Progress 05/12/99 to 05/11/04
Outputs
1. What major problem or issue is being resolved and how are you resolving it (summarize project aims and objectives)? How serious is the problem? What does it matter? Over the past twenty years, exports of US wheat have been both unpredictable and declining. A potentially huge market for wheat is the biorefining and bioconversion of wheat into biobased products, including fuel-grade ethanol and fine chemicals. A key biorefining step is the fractionation of the wheat into starch and protein concentrates. Current separation technologies, which produce concentrates of starch and gluten, are costly and have difficulty competing with foreign imports. Contributing to the expense of the commercial methods are: (1) outdated, nonstandard mill technologies; (2) the inefficient use of energy; and (3) the generation of copious amounts of wastewater. This project researches new and relevant separation technologies and systems. One of these is the cold-ethanol process invented at
WRRC, in which ethanol serves as a process fluid to largely replace the use of water and reduce energy use. The cold-ethanol method of separation has the potential to reduce energy and water usage, leading to optimal use of all co-product streams. Another important technology is the separation of ethanol and water, which is important to the cold ethanol method, as well as to the eventual production of fuel-grade ethanol from surplus starch. The overall project goal is to improve wheat refining, increase wheat usage in bioproducts and biofuels (ethanol), and improve grain-to-ethanol processing efficiency. The total value of US wheat exports is 2/3 of its 1987 value, yet the total production has remained constant. The amount of wheat available for domestic non-food use is roughly 30 billion pounds and growing. Of this amount, the US gluten industry currently separates a little more than 2 billion lbs of wheat into starch and protein for food and non-food uses. This represents 58% of the
total domestic gluten market; the rest of which is mostly imported from Europe due to their relative cost advantage. The potential of improving separation processes to improve starch and gluten separation would lead to increased domestic production of gluten, reduced imports, and improved attractiveness of all fractionated wheat components including starch for fuel-grade ethanol. Wheat starch as a fermentation feedstock could significantly expand grain-to-ethanol production in the US, help to reduce dependence on imported fuels and toxic oxygenates, and improve the nation's ability to produce ethanol in a wider range of diverse regional locations. Improved energy-efficiency through improved ethanol-water separations is crucial to the future of the wheat biorefinery. 2. List the milestones (indicators of progress) from your Project Plan. (FY 2002) a. Complete evaluation of lab scale separation using a screening/drying system to model full-scale operation in an analog of the
conventional batter process. b. Complete evaluation of the influence of drying conditions (particularly temperature) on changes to gluten vitality. (FY 2003) a. Complete development of new project component for using biopolymer membranes to separate ethanol from water during fermentation to fuel- grade ethanol. b. Complete countercurrent extraction experiments on wheat separation. Evaluate opportunity for pentosan recovery. (FY 2004) a. Establish new project: biopolymer-based barriers to separate ethanol from water from ethanol fermentation fluids and from cold-ethanol separation of wheat gluten and starch. b. Establish collaborative research through MU or CRADA for additional evaluation and engineering assessment. c. Assess current project and develop project plan for next 5 years subject to peer review by OSQR. 3. Milestones: FY (2003) a. Completed countercurrent extraction experiments on wheat separation. Evaluated opportunity for pentosan recovery. Substantial progress.
Reevaluation of this milestone suggested a more critical need for compositional studies including the assessment of soluble and insoluble protein removed during the washing of dough with cold ethanol. These studies were completed. Collaboration has been formed with WRRC scientist to assist in the pentosan assessment. FY (2004) a. Established new project: biopolymer-based barriers to separate ethanol from water from ethanol fermentation fluids and from cold-ethanol separation of wheat gluten and starch. Successfully met. New support position filled and analytical instrumentation installed and tested. Literature analysis of ethanol- selective membranes substantially completed and experimentation initiated. b. Established collaborative research using Memorandum of Understanding or CRADA for additional evaluation and engineering assessment. Successfully met. Three companies with interest in barrier separations, plant design, and grain refining have indicated the desire in writing to
collaborate with us in the evaluation and development of this research. c. Assess current project and develop project plan for next 5 years subject to peer review by OSQR. Successfully met. New project plan formulated and in final evaluation received the highest scoring level by peer panel. B. Refer to the annual report for new CRIS project, pending OSQR process completion. 4. What were the most significant accomplishments this past year? A. Single Most Significant Accomplishments With unpredictable and declining exports of US wheat over the past 20 years, creation of new markets for US wheat hinges on efficiently separating or biorefining this grain into its constituents to optimize its value as a feedstock for bioproducts, fine chemicals and ethanol. Researchers at Western Regional Research Center (WRRC) developed and scaled-up cold-ethanol based methods for separating and refining wheat into its major constituents. During this year WRRC researchers developed and implemented
technology that resulted in the ability to track each protein constituent and to identify how ethanol composition and temperature affected the removal, quality and end-use value of each protein. This new knowledge is being used to predict the full-scale capability of this process, define the separation equipment required, and to facilitate industrial adoption of improved wheat bio-refining. B. Other Significant Accomplishments Barrier-based separation of ethanol and water is critical in all ethanol fermentation processes, and thus has widespread implications. It is particularly pertinent in the present research because of the need to manage ethanol concentrations in the cold ethanol starch/gluten separation with the requirement to eliminate added processing water. Researchers at WRRC, Albany invented a "New Filtering Device Utilizing a Combination of Membrane Materials which Allows for Selective Isolation of Target Compounds from a Production Stream" which can be used for separating
ethanol from fermentation broths. This invention, which has been approved by the Area-wide Patent Committee and will be filed shortly, is based on experimental evaluation of ethanol-selective extractants as components of a novel hybrid barrier system employing both selective barriers and solvent extraction. C. Significant Accomplishments/Activities that Support Special Target Populations None. D. Progress Report Barrier-based separation of ethanol and water: This effort is critical in all ethanol fermentation procesess, and thus has widespread implications. A complete overview and analysis of the existing barrier literature is substantially complete. We initiated experimental evaluation of ethanol- selective extractants as components of a novel hybrid barrier system employing both selective barriers and solvent extraction. Wheat separation: Kilogram-scale wheat separation methods are now regularly employed to disperse and separate wheat fractions using enclosed vibratory screening.
