Progress 05/02/02 to 08/27/04
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? World wide crop production has increased faster than demand for agricultural products, resulting in commodity surpluses and low crop prices. These prices are unduly low for some agricultural commodities. These low commodity prices are making it very difficult for farmers to make a profit. New European Community regulations are making it more difficult to export soybean meal, corn gluten meal, and distillers' dried grains to Europe as animal feed. The inability of processors to export co-products as animal feed may decrease the amount of soybeans and starch processed and the profitability of these industries. Alternative products must be found for these commodity surpluses which will give higher value to the commodity and thus more profit to the farmer. One way to add value to the commodity is to
find alternative uses for the protein-based materials from cereal and oilseed co-products. This research addresses Component 2, New Processes, New Uses, and Value-Added Foods and Biobased Products, of National Program 306, Quality and Utilization of Agricultural Products, by enhancing the economic viability and competitiveness of U.S. agriculture by developing environmentally friendly new products from low value co-products of the cereal and soybean refining industries. 2. List the milestones (indicators of progress) from your Project Plan. FY 2002 Identify material responsible for zein aggregation and gelling. Test diols as plasticizers for zein films Improve soybean meal and corn gluten meal dispersibility in glue formulations. FY 2003 Characterize and identify non zein proteins in corn steep liquor, corn fiber feed, corn gluten meals, and corn germ meal from corn wet milling. Remove yellow color from zein. Test peroxidase as a zein cross-linker. FY 2004 Screening methods to reduce
zein gelling. Determining the identity of novel proteins from wet milling co-products. Test glue formulations containing soybean meal. Apply color reduction method to CGM. 3. Milestones: A. List the milestones that were scheduled to be addressed in FY 2004. How many milestones did you fully or substantially meet in FY 2004 and indicate which ones were not fully or substantially met, briefly explain why not, and your plans to do so. Screening methods to reduce zein gelling; Determining the identity of novel proteins from wet milling co-products; Test glue formulations containing soybean meal; Apply color reduction method to CGM. All of the milestones for FY 2004 were met or substantially met except for milestone "screening methods to reduce zein gelling" and "applying color reduction method to CGM". The reducing zein gelling milestone was not met because we are still having difficulties identifying the factors that are causing zein to gel or aggregate in solution. This problem with
gelation of zein in solution is being addressed in the new project plan, certified on 8/11/04 by the Office of Scientific Quality Review as having completed NP 306, Quality and Utilization of Agricultural Products Panel Review, represented by project 3620-41000-119-00D. The color reduction of CGM was not met because our CRADA partner was more interested in zein color reduction and we concentrated on that research. B. List the milestones (from the list in Question #2) that you expect to address over the next 3 years (FY 2005, 2006 & 2007). What do you expect to accomplish, year by year, over the next 3 years under each milestone? This is the final Report of Progress (AD-421) for this project. A new project plan was certified on 8/11/04 by the Office of Scientific Quality Review as having completed NP 306, Quality and Utilization of Agricultural Products Panel Review. The replacement project, 3620-41000- 119-00D, is entitled "Nonfood utilization of cereal and soy based co-
products." This new project will focus on increasing the demand for co- products produced by the cereal, soybean refining industries along with bioethanol production. FY2005 research will identify and purify potential proteins to be evaluated for new uses. FY2006 and 2007 research will focus on evaluating the functional properties of the protein co-products and improving their properties if need be through chemical, enzymatic, or physical means. 4. What were the most significant accomplishments this past year? A. Single most significant accomplishment during FY 2004. Commercial soybean meal samples were ground into smaller particle sizes. They were subjected to protein identification and tested for solubility and surface properties. Results showed that the major protein groups in soy meal were not negatively affected by grinding and that the solubility and surface properties improved markedly with smaller particle sizes, especially at pH 10. This finding established that grinding
