Progress 09/01/08 to 08/31/10
Outputs
OUTPUTS: This project continued an effort focused on developing new processing technologies to underpin second-generation biorefineries using soybeans and corn as feedstocks to produce biofuels (biodiesel and bioethanol) and biobased products (adhesives) thereby replacing imported petroleum. We are integrating a water- and enzyme-based approach known as Enzyme-assisted Aqueous Extraction Processing (EAEP) into biofuel production and replacing a hazardous and polluting petroleum-based solvent, hexane. Hexane is a regulated pollutant and compliance with new emission standards is increasingly difficult. Hexane is also highly flammable posing major safety concerns and can be used only at very large scale. EAEP, being a water-based process, is inherently safe and suitable for small-scale plants. EAEP may also integrate well into biodiesel and corn ethanol production. The project also seeks to break the dogma of food verses fuel by producing improved and healthy food and enhanced feed ingredients as biorefinery co-products. We continued our partnership with Genencor International (enzyme manufacturer), West Central Cooperative (soybean processor), and Arclin (wood adhesives manufacturer). We gained knowledge on what peptides can be captured downstream of oil extraction, with the effectiveness of recovery alternatives dependent on the extent of hydrolysis during extraction, and this knowledge is being used by other team members to alter extraction conditions to improve protein capture. Genencor continued to work with equipment manufacturers to improve adoption potential by industry and with a commercial soybean processor on scale-up and commercial adoption of EAEP. We demonstrated that EAEP can be integrated with a dry-grind ethanol plant to achieve much improved processing efficiencies and higher ethanol yield. Our work continues to show soy flour works as well as other more expensive soy protein ingredients in soybean-based adhesives. We defined the optimum extent of hydrolysis to maximize performance of soy protein in wood adhesives. Arclin is tailoring soy protein adhesives for their customers and are testing soy wood adhesives in various commercial applications to produce safe, environmentally friendly and biorenewable adhesives. We acquired additional funding from the United Soybean Board to assist West Central Cooperative to be able to produce the hydrolyzed soy protein. We faculty published 7 peer-reviewed articles in scientific journals and made 15 presentations at scientific conferences (even in India and France where related research is underway). We presented our results at numerous public forums, such as the dedication of the ISU BioCentury Research Farm (a new ISU integrated biomass production and processing facility) and the ISU Presidential Lecture Series to which the general public was invited. We graduated 1 PhD student and 1 other PhD and 1 MS students worked on the project. We also provided research training to 5 postdoctoral research associates and one visiting scientist from the Federal University of Paraiba, Brazil. PARTICIPANTS: Individuals (Principle Investigators): Lawrence A. Johnson, Project Director, Professor, Food Science & Human Nutrition, responsible for integrating oil demulsification with 2-stage extraction and characterizing protein products; Charles E. Glatz, Professor, Chemical & Biological Engineering, responsible for evaluating alternative protein recovery strategies; Stephanie Jung, Assistant Professor, Food Science & Human Nutrition, responsible for integrating soy fiber conversion to ethanol production; Patricia A. Murphy, University Professor, Food Science & Human Nutrition, responsible for enhancing oleosome extraction and recovering protein products; Tong Wang, Associate Professor, Food Science & Human Nutrition, responsible for integrating soy skim utilization in dry-grind ethanol production; Monlin Kuo, Professor, Natural Resource Ecology and Management, responsible for improving hydrolyzed soy protein in wood adhesives; and Michael Persia, Assistant Professor, Animal Science, responsible for evaluating soy skim and fiber as feed. The following Iowa State University staff worked on the project: Catherine Hauck, Research Associate; William Colonna, Research Associate; and Richard Faris, Research Technician. The following graduate students and post-doctoral research associates received training experiences by working on the project: Kerry Campbell, PhD Candidate, Chemical & Biological Engineering; John Schmitz, PhD Candidate, Food Science & Human Nutrition; Yating Ma, MS Student, Food Science & Human Nutrition; Abdullah Mahfuz, Post-doctoral Research Associate; Juliana M.L. Nobrega de Moura, Post-doctoral Research Associate; Lili Towa, Post-doctoral Research Associate; Virginie Kapchie, Post-doctoral Research Associate; and Neiva de Almeida, Visiting Research Scientist from the Federal University of Paraiba (Brazil). Six undergraduate students also worked on the project gaining laboratory experiences. Collaborators and Contacts: The team collaborated with the international enzyme manufacturer Genencor International (Rochester, NY) and several key Genencor International researchers contributed to the project's success, including Peter Birschbach, Jeff Gerstner, and Chris Barnett. The team collaborated with West Central Cooperative (Ralston, IA) to adopt and commercially produce one of the soy protein products for use in wood adhesives with key individuals being Milan Kucerak and Scott Wernimont. The team also collaborated with Arclin (Mississaugua, Ontario), a major manufacturer of wood adhesives with the key individual being Mark Anderson. TARGET AUDIENCES: Target audiences include: soybean farmers and soybean grower's associations, such as the American Soybean Association and the United Soybean Board; Feed Grains Council; renewable fuels associations; National Biodiesel Board; the wood composite industry, such as Georgia Pacific; soybean processing industry, such the National Oilseed Processors Association; the adhesive compounding industry such as Arclin; and enzyme manufacturers, such as Genencor International and Novozymes. PROJECT MODIFICATIONS: Nothing significant to report during this reporting period.
