Progress 10/01/04 to 09/30/09
Outputs
Progress Report Objectives (from AD-416) To determine the physico-chemical properties of juice from sugarcane varieties subjected to new harvesting and storage practices. Develop markers/indicators of deteriorated and green (unburnt) sugarcane, based on physico-chemical properties, that can be used to predict processing problems. To determine the levels and effects of green trash that impact sugar processing, and improve harvest and processing methods to increase efficiency and reduce sugar losses. Approach (from AD-416) Develop and deliver methods/tests to sugar factory personnel, which can be used to measure sugarcane quality indicator compounds that can predict future processing problems. Undertake studies to characterize the physico-chemical quality and processing ability of different components of green sugarcane trash. Undertake parallel field and factory studies to evaluate the effect of trash quality parameters on factory performance. Undertake collaborations with process managers and designers, to reduce the negative impact of green trash impurities on the efficiency of two specific industrial processes by improving process controls and designs and the use of processing aids. Significant Activities that Support Special Target Populations This project is expiring and this report constitutes the final report. New research objectives will be developed and the project will continue with a different focus. The most significant accomplishments in this project have been the impact that our clarification process has made in the industry. Our process has been adopted by all factories in Louisiana, two factories in Florida, and one factory in Texas. It has been conservatively estimated that from sugar loss and lime consumption savings alone, there is currently almost four million dollars saved per year in Louisiana from the impact of our research. We optimized the use of the enzyme dextranase in sugar manufacture. This enzyme is added in part of the sugarcane treatment train to remove contaminants that cause processing problems. Several factories are now successfully using our simple method to determine how much enzyme to add for best treatment results. We also developed a method based on an enzyme that helps raw sugar factories detect if the sugar from the sugarcane has been degraded by bacteria. Such degradation causes problems and often shut-down, in the factory. This research has already had impact with sugar technologists in Reunion Island (Indian Ocean) who are using the method to monitor deterioration in sugarcane. Also, Brazilian sugar technologists are using the theory of the method to be used as an indicator of bacterial contamination in alcohol yeast fermentations. During the past year we made the following progress on our project: We investigated how trash (sugarcane leaves and top of plants) causes problems when sugarcane is processed to produce raw sugar. It was found that green tops and leaves were the major contributors to changing the normal color of the raw sugar produced. More trash in the mix of the material delivered to factories also caused sugar loss and increased volume of contaminants removed, when the sugar juice is clarified. We investigated how the different types of trash (brown dry leaves and green leaves) contribute to degradation of sugar after sugarcane harvest. It was found that bacteria liked to live on the green leaves more, but that the bacterial attack and breakdown of brown leaves in wet conditions caused more problems at the factory. Technology Transfer Number of Other Technology Transfer: 3
Impacts
(N/A)
Publications
- Zhou, M., Kimbeng, C.A., Eggleston, G., Viator, R.P., Hale, A.L., Gravois, K.A. 2008. Issues of Starch in Sugarcane Processing and Prospects of Breeding for Low Starch Content in Sugarcane. Sugar Cane International. 26(3):3-13.
- Eggleston, G., Karr, J.R., Parris, A., Legendre, B. 2008. Viability of an enzymatic mannitol method to predict sugarcane deterioration at factories. Journal of Food Chemistry. 111:476-482.
- Eggleston, G., Montes, B., Monge, A., Guidry, D. 2008. Optimization of alpha-amylase application in raw sugar manufacture. part I: characterization of commercial alpha-amylases. International Sugar Journal. 110(1310):97-104.
- Eggleston, G., Montes, B., Monge, A., Guidry, D. 2007. Optimization of amylase application in raw sugar manufacture. part II: factory trials. International Sugar Journal. 109(1305):579-584.
- Eggleston, G., Grisham, M.P., Tew, T.L., Triche, R., Antoine, A.C. 2009. Potential Biomass Quantity and Sugar Processing Quality of Trash and Stalk Tissues by Different US Sugarcane Varieties. International Sugar Journal. 111(1322):108-118.
- Eggleston, G. 2008. Sucrose and Related Oligosaccharides. In: Fraser-Reid, B., Tatsuta, K., editors. Glycoscience. 2nd. Edition. Berlin, Germany: Springer-Verlag. Chapter 5.2: p. 1163-1183.