In addition to producing high quality vital gluten, this process has the added benefit of creating separate phases in the chilled ethanol starch "wash-off" that contain pentosans and soluble and insoluble protein. An improved understanding of the composition of the wash-off is important in the identification of co-product and process equipment and was sought during this period. Recovery of these components could have important implications to the overall attractiveness of the cold-ethanol method eg. the pentosans have specific food-ingredient and potential health benefits. Differences in both starch and protein functionality/composition between cold-ethanol-produced and water- produced vital products continue to be studied. Using the cold-ethanol process, gluten properties are generally better, and starch is more specifically fractionated into its morphological components, such as A- type starch, B-type starch. New processing capabilities have been acquired, installed, and tested by
the team, including a solvent ready basket centrifuge, a solvent-ready decanter centrifuge, and capillary electrophoresis. Substantial progress was made in the development of thermoformed gluten polymers. A variety of crosslinking and formulation strategies were assessed for their impact on elastic properties of these pliable polymers. 5. Describe the major accomplishments over the life of the project, including their predicted or actual impact. This project developed the fundamental basis for optimalling separating wheat components in non-aqueous ethanol systems. It established significant new knowledge about the material and chemical properties of sensitive proteins and natural protein combinations following exposure to ethanol. This information is crucial to the development of the novel cold-ethanol method patented by WRRC. Specific accomplishments include: (1) discovery that the cold ethanol extraction method improves wheat gluten quality as determined in farinograph,
mixograph, and baking evaluations. It maintains quality through severe drying conditions, (2) definition of the use of novel "dough-ball" and "dispersed-batter" methods for the production of wheat gluten concentrates, and (3) development of new fundamental knowledge about selective protein solubility and the composition of proteins in processing fluids applied to developed wet-dough. As a whole, these findings provide critical support for adoption of the cold-ethanol method as a processing technology that can produce improved wheat quality. This should lead to market advantages for domestically- produced wheat components. Further, the body of information developed within this project has recently stimulated interest by grain processing companies for further investigation. Advancement of this technology will require preliminary costing, further process definition and small pilot- scale evaluations. In addition, these findings help to improve the fundamental understanding of the
chemical and functional properties of native and processed wheat fractions. The accomplishments were reported in 7 publications and one patent with additional manuscripts in preparation. Oral presentations and individual meetings with company representatives have been included in the ongoing effort to effect technology transfer. Substantially all scientific milestones have been, or will be addressed in these publications. This project was consistent with two components of the National Program 306 Action Plan (a) "New knowledge derived from improved understandings of the structure, properties, metabolism, and function of crop and animal components, particularly carbohydrates, proteins, and lipids, will generate development of a variety of new food, feed, and industrial products." and (b) "New technologies to convert commodities and processing byproducts into important value-added products such as fat substitutes, high-quality animal feeds, improved textiles, pharmaceutical
ingredients, enzymes, and cosmetics will fill demonstrated needs." This project was consistent with two components of the National Program 307 Action Plan (a) "New technologies that integrate feedstock pretreatment, biological conversion and product recovery processes, as well as fundamental knowledge regarding fermentation, milling and membrane separations. The information gained will result in a reduction in capital and processing costs associated with biofuel production." (b) "Higher value coproducts generated from current low-value production byproducts. Envisioned coproducts include specialty oils, novel polysaccharides that will compete with imported gums, sugar alcohol food additives that are currently imported, enzymes, and inexpensive aquaculture feeds." 6. What science and/or technologies have been transferred and to whom? When is the science and/or technology likely to become available to the end- user (industry, farmer, other scientists)? What are the constraints, if
known, to the adoption and durability of the technology products? The technology is currently available through patent and publications. Information has been conveyed to a number of interested companies through reference to web summaries, printed brochures and personal discussions at trade related meetings such as the Fuel Ethanol Workshop and the Corn Utilization and Technology Conference held this year. Particular targets have been grain-processing companies and design firms. Constraints: the separation technology affects many parameters of the overall process system and would require retirement of complex existing facilities and installation of new processing operations. Therefore, reliable data on product quality, drying properties, etc. and larger scale evaluations are essential to implementation. The technology may become available for small-pilot evaluation (outside WRRC) within the next 1-2 years as scale- up experiments proceed. 7. List your most important publications in
the popular press and presentations to organizations and articles written about your work. "Creating and capturing total value of agricultural resources for biofuels and biobased products." 8pp. Posted at http://www.pw.usda.gov. Also distributed as brochure at trade meetings.