Impacts
Water-based enzyme-assisted aqueous extraction processing (EAEP) of soybeans is an environmentally friendly alternative to traditional hexane extraction used to produce oil for food and biofuels. Although nearly all oil can be extracted from soybean solids, the amount unclaimed from the skim after separating the oil-rich cream limits oil recovery. We discovered ways to shift more oil to the cream phase increasing oil recovery. We discovered that moisture content and temperature during soybean flaking affect the oil distribution and ease of demulsifying the cream. We discovered a means of conserving enzyme and ways to produce protein mixtures with different extents of hydrolysis and functional properties. We successfully integrated the extraction and cream demulsification steps of two-stage countercurrent EAEP when recycling enzyme, thereby reducing enzyme cost. Combining acid precipitation and ultrafiltration improved protein recovery. Protein hydrolysis improved many functional properties of the recovered protein. These discoveries should lead to improved process economics and new soy protein products for food and feed. Our results offer guidance on front-end mechanical processing to produce a particular spectrum of protein products. We found no inhibitory action and enhanced yeast cell multiplication, when using EAEP skim in corn fermentation thus enhancing corn ethanol production, feed quality and water conservation. We discovered that soy skim increases fermentation rate of cornstarch. The EAEP soy fiber and soy fiber-enhanced DDGS were used as substrates for solid-state fermentation (SSF) with fungi to improve feed digestibility. We discovered that the soybean extrusion step of our EAEP process increases yield of fermentable sugars from soy fiber, which enables soy fiber to be used to produce fuel ethanol, indicating that our concept of integrating EAEP of soybeans into dry-grind corn ethanol plants is feasible and has great potential. We optimized pre-treatment of the fiber and achieved >95% sugar yield. We demonstrated the fiber and skim fractions contain digestible nutrients and are suitable in poultry rations up to at least 8% inclusion rate. We identified a process to recover soy protein products when using our alternative oleosome process and demonstrated that new enzyme products from Genencor could be utilized to optimize oil recovery. We successfully scaled up oleosome fractionation to pilot scale achieving 93% oil recovery as intact oleosomes. We optimized recycling aqueous phase to extract oleosomes and characterized the functionality of these proteins. Hydrolyzing soy protein to 18% degree of hydrolysis is optimum for phenol formaldehyde (PF) and polyamide-epichlorohydrin (PAE) adhesive formulas, higher degrees of hydrolysis reduce bond strength and increase swelling when exposed to water. Up to 20% soy solids can be incorporated without affecting performance of PF resins. Adding urea to PAE resins increased wet strength and dimensional stability. The wood industry is keen to reduce PF in adhesives to reduce costs, replace petroleum-derived materials, and eliminate formaldehyde exposure (cancer promoting) to workers.
Publications
- Nobrega de Moura, J.M.L, N.M. de Almeida, and L.A. Johnson. 2009. Scale-up of Enzyme-assisted Aqueous Extraction of Soybeans. J. Am. Oil Chem. Soc. 86(8):809-815.
- Jung, S. 2009. Aqueous Extraction of Lupin, a Comparison with Soybean. J. Food Process. Preserv. 33:547-559.
- Jung, S., A. Mahfuz, and D. Maurer. 2009. Structure, Protein Interactions and In Vitro Protease Accessibility of Extruded and Pressurized Full-fat Soybean Flakes. J. Am. Oil Chem. Soc. 86:475-483.