is a beneficial step in preparing soybean meal prior to mixing with other ingredients in the plywood glue formulation. Results also showed that grinding improved the proteins' reactivity, which may facilitate mixing and enhance adhesion properties. These results show that by grinding soybean meal to a smaller particle size it can be incorporated as an extender into standard plywood glues. B. Other significant accomplishment(s), if any. In preparation for the replacement project, 3620-41000-119-00D, entitled "Nonfood utilization of cereal and soy based co-products," evaluations on corn gluten meal (CGM) melts was performed on a Haake torque rheometer. It is essential that melt temperatures and viscosity of CGM is acquired before extrusion runs are carried out. CGM has the advantage of being much less expensive than zein and producing materials directly from it would create a great monetary advantage. The melt rheology and physical properties were evaluated for plasticized extruded
zein. Numerous plasticizers for zein were screened. However, none met the two required goals of improved plastic flow with heat or shear and reduced impact on physical properties on exposure to moisture. Zein films were extruded using various amounts of tri(ethylene glycol) and physical properties were measured parallel and perpendicular to the machine direction. Through the analysis of the physical properties and polarized IR spectroscopy, it was found that zein orientate during extrusion and that this orientation affects physical properties. Predominant proteins in the corn co-products from the wet-milling industries were extracted, freeze-dried and tested for solubility, surface hydrophobicity, heat stability, foaming properties, emulsifying properties, gelling ability, and water-holding capacity. Proteins from corn germ meal (primarily albumins and globulins) were found to have better functional properties than those from fiber or steep liquor. This finding indicates that
corn germ meal may be a possible source of proteins for food/industrial applications or as a nutritional supplement, thereby adding value to a product typically used only as feed. Protein concentrates were produced by ultrafiltration/diafiltration (UF- DF) of expeller-extruded soybean meal and whole lupin meal. This process proved valuable to generate protein concentrates without heat and/or organic solvents currently used in the soy and lupin industries. UF-DF of the partially defatted soy (11% lipid) previously processed by expeller-extrusion or whole lupin meal (12%) removed 67% lipid from soy and 46% from lupin. Soy protein concentrates produced by UF-DF showed improved functional properties, such as solubilities, foaming capacity, emulsifying activity and heat stability compared to concentrates prepared by traditional methods. Methodology using UF-DF in an aqueous system to defat is new and novel. 5. Describe the major accomplishments over the life of the project, including
their predicted or actual impact. Currently when zein is isolated from corn gluten meal it is yellow in color. This yellow color makes it unacceptable for certain applications in foods and coating. Investigations at NCAUR found that the yellow color can be removed by supercritical fluid extraction with carbon dioxide. The extraction yielded almost colorless zein and had excellent zein recoveries. The method also had the added benefit of recovering the yellow causing co-products: xanthophylls and B-carotene. Xanthophylls and B-carotene command a premium price in the nutraceutical market. Investigations at NCAUR also found that zein's yellow color could be removed through ultra-filtration. Pure white zein can be produced by adding a final activated carbon treatment after supercritical extraction or ultra-filtration. White zein will open new marketing opportunities in foods and solve the problem of giving products a yellow hue when using zein as a coating. This new technology
formed the basis for a Cooperative Research and Development Agreement with the Illinois Corn Marketing Board to commercialize decolored zein. 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 work on decolorization of zein has been transferred to a CRADA with the Illinois Corn Marketing Board. Another CRADA was formed with the Illinois Corn Marketing Board to produce zein fibers.
Impacts
(N/A)
Publications
- Hojillaevangelist, M.P., Sessa, D.J., Willett, J.L. 2004. Processing and modification of soy proteins for non-food applications. Soybean Research World Conference Proceedings. p. 1120.
- Sessa, D.J., Hojillaevangelist, M.P., Mohamed, A. 2004. Protein concentrates and isolates by ultrafiltration/diafiltration of fatted and defatted soy and lupin meals. American Oil Chemists Society. p. 116.
- Hojillaevangelist, M.P., Sessa, D.J., Mohamed, A. 2004. Functional properties of soybean and lupin protein concentrates produced by ultrafiltration/diafiltration. American Oil Chemists Society. p. 117.
- Selling, G.W., Sessa, D.J. 2004. Effect of water and tri(ethylene) glycol on rheological properties of zein. American Chemical Society. p. 75.
