.fda.gov

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Issues of Concern

• What is a food-grade product?
• Sample DDGS exiting the dryer
• Antibiotics
• Heavy metals
• Mycotoxins
• Pathogens
• Other toxins
• If you can produce a clean, wholesome product
• Can it be used as a food ingredient?
• If so, perhaps FDA approval marketing are only
  steps needed
• What about quality standards?

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Conclusions Final Thoughts

• Corn DDGS
• Can be successfully used as a food ingredient
• 20 to 25 appears optimum substitution level
• Depending upon
• Chemical leavening
• Yeast leavening
• Ingredient matrix
• Trying to conduct a balancing act
• Promising ingredient for diabetic celiac diets

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Thank You

• Questions?
• Comments?

Kurt Rosentrater [phone] kurt.rosentrater_at_a
rs.usda.gov