- Campbell, K.E., and C.E. Glatz. 2009. Protein Recovery from Enzyme-Assisted Aqueous Extraction of Soybean. Biotechnol. Prog. Published on-line Nov. 25, 2009. http://dx.doi.org/10/1002/btpr/341.
- Campbell, K.E. and C.E. Glatz. 2009. Mechanisms of Aqueous Extraction of Soybean Oil. J. Agric. Food Chem. 57:10904-10912.
- Yao, L., and S. Jung. 2010. 31P NMR Phospholipids Profiling of Soybean Emulsion Recovered from Aqueous Extraction. J. Agric. Food Chem. 58:4866-4872.
- Kapchie, V.N., L.T. Towa, C.C. Hauck, and P.A. Murphy. 2010. Evaluation of Enzyme Efficiency for Soy Oleosome Isolation and Ultrastructural Aspects. Food Res. Internat. 43:241-247.
|
Progress 09/01/08 to 08/31/09
Outputs
OUTPUTS: This project continues an effort focused on developing new processing technologies to underpin second-generation biorefineries using soybeans and corn as feedstocks to produce biofuels (biodiesel and bioethanol) and biobased products (adhesives), to replace imported petroleum. We are integrating a water- and enzyme-based approach known as Enzyme-assisted Aqueous Extraction Processing (EAEP) into biofuel production and replacing a hazardous and polluting petroleum-based solvent, hexane. The project also seeks to break the dogma of food verses fuel by producing improved and healthy food and enhanced feed ingredients as biorefinery co-products. We continued our partnership with Genencor International (enzyme manufacturer), West Central Cooperative (soybean processor), and Arclin (wood adhesives manufacturer). Our work continues to show soy flour works as well as other more expensive soy protein ingredients. We have gained knowledge on what peptides can be captured downstream of oil extraction, which is being used by other team members to alter extraction conditions to improve protein capture. We are determining if we should file a parent disclosure. Genencor continued to work with equipment manufacturers to improve adoption potential by industry and with a commercial soybean processor on scale-up and commercial implementation of the full aqueous process. We defined the optimum extent of hydrolysis to maximize performance of soy protein in wood adhesives. Arclin is tailoring the soy adhesive for their customers and are testing soy wood adhesives in various commercial applications to produce safe, environmentally friendly and biorenewable adhesives. We acquired additional funding from the United Soybean Board to assist West Central Cooperative to be able to produce the hydrolyzed soy protein. ISU faculty published 3 peer-reviewed articles in scientific journals and made 12 presentations at scientific conferences (even in India and France where related research is underway). We presented our results at numerous public forums, such as the dedication of the ISU BioCentury Research Farm and the ISU Presidential Lecture Series. We graduated 1 PhD student and 1 more MS and 1 PhD students are in training by working on the project. We also provided research training to 5 postdoctoral research associates. PARTICIPANTS: Individuals (Principle Investigators): Lawrence A. Johnson, Project Director, Professor, Food Science & Human Nutrition, responsible for integrating oil demulsification with 2-stage extraction and characterizing protein products; Charles E. Glatz, Professor, Chemical & Biological Engineering, responsible for evaluating alternative protein recovery strategies; Stephanie Jung, Assistant Professor, Food Science & Human Nutrition, responsible for integrating soy fiber conversion to ethanol production; Patricia A. Murphy, University Professor, Food Science & Human Nutrition, responsible for enhancing oleosome extraction and recovering protein products; Tong Wang, Associate Professor, Food Science & Human Nutrition, responsible for integrating soy skim utilization in dry-grind ethanol production; Monlin Kuo, Professor, Natural Resource Ecology and Management, responsible for improving hydrolyzed soy protein in wood adhesives; and Michael Spurlock, Professor, Animal Science, responsible for enhancing soy skim and fiber as feed. The following Iowa State University staff worked on the project: Catherine Hauck, Research Associate; William Colonna, Research Associate; and Richard Faris, Research Technician. The following graduate students and post-doctoral research associates received training experiences by working on the project: Kerry Campbell, PhD Candidate, Chemical & Biological Engineering; John Schmitz, Food Science & Human Nutrition; Yating Ma, MS Student, Food Science & Human Nutrition; Abdullah Mahfuz, Post-doctoral Research Associate; Juliana M.L. Nobrega de Moura, Post-doctoral Research Associate; Neiva de Almeida, Visiting Research Associate; Virginie Kapchie, Post-doctoral Research Associate; and Lili Towa, Post-doctoral Research Associate. Five other undergraduate students also worked on the project gaining laboratory experiences. Collaborators and Contacts: The team collaborated with the international enzyme manufacturer Genencor International (Rochester, NY) and several key Genencor International researchers contributed to the project's success, including Peter Birschbach, Jeff Gerstner, and Chris Barnett. The team collaborated with West Central Cooperative (Ralston, IA) to adopt and commercially produce one of the soy protein products for use in wood adhesives with key individuals being Milan Kucerak and Scott Wernimont. The team also collaborated with Arclin (Mississaugua, Ontario), a major manufacturer of wood adhesives with the key individual being Mark Anderson. TARGET AUDIENCES: Target audiences include: soybean farmers and soybean grower's associations, such as the American Soybean Association and the United Soybean Board; Feed Grains Council; renewable fuels associations; National Biodiesel Board; the wood composite industry, such as Georgia Pacific; soybean processing industry, such the National Oilseed Processors Association; the adhesive compounding industry such as Arclin; and enzyme manufacturers, such as Genencor International and Novozymes. PROJECT MODIFICATIONS: Nothing significant to report during this reporting period.