Impacts
(N/A)
Publications
- Robertson, G.H., Cao, T.K. Effect of processing on functional properties of wheat gluten prepared by cold-ethanol displacement of starch. Cereal Chemistry. 2003. v. 80. p. 212-217.
- Robertson, G.H., Cao, T.K. Mixograph responses of gluten and gluten- fortified flour for gluten produced by cold-ethanol or water displacement of starch from wheat flour. Cereal Chemistry. 2002. v. 79. p. 737-740.
- Robertson,G.H., Cao, T.K. Options and opportunities for Biorefining of Wheat. American Institute of Chemical Engineers. 2002. Abstract Page No. 293a.
- Robertson, G.H., Cao, T.K. Altering gluten mixing and baking quality by method of separation and drying. American Association of Cereal Chemists. 2002. Abstract No. 419.
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Progress 10/01/02 to 09/30/03
Outputs
1. What major problem or issue is being resolved and how are you resolving it? Over the past twenty years, exports of US wheat have been both unpredictable and declining. A potentially huge market for wheat is the biorefining and bioconversion of wheat into biobased products, including fine chemicals and fuel-grade ethanol. A key biorefining step is the fractionation of the wheat into starch and protein concentrates. Current separation technologies, which produce concentrates of starch and gluten, are costly and have difficulty competing with foreign imports. Contributing to the expense of the commercial methods are: (1) outdated, nonstandard mill technologies; (2) the inefficient use of energy; and (3) the generation of copious amounts of wastewater. This project researches new and relevant separation technologies and systems. One of these is the cold-ethanol process invented at WRRC, in which ethanol serves as a process fluid to largely replace the use of water
and reduce energy use. The cold-ethanol method of separation has the potential to reduce energy and water usage, leading to optimal use of all co-product streams. Another important technology is the separation of ethanol and water, which is crucial to the cold ethanol method, as well as to the eventual production of fuel-grade ethanol from surplus starch. The overall project goal is to improve wheat refining, increase wheat usage in bioproducts and biofuels (ethanol), and improve grain-to-ethanol processing efficiency. 2. How serious is the problem? Why does it matter? The total value of US wheat exports is 2/3 of its 1987 value, yet the total production has remained constant. The amount of wheat available for domestic use is roughly 30 billion pounds and growing. Of this amount, the US gluten industry currently separates a little more than 2 billion lbs of wheat into starch and protein for food and non-food uses. This represents 58% of the total domestic gluten market; the rest of
which is mostly imported from Europe due to their relative cost advantage. The potential of improving separation processes to improve starch and gluten separation would lead to increased domestic production of gluten, reduced imports, and improved attractiveness of all fractionated wheat components including starch for fuel-grade ethanol. Wheat starch as a fermentation feedstock could significantly expand grain-to-ethanol production in the US, help to reduce dependence on imported fuels and toxic oxygenates, and improve the nation's ability to produce ethanol in a wider range of diverse regional locations. Improved energy-efficiency through improved ethanol-water separations is crucial to the future of the wheat biorefinery. 3. How does it relate to the National Program(s) and National Program Component(s) to which it has been assigned? This project is 60% assigned to National Program 306: Quality, Utilization of Agricultural Products and 40% to National Program 307: Bioenergy and
Energy Alternatives. The research directly addresses the stated needs for new uses and process innovation for the separation of wheat into constituent concentrates and creation of new, high-value and biobased products. The separation of wheat into protein and starch leads to the potential availability and use of the starch as an ethanol fermentation feedstock. The separation of ethanol and water is key to the proposed wheat separation process and to the overall energy efficiency of grain-to-ethanol manufacturing. 4. What were the most significant accomplishments this past year? A. With exports of US wheat over the past 20 years have been both unpredictable and declining, creation of new markets for US wheat may hinge on efficiently separating it into its constituents to use as a feedstock for bioproducts, fine chemicals and ethanol. Researchers at Western Regional Research Center have developed and scaled-up cold- ethanol based methods for wheat separation and refining into its major
constituents. A semi-continuous, kg-scale method for separating and drying wheat fractions was demonstrated to be capable of producing gluten with superior mixing and baking functionality when compared to conventional vital wheat gluten separated by traditional water-based methods. This new medium-scale process can predict the full-scale capability of this process, enable the evaluation of newly identified fractions, and ultimately lead to industrial adoption of improved wheat biorefining. B. Other Significant Accomplishments: None C. Significant Accomplishments/Activities that Support Special Target Populations: None. D. Progress Report: The scope of this research has recently been expanded to include efforts toward more efficient barrier separation of ethanol and water. This issue is critical in all ethanol biorefining, and thus has widespread applications. It is particularly pertinent in the present research because of the need to manage ethanol concentrations in the cold ethanol
starch/gluten separation with the requirement to eliminate added processing water. An Engineer SY who was recently added to the project has initiated materials-focused research to identify and evaluate energy efficient barrier-based separation methods for this problem. Recent Developments: Large-scale wheat separation methods are now employed to disperse and separate wheat fractions using enclosed vibratory screening. In addition to producing high quality vital gluten, this process has the added benefit of creating separate phases in the chilled ethanol starch "wash- off" that is identified as a pentosan-rich phase. Recovery of this fraction could have important implications to the overall attractiveness of the cold-ethanol method, as the pentosans have specific ingredient and health benefits. Differences in both starch and protein functionality/composition between cold-ethanol-produced and water- produced vital products have been established. Using the cold-ethanol process, gluten
properties are generally better, and starch is more specifically fractionated into its morphological components, such as A- type starch, B-type starch and pentosans. 5. Describe the major accomplishments over the life of the project, including their predicted or actual impact. In this project accomplishments include: (1) discovery that the ethanol extraction method improves wheat gluten quality as determined in farinograph, mixograph, and baking evaluations, and maintains quality through severe drying conditions, and (2) development of a "batter"-like method for the production of wheat gluten concentrates. 6. What do you expect to accomplish, year by year, over the next 3 years? FY 2004: Establish new project emphasis on using biopolymer-based barriers to separate ethanol from water during fermentation to fuel-grade ethanol and during separation of wheat gluten and starch. Complete countercurrent extraction experiments on wheat separation. Evaluate opportunity for pentosan recovery.