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Progress 10/01/06 to 09/30/07
Outputs
Progress Report Objectives (from AD-416) To determine the physico-chemical properties of juice from sugarcane varieties subjected to new harvesting and storage practices. Develop markers/indicators of deteriorated and green (unburnt) sugarcane, based on physico-chemical properties, that can be used to predict processing problems. To determine the levels and effects of green trash that impact sugar processing, and improve harvest and processing methods to increase efficiency and reduce sugar losses. Approach (from AD-416) Develop and deliver methods/tests to sugar factory personnel, which can be used to measure sugarcane quality indicator compounds that can predict future processing problems. Undertake studies to characterize the physico-chemical quality and processing ability of different components of green sugarcane trash. Undertake parallel field and factory studies to evaluate the effect of trash quality parameters on factory performance. Undertake collaborations with process managers and designers, to reduce the negative impact of green trash impurities on the efficiency of two specific industrial processes by improving process controls and designs and the use of processing aids. Significant Activities that Support Special Target Populations The impact on juice quality of brown, dried, leaves and green plant matter in the harvested sugar cane was studied. It was found that some of this plant matter was beneficial for the clarification of the juice, while other parts were not beneficial. A method developed for determining bacterial deterioration of sugarcane sugar was tested for detection of deterioration of sugarbeet sugar. The method was found valid. The procedure was also tested as a method to detect bacterial contamination in alcohol fermentation. This project is the in-house project to subordinate Trust Agreements, 6435-41000-095-02T, "Combined Research on the Factory Applications of Dextranase" and, 6435-41000-095-03T, "Continuation of Measures of Sugarcane Deterioration for Louisiana factories" with the American Sugar Cane League (ASCL). Additional details of research can be found in the reports for these projects. The project is also the in-house project to subordinate Specific Cooperative Agreement 6435-41000-095-01S, "Characterization on Improvement of Sugarcane and Sugarbeet Process Units" with the Sugar Processing Research Institute. Additional details of the research can be found in the report for this project. Accomplishments Evaluated the Effect of Different Trash Components from Five Commercial Sugarcane Varieties on Industrial Processing. -- Currently, there is a dramatic shift in the U.S. from harvesting burnt sugarcane to harvesting unburnt (green) sugarcane. The effect of green sugarcane harvesting on processing has not been properly or fully characterized and, therefore, few solutions to alleviate the detrimental repercussions have been found. Evaluated the delivery and processing quality of juice from different tissues of five commercial Louisiana sugarcane varieties: LCP 85-384, HoCP 96-540, L 97-128, L 99-226 and L 99-233. The growing point region at the top of the sugarcane plant was found critical for industrial clarification and, therefore, removal of this trash component could adversely affect to processing in the factory. Green leaves slowed down industrial clarification, and brown leaves contributed markedly to unwanted turbidity in clarified juice. This research will help to alleviate the increased detrimental effect of trash being delivered to the factory and, therefore, increase processing efficiency and factory profits. The NP 306 Action Plan, Component 1, "Quality Characterization, Preservation and Enhancement, Problem area 1c �Factors and processes that affect quality." Evaluated the Measurement of Mannitol as an Indicator of Sugarbeet deterioration and Bacterial Contamination in Fuel Alcohol Production from Sugarcane. -- Current methods to measure sugarcane deterioration at the factory are either (1) too complicated, (2) too time-consuming, (3) too expensive, or (4) the results are too difficult to interpret. A new method that overcomes all of these problems is urgently required for factory staff to predict which consignments of sugarcane will cause factory problems and which could be used in a cane payment formula for growers. Sugarbeet processors also face similar problems. We have previously identified mannitol (a sugar alcohol) as a sensitive indicator of sugarcane bacterial deterioration and developed an enzymatic method to measure mannitol at the factory. This method was evaluated on sugarbeet juices from a U.S. factory and found to be valid for determining sugarbeet deterioration and in collaboration with Brazilian sugar technologists, mannitol was shown to be an indicator of bacterial contamination in fuel alcohol fermentations from sugarcane. This research has already had impact in Brazil with the use of mannitol as an indicator of bacterial contamination in fuel alcohol yeast fermentations. Sugar technologists in Reunion Island (Indian Ocean) used the enzymatic method to monitor deterioration in sugarcane in 2005. Sugar technologists in France are monitoring the use of the enzymatic mannitol method to measure sugarbeet deterioration in 2007. The NP 306 Action Plan, Component 1, "Quality Characterization, Preservation and Enhancement, Problem area 1b �Methods to evaluate and predict quality." Technology Transfer Number of Non-Peer Reviewed Presentations and Proceedings: 1 Number of Newspaper Articles,Presentations for NonScience Audiences: 2
Impacts
(N/A)
Publications
- Eggleston, G., Monge, A., Montes, B., Steward, D. 2006. Factory trials to optimize the application of dextranase in raw sugar manufacture: part i. International Sugar Journal. 108(1293):529-537
- Eggleston, G., Basso, L.C., Amorim, H., Paulillo, S.C., Basso, T.O. 2007. Mannitol as a Sensitive Indicator of Sugarcane Deterioration and Bacterial Contamination in Fuel Alcohol Production. Zucker Industrie. 132(1):33-39
- Eggleston, G., Salassi, M., Richard, E., Birkett, H. 2007. Sustainability of the Sugar Industry: Future Value Addition from Sugarcane. International Sugar Journal. 109(1303):415-432.
- Eggleston, G., Amorim, H. 2007. Reasons for the chemical destruction of sugar during the processing of sugarcane for raw sugar and fuel alcohol production. International Sugar Journal. 108(1289):271-282.