Impacts
Water-based enzyme-assisted aqueous extraction processing (EAEP) of soybeans is an environmentally friendly alternative to traditional hexane extraction to produce oil for food and biofuels. Hexane is a regulated pollutant and compliance with new emission standards is increasingly difficult. Hexane is also highly flammable posing major safety concerns and can be used only at very large scale. EAEP is inherently safe and suitable for small-scale plants. EAEP may also integrate well into biodiesel and corn ethanol production. Although nearly all oil can be extracted from soy solids, the amount that is unclaimed from the skim after separating the oil-rich cream limits oil recovery. We discovered how to shift more oil to the cream phase increasing oil recovery from 76 to 86%. We discovered that moisture content and temperature during soybean flaking affect the oil distribution and ease of demulsifying the cream. We discovered a means of conserving enzyme and how to produce protein mixtures with different extents of hydrolysis and functional properties. These discoveries should lead to improved process economics and new soy protein products for food and feed. We identified processing steps that remove antinutritional factors from the protein and provide peptides with potential nutraceutical value. This work is evolving into an overall process capable of capturing oil and protein values with higher-value nutritional characteristics. Our results can offer guidance on what front-end mechanical processing should produce a particular spectrum of protein products. When utilizing EAEP skim in corn fermentation media we found no inhibitory action and enhanced yeast cell multiplication, thus this approach shows considerable promise as means of enhancing corn ethanol production, feed quality and water conservation. We discovered that the soybean extrusion step of our EAEP process increases yield of fermentable sugars from soy fiber, which enables soy fiber to be used to produce fuel ethanol giving us further encouragement that our concept of integrating EAEP of soybeans into dry-grind corn ethanol plants is feasible and has great potential. We identified a process to recover soy protein products when using our alternative oleosome process and demonstrated that new enzyme products from Genencor could be utilized to optimize oil recovery. A bench-scale oleosome aqueous phase recirculation protocol was identified that should lead to more economical use of resources. This protocol blunts the protease-induced loss in soy protein isolate. We also discovered that hydrolyzing soy protein to 18% degree of hydrolysis is optimum for incorporating into phenol formaldehyde (PF) and polyamide-epichlorohydrin (PAE) adhesive formulas, higher degrees of hydrolysis reduce bond strength and increase swelling when exposed to water. Up to 20% soy solids can be incorporated without affecting performance of PF resins. We discovered adding urea to PAE resins increased wet strength and dimensional stability. The wood industry is keen to reduce PF in adhesives to reduce costs, replace petroleum-derived materials, and eliminate formaldehyde exposure (cancer promoting) to workers.
Publications
- Nobrega de Moura, J.M.L, N.M. de Almeida, and L.A. Johnson. 2009. Scale-up of Enzyme-assisted Aqueous Extraction of Soybeans. J. Am. Oil Chem. Soc. 86(8):809-815.
- Jung, S. 2009. Aqueous Extraction of Lupin, a Comparison with Soybean. J. Food Process. Preserv. 33:547-559.
- Jung, S., A. Mahfuz, and D. Maurer. 2009. Structure, Protein Interactions and In Vitro Protease Accessibility of Extruded and Pressurized Full-fat Soybean Flakes. J. Am. Oil Chem. Soc. 86(6):475-483.
|