Establish collaborative research through MU or CRADA for additional evaluation and engineering assessment. FY 2005: Characterize and optimize barrier properties for optimal ethanol separation efficiency. Optimize countercurrent processing of ethanol for wheat separation. Develop pilot scale evaluation in conjuntion with a collaborator. FY 2006: Evaluate fractionated gluten properties vis-a-vis production of pure glutenin and gliadin fractions for uses in biopolymer formulation. Conduct pilot scale experimentation. 7. What science and/or technologies have been transferred and to whom? When is the science and/or technology likely to become available to the end- user (industry, farmer, other scientists)? What are the constraints, if known, to the adoption and durability of the technology products? The technology is currently available to scientists through patent and publications. Constraints: the separation technology affects many parameters of the overall process system and
would involve retirement of complex existing facilities, and installation of new processing operations. Therefore, reliable data on product quality, drying properties, etc. and larger scale evaluations are essential to implementation. The technology may become available commercially within the next year as scale-up experiments proceed. 8. List your most important publications in the popular press and presentations to organizations and articles written about your work. (NOTE: This does not replace your peer-reviewed publications listed below). Invited presentation: Robertson, G.H. Separation, Disassembly, and Assembly: Redefining Biorefining. California Institute of Food and Agriculture. 2002. Abstract. p. 13.
Impacts
(N/A)
Publications
- Robertson, G.H., Cao, T.K. Effect of processing on functional properties of wheat gluten prepared by cold-ethanol displacement of starch. Cereal Chemistry. 2003. v. 80. p. 212-217.
- Robertson, G.H., Cao, T.K. Mixograph responses of gluten and gluten- fortified flour for gluten produced by cold-ethanol or water displacement of starch from wheat flour. Cereal Chemistry. 2002. v. 79. p. 737-740.
- Robertson,G.H., Cao, T.K. Options and opportunities for Biorefining of Wheat. American Institute of Chemical Engineers. 2002. Abstract Page No. 293a.
- Robertson, G.H., Cao, T.K. Altering gluten mixing and baking quality by method of separation and drying. American Association of Cereal Chemists. 2002. Abstract No. 419.
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Progress 10/01/01 to 09/30/02
Outputs
1. What major problem or issue is being resolved and how are you resolving it? Over the past twenty years, exports of US wheat have been both unpredictable and declining. A potentially huge market for wheat is the biorefining and bioconversion of wheat into biobased products including fine chemicals and fuel-grade ethanol. A key biorefining step is the fractionation of the wheat into starch and protein concentrates. Current separation technologies produce concentrates of starch and gluten that are costly and have difficulty competing with foreign imports. Contributing to the expense of the commercial methods are: (1) outdated, nonstandard mill technologies; (2) the inefficient use of energy; and (3) the generation of copious amounts of waste water. This project researches separation technologies and systems that use cold ethanol as a process fluid to largely replace the use of water and reduce energy use. The cold-ethanol method of separation has the potential to
reduce energy and water usage, leading to optimal use of all co-product streams. The overall goal is to improve the economics of wheat processing, and increase wheat usage in bioproducts, especially biofuels, and ethanol separation during biofuel production. 2. How serious is the problem? Why does it matter? The total value of US wheat exports is 2/3 of its 1987 value, yet the total production has remained constant. The amount of wheat available for domestic use is roughly 30 billion pounds. Of this amount, the US gluten industry currently separates a little more than 2 billion lbs of wheat into starch and protein for food and non-food uses. This represents 58% of the total domestic gluten market; the rest of which is mostly imported from Europe due to their relative cost advantages. The potential of improving separation processes to improve starch and gluten separation would lead to increased domestic production of gluten, reduced imports, and improved attractiveness of all
fractionated wheat components including starch for fuel-grade ethanol. Wheat starch as a fermentation feedstock could significantly expand grain-to-ethanol production in the US, help to reduce dependence on imported fuels and toxic oxygenates, and improve the nation's ability to produce ethanol in a wider range of diverse regional locations. Additionally, by characterizing the properties of each of the separation streams during wheat milling, one can create new co-products, such as wheat gluten thermoplastics for biodegradable films. 3. How does it relate to the national Program(s) and National Program Component(s) to which it has been assigned? This project is 60% assigned to National Program 306: New Uses, Quality, & Marketability of Plant and Animal Products and 40% to National Program 307: Bioenergy and Energy Alternatives. The research directly addresses the stated needs for new uses and process innovation for the separation to constituent concentrates and creation of new,
