ALTERNATIVE USES FOR TOBACCO, 2008

• Sponsoring Institution: National Institute of Food and Agriculture
• Project Status: COMPLETE
• Funding Source: SPECIAL GRANT
• Reporting Frequency: Annual
• Accession No.: 0215264
• Grant No.: 2008-34467-19445
• Proposal No.: 2008-03175
• Project Start Date: Aug 15, 2008
• Project End Date: Aug 14, 2011
• Grant Year: 2008
• Program Code: [TU]- Alternative Uses for Tobacco, MD

Recipient Organization
UNIV OF MARYLAND
(N/A)
COLLEGE PARK,MD 20742

Performing Department
OFFICE OF THE DIRECTOR

Non Technical Summary
This project???Ts intent is to develop beneficial new non-smoking uses for tobacco including exploitation of its phenomenal biomass, potentially useful leaf proteins and other compounds. We plan to establish a ???obiorefinery??? capable of using tobacco as a feedstock to produce a combination of food, feed, industrial raw materials and energy products. We envision a process which recovers leaf proteins from tobacco, and then utilizes the residual biomass for a combination of food, fuel and industrial products. Our goal is to establish a commercial production facility capable of producing leaf proteins and co-products from tobacco in Southern Maryland in approximately three years. Our project is multidisciplinary: Agronomy: Cultivation of tobacco for proteins and biomass is very different from traditional tobacco production. The process is largely mechanized, involves very high plant densities, and multiple harvests in a single growing season. We propose several studies to examine seeding techniques, weed control and cultivation practices associated with this new non-traditional tobacco production. Harvesting and Post-Harvest Handling: Tobacco must be harvested and handled in a manner which minimizes protein degradation and other product loss, as well as transportation costs. We have proposed several studies which examine whether techniques used to harvest and handle perishable agricultural products are suitable for handling tobacco biomass. Proteins and Other New Products: Tobacco naturally produces large volumes of leaf proteins which have nutritional value comparable to milk protein and are considered non-allergenic. These proteins also have excellent binding and emulsifying characteristics. Tobacco also produces other potentially useful materials including solanesol, which is used in the manufacture of nutraceuticals and dietary supplements. We will assess the feasibility of recovering solanesol as a co-product in a biorefinery along with leaf proteins. Other potentially useful compounds in tobacco will be sought. Industrial Scale-Up. We have already developed techniques for recovering tobacco leaf proteins on a pilot scale. Several studies regarding the scale-up of our pilot technology to an industrial level in preparation for commercial production are proposed. Success of this project could help maintain a viable agricultural base in the historically tobacco-producing region of Southern Maryland based on the production of tobacco for safe and beneficial purposes. It could also provide a model for revitalizing tobacco-producing regions across the southeastern United States. The commercial establishment of tobacco biorefineries would lead to new jobs, markets and industries in tobacco-growing regions. Success of this project could also result in the commercial production of a new source of protein - leaf proteins - which may ultimately rival milk, soy or egg protein in importance. The residual biomass which remains following protein extraction could also become a new source of renewable energy.

Animal Health Component

50%

Research Effort Categories

Basic

25%

Applied

50%

Developmental

25%

Classification

Knowledge Area (KA)	Subject of Investigation (SOI)	Field of Science (FOS)	Percent
204	1999	1060	10%
502	1999	1060	30%
503	1999	1060	20%
511	1999	1060	40%

Knowledge Area
511 - New and Improved Non-Food Products and Processes; 204 - Plant Product Quality and Utility (Preharvest); 503 - Quality Maintenance in Storing and Marketing Food Products; 502 - New and Improved Food Products;

Subject Of Investigation
1999 - Tobacco, general/other;

Field Of Science
1060 - Biology (whole systems);