- Willett, J.L., Finkenstadt, V.L. Reactive extrusion of starch:continuous production of starch graft copolymers. Abstract n. 41-3. p. 102.
- Sessa, D.J. Processing of soybean hulls to enhance the distribution and extraction of value-added proteins*. Journal of the Science of Food and Agriculture 84.2003. p. 75-82.
- Lawton Jr, J.W. Plasticizers for zein:their effect on tensile properties and water absorption of zein films. Cereal Chemistry. 2004. v.81. n.1. p. 1-5.
- Selling, G.W., Sessa, D.J., Palmquist, D.E. 2004. Effect of water and tri(ethylene)glycol on rheological properties of zein. Polymer. Available: http://authors.elseviere.com/sd/article/S0032386104003611.
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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? Worldwide crop production has increased faster than demand for agricultural products, resulting in commodity surpluses and low crop prices. Alternative products must be found for these surpluses which will give higher value to the commodity and thus more profit to the farmer. One way to add value to the commodity is to find alternative uses for the protein-based materials from cereal and oilseed co-products. 2. How serious is the problem? Why does it matter? Prices for agricultural commodities are unduly low. These low commodity prices are making it very difficult for farmers to make a profit. New European Community regulations are making it more difficult to export soybean meal, corn gluten meal, and distillers dried grains to Europe as animal feed. The inability of processors to export co-products as animal feeds may decrease the amount of soybeans and starch processed and the
profitability of these industries. 3. How does it relate to the National Program(s) and National Program Component(s) to which it has been assigned? National Program 306, Quality and Utilization of Agricultural Products (100%). Finding new uses for these co-products will increase the value of proteinaceous co-product, and improve the economics of ethanol fuel production from grain in support of this National Program. 4. What were the most significant accomplishments this past year? A. Single most significant accomplishment during FY2003: Zein is a film forming protein from corn. Zein films are brittle and adding plasticizers to increase its flexibility weakens it. Research was conducted at USDA-ARS-National Center for Agricultural Utilization Research (NCAUR), Peoria, IL, to toughen zein film. Zein films could be significantly toughen by cross-linking the films with a combination of N- hydrosuccinimide and 1-ethyl-3 (3-dimethylaminopropyl) carbodimide hydrochloride followed by
ultraviolet radiation treatment. The cross- linked zein films are superior to films prepared with plasticizers alone. Stress-strain curves of tested cross-linked films resemble the performance of synthetic films. Zein films with improved toughness will expedite the use of zein which would give a much needed coproduct for the bioethanol industry. B. Other significant accomplishment(s), if any: To fully utilize the coproducts from corn bio-processing plants, research was performed at NCAUR to analyze the functional properties (solubility, surface hydrophobicity, foaming, emulsification, heat stability) of proteins extracted from corn germ meal, fiber feed, and steep liquor were completed. Results indicated that proteins from corn germ meal have better functional properties (and therefore, possess greater potential for novel applications) than those from fiber feed and steep liquor. The final drying step during wet-milling appears to have a significantly detrimental effect on the
proteins. The effects of grinding on the reactivity of soybean protein was analyzed. The major protein groups in soybean meal do not appear to have been affected negatively by grinding, and solubility and surface hydrophobicity improved with smaller particle size and at higher pH, which indicated that grinding may improve the reactivity of soybean meal protein enough to make it an effective extender in plywood glues. C. Significant activities that support special target populations: None. 5. Describe the major accomplishments over the life of the project, including their predicted or actual impact. Currently when zein is isolated from corn or corn gluten meal it is yellow in color. This yellow color makes it unacceptable for certain applications in foods and coatings. Investigations at NCAUR found that the yellow color can be removed by supercritical fluid extraction with carbon dioxide using ethanol as an entrainer. The extraction yielded almost colorless zein and had excellent