high-value and biobased products. The separation of wheat into protein and starch leads to the potential availability and use of the starch as an ethanol fermentation feedstock. 4. What was your most significant accomplishment this past year? A. In the traditional water-based separation of gluten from wheat, the gluten loses much of its vitality. Using a novel ethanol-based method to displace starch from a well-developed dough, ARS researchers improved the vitality of gluten significantly relative to that from the conventional water displacement method. The gluten derived from ethanol cold- processing exhibited better mixing properties, and comparable or improved baking properties. Most importantly, the ethanol-separated gluten was much more resistant to high temperature extremes of drying. Improved gluten quality via the ethanol process will reduce energy costs and improve the competitiveness of US-produced gluten. B. Other Significant Accomplishments: None C. Significant
Accomplishments/Activities that Support Special Target Populations: None. D. Progress Report: The identification of superior quality in the cold- ethanol-produced gluten is a significant milestone in that it gives access of the gluten from this technology to traditional gluten markets. This eliminates an important potential barrier to the adoption of this novel technology. We believe that the advantage arises from both reduced condensation of the protein and reduced water activity during drying. Concentrated efforts have been directed toward scale-up of the mixing and separation technologies; thus making this process more accessible to potential industrial partners. The method for separating starch from the gluten is multifunctional because it also removes water, thereby accelerating and simplifying drying. Further scale-up is being pursued to facilitate Technology Transfer. Studies to characterize unique material properties of the gluten for conventional bread fortification and
as a component in a number of industrial products are underway. 5. Describe your major accomplishments over the life of the project, including their predicted or actual impact? In this project the accomplishments include: (1) Discovery that the ethanol extraction method improves wheat gluten quality attributes in farinograph, mixograph, and baking evaluations, and maintains quality through severe drying conditions. (2) A "batter"-like method for the production of wheat gluten concentrates. In preceding projects, related accomplishments include: (1) Discovery of the cold ethanol method for displacing starch from developed wheat dough, which was patented. (2) Description of the physical factors (temperature, moisture, and dough development) important to the separation of starch from dough by either by water or cold ethanol displacement. 6. What do you expect to accomplish, year by year, over the next 3 years? Year 1: Develop new program on using biopolymer membranes to separate
ethanol from water during fermentation to fuel-grade ethanol. Complete countercurrent extraction experiments on wheat separation. Evaluate opportunity for pentosan recovery. Establish collaborative research through MU or CRADA for additional evaluation and engineering assessment. Year 2: Characterize and optimize membrane properties for optimal ethanol separation efficiency. Optimize countercurrent processing of ethanol for wheat separation. Develop pilot scale evaluation in conjunction with collaborator. Year 3: Evaluate fractionated gluten properties vis-a-vis production of pure glutenin and gliadin fractions for uses in biopolymer formulation. Conduct pilot scale experimentation. 7. What technologies have been transferred and to whom? When is the technology likely to become available to the end user (industry, farmer other scientist)? What are the constraints, if known, to the adoption durability of the technology? The technology is currently available to scientists through
patent and publications. Constraints: the separation technology affects many parameters of the overall process system and would involve retirement of complex existing facilities, and installation of new processing operations. Therefore, reliable data on product quality, drying properties, etc. and larger scale evaluations are essential to implementation. The technology may become available commercially within the next year as scale-up experiments proceed.
Impacts
(N/A)
Publications
- Robertson, G.H., Cao, T.K. Farinograph responses for wheat flour dough fortified with wheat gluten produced by cold-ethanol or water displacement of starch. Cereal Chemistry. 2001. v. 78. p. 538-542.
- Robertson, G.H., Cao, T.K. Comparison of separation method (cold-ethanol or water displacement) on the functional properties of freeze-dried vital wheat gluten. 2001. American Association of Cereal Chemists Annual Meeting. Abstract No. 330.
- Gregorski, K.S., Cao, T.K., Robertson, G.H. Development of wheat flour dough as observed through Fourier-transform infrared spectroscopy. American Association of Cereal Chemists Annual Meeting. 2001. Abstract No. 418.