Keywords

tobacco

proteins

solanesol

neutraceuticals

agronomy

biomass

biofuel

Goals / Objectives
We intend to develop beneficial non-smoking uses for tobacco in southern Maryland and other tobacco-producing regions. Our proposed biorefinery will exploit tobacco as a feedstock to produce a combination of food, feed, industrial raw materials and energy products. We envision a process which recovers leaf proteins from tobacco, then utilizes the residual biomass for a combination of food, fuel and industrial products. We strive to establish a commercial production facility capable of producing leaf proteins and co-products from tobacco in approximately three years. Our project includes the following multi-disciplinary research activities: AGRONOMY: Several studies will examine seeding techniques, weed control and cultivation practices specific to tobacco cultivation for proteins and biomass. HARVESTING AND POST-HARVESTING HANDLING: Several studies will examine whether techniques used to harvest and handle perishable agricultural products effectively safeguard the proteins and biomass. PROTEINS AND OTHER NEW PRODUCTS: Several studies will determine the functional characteristics of tobacco leaf proteins and their suitability for food and non-food applications. We will investigate the feasibility of recovering solanesol (integral to the manufacture of nutraceuticals and dietary supplements) as a co-product in a biorefinery along with leaf proteins. INDUSTRIAL SCALE-UP: We will scale up our techniques for recovering tobacco leaf proteins from the pilot scale to an industrial level in preparation for commercial production. Success of this project could help maintain viable tobacco-based agriculture in southern Maryland and across the southeastern United States. Tobacco biorefineries will create new jobs, markets and industries. Leaf proteins may ultimately rival milk, soy or egg proteins in importance. The residual biomass has potential as a source of renewable energy.

Project Methods
1 Agronomic Field Trials and Weed Control Objective: To increase our knowledge regarding planting, cultivation and harvesting practices when tobacco is produced for non-smoking purposes. Procedures: Bulk Production Direct Planting Weed Management Nitrogen Management Time of Harvest 2 On Farm Field Trials Objective: Evaluate production of tobacco for non-smoking purposes under actual farm conditions. Procedures: Farmers to plant .25 acre of non-smoking tobacco then experiment with different planting techniques, weed control, cultivation practices, and harvesting techniques, then assess and record. 3 Harvesting and Transportation Objective: Retain freshness during harvesting and transportation. Procedures: Devise some form of pressing or squeezing during harvest. The resulting green juice would contain much of the soluble protein. Transportation - investigate the suitability of portable refrigeration systems commonly used in transporting perishable products. Explore use of forced air systems. 4 Post-Harvest Handling Objective: Determine applicability of post-harvest methodologies for fresh, leafy vegetables (spinach) with tobacco. Procedures: Conduct individual trials of the effects of a series of independent variables (storage temperature, oxygen concentration and two ethylene antagonists, carbon dioxide and 1-MCP) on the senescence of fresh-cut tobacco leaves. Conduct factorial studies of the effect of promising independent variables to optimize temperature, gas concentration and ethylene inhibitor for optimal storageability, then test whether this process can be scaled-up for commercial usage. 5 Bioprocessing Scale-Up Objective: Enable industrial-scale production of protein from tobacco by establishing the criteria and characterizing the controllable parameters crucial during scale-up operations. Procedures: The project involves three major aspects: (1) design criteria for optimizing protein productivity; (2) correspondent yield of protein under a spectrum of processing settings; and (3) quality and stability of the proteins as affected by scaling up of the processing steps. 6 Leaf Proteins Obj. a: Assess the suitability of rubisco and other tobacco proteins as components in food or industrial products Procedures: Test effect of Temperature on Stability Moisture on Stability Oxygen on Stability Obj b: Identify a technique that does not denature the proteins yet preserves its functional qualities. Procedures: Test three processing technologies for creating powder products from tobacco proteins. 7 Recovery of Solanesol Objective: Determine feasibility of producing solanesol more efficiently and in higher purity as a co-product along with leaf proteins. Procedures: Establish analytical protocols for the identification, characterization, and quantification of solanesol. Evaluate extraction techniques. 8 Additional Co-Products from Tobacco Objective: Determine existence of additional compounds in tobacco . Procedures: Issue an FP within the University to obtain proposals for research on producing new compounds from tobacco. Analyze tobacco stalk material to determine its suitability for pulping, composite material or energy production.