zein recoveries. The method also had the added benefit of recovering the yellow causing co-products: xanthophylls and B-carotene. Xanthophylls and B-carotene command a premium price in the nutraceutical market. Pure white zein can be produced by adding a final activated carbon treatment after supercritical extraction. White zein will open new marketing opportunities in foods and solve the problem of giving products a yellow hue when using zein coatings. The process was presented to the Illinois Corn Marketing Board. We are currently in the process of forming a Cooperative Research and Development Agreement (CRADA) with them to help their start-up company produce zein and white zein. 6. What do you expect to accomplish, year by year, over the next 3 years? This is the final Report of Progress for this 25 month bridging project. A new Project Plan is currently being written for peer review later in 2004 and is expected to be implemented in 2004. The first year of new project will
consist of performing functionality test on proteinaceous co-products and evaluating protein structure. In the next fiscal year, identification of potential novel applications for the corn proteins will be performed. Corn proteins will be recovered in greater quantities and will be evaluated for their performance in the novel applications. The following year will be devoted to more in-depth evaluations of the most promising application(s) and possibly pilot-scale trials. During the first year of the project, zein structure will be evaluated to establish the mechanism of zein gelling and aggragation. Means of cross-linking of zein will continue to be evaluated. During year two, a particular zein cross-linking procedure will be selected and scale-up of the procedure will be started on plastic processing equipment. Evaluation of the cross-linked zein products will be conducted in year three. For the soybean meal study, the meal will be incorporated in plywood glue formulations,
which will then be applied to plywood samples. Glue strength and water resistance will be evaluated. 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? Zein decolorization of zein was presented to Illinois Corn Marketing Board, a possible CRADA is being discussed.
Impacts
(N/A)
Publications
- LAWTON JR, J.W., SESSA, D.J., BISWAS, A., WILLETT, J.L. IMPROVING ZEIN FILMS BY CROSS-LINKING. AMERICAN OIL CHEMIST SOCIETY MEETING. 2003. Abstract p. 115.
- LAWTON JR, J.W. PROTEINS OF THE KERNEL. White, P.J. and Johnson, L.A., editors. American Association of Cereal Chemists, St. Paul, MN. Corn Chemistry and Technology. 2003. 2nd edition. p. 313-354.
- HOJILLAEVANGELIST, M.P. ADHESIVE QUALITIES OF SOYBEAN PROTEIN-BASED FOAMED PLYWOOD GLUES. JOURNAL OF THE AMERICAN OIL CHEMISTS SOCIETY. 2002. v. 79. n. 11. p. 1145-1150.
- SESSA, D.J., ELLER, F.J., LAWTON JR, J.W. ZEIN DECOLORIZATION METHODS. CORN UTILIZATION CONFERENCE PROCEEDINGS. 2002. Abstract p. 210.
- WILLETT, J.L., HOJILLAEVANGELIST, M.P., LAWTON JR, J.W., SESSA, D.J. UTILIZATION OF PROTEINS FROM AGRICULTURAL CO-PRODUCTS IN NONFOOD APPLICATIONS. WORLD CONFERENCE ON OILSEED AND EDIBLE OIL PROCESSING. 2002. Abstract p. 4.
- SESSA, D.J., ELLER, F.J., LAWTON JR, J.W. METHODS FOR DECOLORIZING CORN ZEIN. CEREAL CHEMISTRY. 2002. Abstract p. 100.
- LAWTON JR, J.W., WILLETT, J.L. GELLING OF ZEIN IN SOLUTION. AMERICAN ASSOCIATION OF CEREAL CHEMISTS MEETINGS. 2002. Abstract p. 89.
- SESSA, D.J. PROTEIN CONCENTRATES AND ISOLATES FROM SOYBEAN HULLS VIA ULTRAFILTRATION/DIAFILTRATION. AMERICAN OIL CHEMIST SOCIETY MEETING. 2003. Abstract p. 113.
- SESSA, D.J., ELLER, F.J., PALMQUIST, D.E., LAWTON JR, J.W. IMPROVED METHODS FOR DECOLORIZING CORN ZEIN. INDUSTRIAL CROPS and PRODUCTS. 2003. v. 18. p. 55-65.
- LAWTON JR, J.W. NEW USES OF CORN PROTEINS. PROCEEDINGS NTERNATIONAL STARCH TECHNOLOGY CONFERENCE. 2003. Abstract p. 39.