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Progress 10/01/00 to 09/30/01
Outputs
1. What major problem or issue is being resolved and how are you resolving it?
Exports of US wheat have been declining and are an unpredictable market. These factors have led to the need and desire to identify new and expanded markets for wheat and its fractions. Many potential markets will depend on the biorefining and bioconversion of wheat into higher-value food and biobased products. A key component of biorefining is the fractionation or separation of the wheat into starch and protein concentrates. Current technologies for the separation are inefficient and the concentrates of starch and gluten are costly to produce. In part due to their price, these concentrates have difficulty competing with foreign imports. Contributing to the expense of the commercial methods are outdated, nonstandard technologies; the use of capital intensive separation and highly specialized drying equipment; the inefficient use of energy; and the generation of copious amounts of aqueous waste. This project researches systems of separation technologies that are based on the use of
ethanol as a process fluid. These novel separation technologies may overcome the limitations of the current methods. The research also seeks to define new uses for the resulting gluten fraction(s) not only to help create new stable and large markets, thereby meeting producer/processor needs, but also to meet national needs and desires for environmental and wildlife-friendly biopolymers.
2. How serious is the problem? Why does it matter?
Wheat exports from the US are about 2/3 of their value in 1987 even though total production has been relatively constant. The amount of wheat available for other uses can be nearly 30 billion pounds. An expanded and improved wheat gluten industry is an attractive way of utilizing this because it produces purified value-added fractions with large market potential. The US gluten industry, which separates wheat starch and protein by a water-based washing technique, currently uses about 2 billion pounds of wheat annually. From this wheat the industry produces 170 million lb of gluten with an approximate value (assuming 70 cents/lb) of $121 million. This constitutes only 58% of recent domestic usage of purified gluten and the remaining $87 million worth of gluten is imported from Australia and Europe. The value of the domestic starch production (assuming 70% of the wheat is starch at 9 cents/lb) is approximately $126 million. Some of this starch serves as fermentation feedstock to
ethanol. Reduction of the cost of separation could lead to increased domestic production of gluten, reduced imports and improved attractiveness of all fractionated wheat products including starch for bioethanol. The use of wheat starch as a fermentation feedstock could significantly expand grain-to-ethanol production in the US and help to reduce dependence on imported fuels and toxic oxygenates. The use of wheat gluten in products such as structural, flexible films may be an alternate biodegradable, thermoplastic polymer for specialized uses such as the ubiquitous six-pack ring. This use could reduce wildlife death (choking and strangulation), beach litter, and landfill volume.
3. How does it relate to the National Program(s) and National Component(s)?
This project is wholly assigned to National Program 306, Quality and Utilization of Agricultural Products. The research directly addresses the stated needs for new uses and process innovation for the separation to constituent concentrates and creation of new, high-value and biobased products. This project also contributes to the objectives of National Program 307, Bioenergy And Energy Alternatives, but is not formally assigned to it. The separation of wheat into protein and starch leads to the potential availability and use of the starch as an ethanol fermentation feedstock.
4. What were the most significant accomplishments this past year?
A. Single Most Significant Accomplishment: Wheat gluten loses much of its vitality during its processing from flour. Using a novel ethanol-based method to displace starch from a developed dough, ARS researchers compared vitality for gluten produced by the experimental method to that from the conventional water displacement method. They found that the new method yielded gluten with improved mixing properties measured by either farinograph or mixograph and comparable or improved baking properties measured by the gluten-ball baking method. Improved quality for bread making will enhance the uses of wheat gluten, may reduce energy use, and improve the competitiveness of US produced gluten. B. Other Significant Accomplishments: C. Significant Accomplishments/Activities that Support Special Target Populations: None. D. Progress Report: The identification of superior quality in the cold-ethanol-produced gluten is a significant milestone in that it gives access of the gluten from this
technology to traditional and major gluten markets. This eliminates an important potential barrier to the adoption of this novel technology. We believe that the advantage arises from both reduced condensation of the protein and reduced water activity during drying. Concentrated efforts have been directed toward development of an improved cold ethanol batter-like method and in the application of equipment capable of performing the separation and gently drying the product. Studies to characterize unique material properties of the gluten for conventional bread fortification and as a component in a number of industrial products are underway.
5. Describe the major accomplishments over the life of the project including their predicted or actual impact.
In this project the accomplishments include: (1) Discovery of improved wheat gluten quality attributes in farinograph evaluation for gluten prepared by the cold-ethanol method (2) A batter analogous method for the production of wheat gluten concentrates. In preceding projects related accomplishments include: (1) Discovery of the cold ethanol method for displacing starch from developed wheat dough. Method is analogous to the Martin method and was patented. (2) Description of the physical factors (temperature, moisture, and dough development) important to the separation of starch from dough by either by water or cold ethanol displacement. This method of separation could be an important component of a wheat biorefinery leading to products based on the separated components, reducing energy usage, and increasing markets for US wheat.
6. What do you expect to accomplish, year by year, over the next 3 years?
Year 1: Develop lab scale separation using a screening/drying system to model full-scale operation in an analog of the conventional batter process. Begin evaluation of the influence of drying conditions (particularly temperature) on changes to gluten vitality. Optimize gluten and gluten-keratin formulation and process parameters to achieve desired mechanical and biodegradability properties in targeted applications. Establish collaborative research through MU or CRADA. Year 2: Optimize separation efficiency for the cold ethanol batter process. Quantify drying rates of gluten and starch. Evaluate extensibility properties of gluten dough. Make plans for pilot scale evaluation in conjunction with collaborator. Develop initial fractionation strategies for cold ethanol protein. Year 3: Evaluate fractionated gluten properties vis a vis production of pure glutenin and gliadin fractions for uses in biopolymer formulation. Conduct pilot scale experimentation.