Progress 08/15/08 to 08/14/11

Outputs
OUTPUTS: The research team made advances in both the production and processing of tobacco for non-smoking uses. We also continued to make progress in identifying new non-smoking applications for tobacco. The research team organized on-farm trials for the production of tobacco for non-smoking uses. These trials resulted in new cropping systems which utilize plastic strips for weed control. Using this system, we were able to obtain up to four biomass harvests in a growing season and obtained approximately 25-30 wet tons of tobacco/year (about 2.5 - 3 dry tons). This step utilized transplanted seedlings. An important advantage of this approach is that we were able to substantially reduce weed problems and weed control costs. This improved weed control reduced crop impurities in the harvested product. We also began a two-year study on the optimal time between harvests for leaf protein and biomass production. First-year data indicated that the optimal time between harvests is approximately 5 weeks. We also began post-harvest handling studies. These tests have resulted in techniques which significantly extend the viability of leaf protein following harvest. These techniques could extend the processing season, and increase the capacity of an industrial processing facility. On the processing side, we continued to refine and improve our leaf protein processing technology. We also continued to improve our processes for using the residual leaf biomass which remains following leaf protein extraction as a substrate for producing organic chemicals through fermentation. In addition, we continued our work on developing new leaf biomass co-products from tobacco. We found that the residual leaf biomass which remains following protein extraction contains solanesol, which is an intermediate used in the production of several high-value dietary supplements. We also performed tests which identified efficient techniques for recovering the solanesol. In addition, we initiated an engineering study for the purpose of designing a scaled-up facility capable of producing tobacco leaf proteins and biobased co-products on a bulk scale. PARTICIPANTS: Dr. Cheng-i Wei, University of Maryland. Dr. Y. Martin Lo, University of Maryland. Dr. Robert Kratochvil, University of Maryland. Dr. Chris Walsh, University of Maryland. Dr. Liangli Yu, University of Maryland. Neil A. Belson, NewAgriculture, Inc., Port Tobacco, Maryland. Gary V. Hodge, Regional Policy Advisors, White Plains, Maryland TARGET AUDIENCES: Agricultural and nutritional scientists. Agricultural processing companies. Farmers and farm organizations. Companies in the following industries: paper, packaging, coatings, adhesives, protein and nutrition, dietary supplements. PROJECT MODIFICATIONS: Nothing significant to report during this reporting period.

Impacts
The purpose of this project is to develop methods and technologies for producing tobacco for non-smoking purposes. This includes both identifying non-smoking products from tobacco, and developing cultivation practices suitable for producing tobacco for non-smoking uses. Development of a new industry based on the production of tobacco for non-smoking products could have a dramatic economic impact in the rural southeastern United States. Many communities in the southeastern U.S. have traditionally depended upon tobacco, and their economies have suffered in recent years as conventional tobacco production has declined. Our research during FY 2008 involved several advances which can facilitate the production of tobacco for non-smoking uses. For example, we developed new cultivation practices which could substantially reduce weed control costs. Weed control of seedlings is a major limiting factor. While effective weed control for direct seeding is possible using pre-emergent herbicides, such control is expensive. We found that using plastic strips is an inexpensive and effective means of obtaining weed control. This new cultivation technique could significantly reduce the cost of producing tobacco for non-smoking products, and also reduce crop impurities. Our development of new post-harvest handling practices can increase the longevity of the leaf protein following harvest, and consequently could increase the portion of the year in which processing facilities can remain operational. By permitting a processing facility to remain operational for a longer proportion of a year, this finding could significantly increase a facility's annual processing capacity. Our continued refinements of our leaf protein processing techniques are of significance. During the FY 2008 project, our project team received requests for leaf protein samples from private companies in a range of potentially relevant industries, including the paper and packaging industries and several industrial formulating companies. These requests indicate the existence of a commercial market for leaf proteins. The fact that residual leaf biomass appears useful in the production of biobased organic acids is also significant. Biobased chemicals and fuels could replace many petroleum-derived products during the next several decades. Use of the tobacco leaf biomass in the production of biobased chemicals could represent an important co-product which could increase revenue from producing tobacco for non-smoking uses. Similarly, our ability to recover solanesol, a high-value product used as an intermediate in the production of several dietary supplements, from the residual leaf biomass indicates the possibility of generating another revenue stream from tobacco biomass. Our objective in this project is to produce a tobacco "biorefinery," capable of processing tobacco for a combination of non-smoking-related products obtained from different portions of the tobacco plant. Our advances in FY 2008 increase the feasibility of establishing such a biorefinery.

Publications

• Fu, H., P. Machado, T. Hahm, R. Kratochvil, C. Wei and Y. Lo (2010), "Recovery of nicotine-free proteins from tobacco leaves using phosphate buffer system under controlled conditions." Bioresource Technology 101: 2034-2042.
• Machado, P.A., H. Fu, R. Kratochvil, Y. Yuan, T. Hahm, C. Sabliov, C. Wei and Y. Lo (2010), "Recovery of solanesol from tobacco as a value-added byproduct for alternative applications." Bioresource Technology 101: 1091-1096.