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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? Worldwide crop production has increased faster than demand for agricultural products, resulting in commodity surpluses and low crop prices. Alternative products must be found for these surpluses which will give higher value to the commodity and thus more profit to the farmer. One way to add value to the commodity is to find alternative uses for the protein-based materials from cereal and oilseed co-products. 2. How serious is the problem? Why does it matter? Prices for agricultural commodities are unduly low. These low commodity prices are making it very difficult for farmers to make a profit. New E. C. regulations are making it more difficult to export soybean meal, corn gluten meal, and distillers dried grains to Europe as animal feed. The inability of processors to export co-products as animal feeds may decrease the amount of soybeans and starch processed and the profitability of
these industries. 3. How does it relate to the national Program(s) and National Program Component(s) to which it has been assigned? Finding new uses for these co-products will increase the value of proteinaceous co-product, and improve the economics of ethanol fuel production from grain. This research supports National Program 306, Quality and Utilization of Agricultural Products (100%). 4. What was your most significant accomplishment this past year? A. Single most significant accomplishment during FY 2002: Zein solutions gel with time, in order for zein to have a greater acceptance in coating applications, this propensity to gel or aggregate needs to be alleviated. Investigations at NCAUR found that zein solutions prepared with different solvents aggregated at different rates. Zein solutions prepared with ethanol and water aggregated the fastest, while zein solutions prepared with isopropanol and water took up to two weeks to aggregate and zein solutions containing the single
solvent, 2- ethoxyethanol, did not show shown signs of aggregation after two months. Studying the effect of zein aggregation in different solvents will allow us to propose mechanisms for zein aggregation and determine methods to prevent it. B. Other significant accomplish(s), if any: Research on the potential of using soybean meal as an extender in plywood glues has been initiated. Samples were procured from various sources and experiments are being set up to determine the effects of particle size on the reactivity and functionality of the protein in the meal. C. Significant accomplishments/activities that support special target populations: none. 5. Describe your major accomplishments over the life of the project, including their predicted or actual impact? The new project, based on a Project Plan certified by OSQR 2/28/02, emphasizes proteins obtained as a co-product of fuel alcohol production. This is an extension of the work done on zein in the old project where it was found
that water absorption of zein films was dependent upon the type of plasticizer used. During research on finding new plasticizers for zein, there were discussions involving industrial contacts on the industrial need for colorless and nongelling/nonaggregating zein. The new project was written to include basic research on mechanisms gelling and aggregation in zein solutions. The new project will also stress applied research on zein such as decolorization of zein and physical properties of zein films and coatings. Even though the principal goal of the new project addresses research on the co-products of fuel alcohol production, it will still further investigate soy-based adhesives. The former project (3620-41000-090-00D, Chemistry and Thermal Processing of Proteinaceous Co-products for Nonfood Utilization) had significant technology transfer by showing that soy flour and soy protein concentrate performed as well as blood protein in standard phywood foam glues. The new project will
address the problems of using soybean meal as a replacement for blood protein. 6. What do you expect to accomplish, year by year, over the next 3 years? In the final year of this 25 month project, aggregation of zein will be monitored by light scattering. It will be important to establish how the gels and aggregates are forming in order to best prevent them from gelling. Under a similar strategy to determine the mechanism of gelling, zein solution viscosities will be measured as well to determine how their viscosities change over time. In the next fiscal year, the remaining functionality tests and protein structure evaluations will be completed. This information will be used to identify potential novel applications for the corn proteins. 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?
Collaborative research with scientists from the corn wet milling industry was done on the extraction and decolorization of zein from corn gluten meal. The research involved using charcoat to decolorizing zein.
Impacts
(N/A)
Publications
- Kim, S., Willett, J.L. Phase separation in potato starch solutions. Proceedings of Polymeric Materials: Science & Engineering. 2001. v. 85. p. 528-529.
- Lawton, J.W. Influence of plasticizers on the water absorption of cast zein film. 7th World Conference on Biodegradable Polymers and Plastics. 2002. Abstract p. 53.
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