7. What science and/or technologies have been transferred and to whom? When is the science and/or technology likely to become available to the end user (industry, farmer, other scientists)? What are the constraints if known, to the adoption & durability of the technology product?
The technology is currently available to scientists through patent and publications. Constraints: the separation technology affects many parameters of the overall process system; therefore, data on product quality, drying properties, etc. and larger scale evaluations are essential to implementation. The technology may become available commercially within 3 years as most of the types of equipment employed are readily available.
8. List your most important publications in the popular press (no abstracts) and presentations to non-scientific organizations and articles written about your work (NOTE: this does not replace your peer-reviewed publications which are listed below)
(1) Biobased Products and Bioenergy, an oral presentation by G.Robertson to the Northwest Biofuels steering committee attended by US Department of Energy, Washington State University, Washington and Idaho Barley and Wheat Commissions, growers and a Spokane environmental group (Spokane, WA 11/2000). (2) New Technologies for Wheat, an oral presentation by G.Robertson to the Farm Expo/Farm Bureau Meeting attended by wheat and barley growers(Spokane,WA 12/2000). (3) Biobased Products from Wheat, an oral presentation by G.Robertson to the American Bakers Association, Technical Liaison Committee attended by millers, bakers, and the National and California Wheat Growers Associations (Albany,CA 3/2001). (4) Wheat to Ethanol, an oral presentation by G.Robertson to the 17th International Ethanol Workshop attended by ethanol producers, DOE, USDA (St.Paul, MN 6/2001).
Impacts
(N/A)
Publications
- Pavlath,A.E., Robertson,G.H. Biodegradable polymers vs. recycling: what are the possibilities. Critical Reviews in Analytical Chemistry. 1999. v. 29(3). p. 231-241.
- Robertson,G.H., Cao,T.K., Ong,I. Wheat gluten swelling and partial solubility with potential impact on starch-from-gluten separation. Cereal Chemistry. 1999 v. 76(6). p. 843-845.
- Robertson,G.H., Cao,T.K., Irving, D. Effect of morphology of mechanically developed wheat flour and water on starch from gluten separation using cold ethanol displacement. Cereal Chemistry. 2000. v. 77(4). p.439-444.
- Robertson,G.H., Cao,T.K. Protein and starch segregation in wheat flour batters and doughs leading to separability. American Association of Cereal Chemists, Seattle, WA. 1999. Paper #182.
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Progress 10/01/99 to 09/30/00
Outputs
1. What major problem or issue is being resolved and how are you resolving it?
Exports of US wheat have been declining. This decline has led to the need and desire new and expanded markets to make use of this now surplus capacity. Many potential markets will depend on the bio-refining and bio-conversion of wheat into higher-value food and bio-based products. A key component of bio-refining is the fractionation or separation of the wheat into starch and protein concentrates. Current technologies for the separation are inefficient and the concentrates of starch and gluten are relatively costly. In part due to their price, these concentrates have difficulty competing with foreign imports. Contributing to the expense of the commercial methods are outdated, non-standard technologies; the use of capital intensive separation and highly specialized drying equipment; the inefficient use of energy; and the generation of copious amounts of aqueous waste. This project researches systems of separation technologies that are based on the use of ethanol as a process fluid
and that can overcome the limitations of the current methods. The research also seeks to define new uses for the resulting gluten fraction(s) not only to help create stable and large markets, thereby meeting producer/processor needs, but also meeting national needs and desires for environmental and wildlife-friendly bio-polymers.
2. How serious is the problem? Why does it matter?
Wheat exports from the US are about 2/3 of their value in 1987 even though total production has been relatively constant. The amount of wheat available for other uses can be nearly 30 billion pounds. An expanded and improved wheat gluten industry is an attractive way of utilizing this because it produces purified value-added fractions with the potential for creating large markets. The US gluten industry, which separates wheat starch and protein by a water-based washing technique, currently uses about 2 billion pounds of wheat annually. From this wheat the industry produces 170 million lb of gluten with an approximate value (assuming 70 cents/lb) of $121 million. This constitutes only 58% of recent domestic usage of purified gluten and the remaining $87 million worth of gluten is imported from Australia and Europe. The value of the domestic starch production (assuming 70% of the wheat is starch at 9 cents/lb) is approximately $126 million. Some of this starch serves as fermentation
feedstock to ethanol. Reduction of the cost of separation could lead to increased domestic production of gluten, reduced imports and improved attractiveness of all fractionated wheat products including bio-fuel or oxygenate ethanol. The use of wheat starch as a fermentation feedstock could significantly expand grain-to-ethanol production in the US and help to reduce dependence on imported fuels and toxic oxygenates. The use of wheat gluten use in products such as structural, flexible films may be an alternate biodegradable, as a thermoplastic for specialized uses such as the ubiquitous six-pack ring could reduce wildlife death (choking and strangulation), beach litter, and landfill requirements.
3. How does it relate to the National Program(s) and National Component(s)?
This project is assigned to National Program 306 100% New Uses, Quality, & Marketability of Plant Products. The research directly addresses the stated needs for new uses and process innovation for the separation to constituent concentrates and creation of new, high-value and bio-based products. This project also contributes to the objectives of National Program 307, Bio-energy And Energy Alternatives, but is not formally assigned to it. The separation of wheat into protein and starch leads to the potential availability and use of the starch as an ethanol fermentation feedstock.
4. What were the most significant accomplishments this past year?
A. Single Most Significant Accomplishment: The cold-ethanol method for separating wheat starch and protein from wheat flour was developed at the Western Regional Research Center to solve long-standing efficiency and environmental problems and could lead to further expansion of the use of wheat for food and nonfood bioproducts but has been limited because the relative quality of the wheat protein produced by the method was unknown. ARS researchers at the Western Regional Research Center conducted tests of the mixing properties of cold-ethanol wheat gluten added to protein deficient flour and compared these to conventional process gluten. The research team found that the gluten produced by the cold ethanol method (and freeze dried) was at least as good as the conventional process gluten (freeze dried) in improving the mixing properties of the wheat flour to which it was added. This unexpected and important quality attribute will enhance the attractiveness of this radically new
technology to the wheat separation industry. B. Other Significant Accomplishments: C. Significant Accomplishments/Activities that Support Special Target Populations: D. Progress Report:
5. Describe the major accomplishments over the life of the project including their predicted or actual impact.
The major accomplishment for this project (formerly 5325-41000-030) has been the discovery and invention of the patented refrigerated or cold-ethanol process. This has included experimental characterization of the hydration, development, and washing conditions leading to successful separation by ethanol displacement of water and starch. In addition recent basic studies to identify the role of particle swelling and temperature as well as microscopic investigation of aggregated protein structures leading to separability of wheat protein and starch. This accomplishment has the potential for widespread application for gluten/starch production in the United States and foreign countries. We have also discovered that gluten and gluten-feather combinations, reductive chemistry, and thermoforming will produce polymers with properties similar to polypropylene. This or analogous formulations are potential candidates to replace synthetic polymers for environmentally sensitive products like
six-pack rings.
6. What do you expect to accomplish, year by year, over the next 3 years?
Year 1: Scale-up of the refrigerated-ethanol-based separation to 1 kg capacity of larger. Completed materials characterization of CE-gluten employing gluten baking tests (without starch and yeast) and dough inflation tests (proofing analog). Optimized gluten and gluten-keratin formulation and process parameters to achieve desired mechanical and biodegradability properties in targeted applications. Development with CRADA partner of mini-pilot scale component testing at WRRC leading to initial pilot plant designs. Year 2: Optimized separation efficiency for the cold ethanol process. Report of bread baking characteristics. Evaluation of drying rates of the gluten, drying rate of starch, extensibility properties of gluten. Evaluation and completion of plans for pilot scale evaluation in process plant (collaboratively with existing CRADA partner). Year 3: Development of initial subfractionation strategies for CE-protein. Evaluation of pilot scale experimentation (collaboratively with
existing CRADA partner).
7. What science and/or technologies have been transferred and to whom? When is the science and/or technology likely to become available to the end user (industry, farmer, other scientists)? What are the constraints if known, to the adoption & durability of the technology product?
A summary including publications and poster reprints from recent meetings was sent to the National, Washington, Idaho, and Kansas Wheat Commissions and to known wheat-to-gluten processors (Robertson author, 1/2000). There is an ongoing CRADA to evaluate the practicality of this technology for large scale. The technology is currently available to scientists through patent and publication. Constraints: the separation technology affects many parameters of the overall process system; therefor, data on product quality, drying properties, etc. and larger scale evaluations are essential to implementation. The technology may become available commercially within 3 years.
8. List your most important publications in the popular press (no abstracts) and presentations to non-scientific organizations and articles written about your work (NOTE: this does not replace your peer-reviewed publications which are listed below)
(A) This research was reported to the National Program 306 Workshop, (St. Louis MO. 11/99). (B) An oral presentation was made to the Ethanol Producers and Consumers 10th Annual Meeting (Red Lodge, MT. 6/2000 with 60 participants from US, Japan, Canada, and Sweden.) (C) Robertson,G.H., Grain biorefining/bioethanol research. Energy Independent. 2000. v.6(7) p.5 (D) An oral presentation was made to the Washington, Idaho, and Oregon Wheat Commissioners, WRRC. Albany, CA(6/2000).
Impacts
(N/A)
Publications
- Pavlath,A.E., Robertson,G.H. Biodegradable polymers vs. recycling: what are the possibilities. Critical Reviews in Analytical Chemistry. 1999. v. 29(3). p. 231-241.
- Robertson,G.H., Cao,T.K., Ong,I. Wheat gluten swelling and partial solubility with potential impact on starch-from-gluten separation. Cereal Chemistry. 1999 v. 76(6). p. 843-845.
- Robertson,G.H., Cao,T.K., Irving, D. Effect of morphology of mechanically developed wheat flour and water on starch from gluten separation using cold ethanol displacement. Cereal Chemistry. 2000. v. 77(4). p.439-444.
- Robertson,G.H., Cao,T.K. Protein and starch segregation in wheat flour batters and doughs leading to separability. American Association of Cereal Chemists, Seattle, WA. 1999. Paper #182.
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