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Progress 10/01/05 to 09/30/06
Outputs
Progress Report 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? Why does it matter? This research supports National Program 306: Quality and Utilization of Agricultural Products. It directly addresses the NP 306 Action Plan, Component 1, Quality Characterization, Preservation and Enhancement, Problem area 1b "Methods to evaluate and predict quality," and 1c "Factors and processes that affect quality." In recent years in the U.S., there has been a dramatic shift from the harvesting of whole-stalk to billeted (15-21cm long) sugarcane, and from burnt to unburnt (or green) sugarcane. While this has meant an increase in sugar yields per acre, these production practices have also often reduced the quality of the processed sugarcane, and made processing much more difficult. The two major sources of reduced quality sugarcane are from deterioration reactions, and the delivery
of extraneous matter or trash, i.e., leaves and plant tops, with the green sugarcane to the factory. Sugarcane burning has often been used to remove trash, but pressure from the public and environmental agencies is mounting against open field burning, especially near urban areas, and is expected to be curtailed in the next few years. For sugarcane processors there is an urgent need for factory measurements to indicate and predict sugarcane quality problems associated with deteriorated and green sugarcane. In this project it is proposed to develop and deliver tests to factory personnel, which can be used to measure sugarcane quality indicator compounds that can predict future processing problems. The physico- chemical quality and processing ability of different components of trash, will be characterized. Trash quality parameters will be further evaluated for their effect on factory performance in a large field and factory study. Finally, in collaboration with process managers and
designers, the negative impact of green impurities on the efficiency of specific industrial processes will be reduced by improving process controls and designs and the use of processing aids. The project has two objectives: 1) to determine the physico-chemical properties of juice from sugarcane varieties subjected to new harvesting and storage practices, and develop makers/indicators of deteriorated and green (unburnt) sugarcane, that can be used to predict processing problems, and 2) to determine the levels and effects of green trash that impact sugar processing, and improve harvest and processing methods to increase efficiency and reduce sugar losses. 2. List by year the currently approved milestones (indicators of research progress) FY 2005: * A new mannitol factory assay to measure sugarcane deterioration will have been developed. * A study on the use of mannitol and D-lactic acid at the factory will have begun. * Planting of sugarcane will have been accomplished to evaluate the
processing quality of differentiated sugarcane tissue. * Planting of sugarcane will have been accomplished to evaluate the processing quality of dried, dead leaves compared to fresh, green leaves. * Preliminary studies on the impact of green sugarcane on factory unit processes will have been undertaken. FY 2006: * The evaluation of the use of mannitol and D-lactic acid at the factory to measure sugarcane deterioration will have been completed. * Differences in the processing quality of differentiated sugarcane tissue will have been determined. * The processing quality of dried, dead leaves compared to fresh, green leaves will have been evaluated. * Planting of sugarcane will have been accomplished for a FY 2008 study on the evaluation of the trash components of different sugarcane varieties on processing. * Preliminary studies on the factory performance of green versus burnt billeted sugarcane will have been undertaken. * Factory studies for the determination of the impact of green
sugarcane on factory unit processes will have begun. FY 2007: * The evaluation of the trash components of different sugarcane varieties on processing will have been completed. * Planting of sugarcane will have been accomplished for a FY 2008 large factory study on the factory performance of green versus burnt billeted sugarcane. * Determination of the effects of trash on the boiling ability of juices will have begun. * Factory studies for the determination of the impact of green sugarcane on factory unit processes will have continued. FY 2008: * A large factory study to determine the factory performance of green versus burnt billeted sugarcane will have been conducted. * Determination of the effects of trash on the boiling ability of juices will have continued. * Factory studies for the determination of the impact of green sugarcane on factory unit processes will have continued. FY 2009: * Determination of the effects of trash on the boiling ability of juices/syrups will have been
completed. * Factory studies for the determination of the impact of green sugarcane on factory unit processes will have been completed. 4a List the single most significant research accomplishment during FY 2006. Factory Evaluation and Optimization of the Use of alpha-Amylase to Breakdown Starch in U.S. Sugar Manufacture. Specific accomplishment Evaluated and optimized the application of alpha-amylase (an enzyme that speeds up the reaction of the breakdown of starch) at three Louisiana sugarcane factories in the 2005 processing season. Problem the accomplishment addresses Starch is an unwanted compound that is largely associated with sugarcane trash. The application of alpha-amylase enzyme to breakdown starch in U. S. sugar factories is not optimized. Laboratory studies showed that commercial U.S. alpha-amylases exist in low and high activity forms that do not always reflect the difference in price. U.S. alpha-amylases also exist in high and intermediate temperature stable forms,
and residual activity of the former in raw sugar is a large problem for refiners and end users of sugar and molasses. What was done? Factory studies were undertaken to optimize the addition of intermediate temperature stable alpha-amylases to syrups. Low activity alpha-amylase was not economical to apply. It was found that starch breakdown could be improved by adding working solutions of the alpha-amylase that have been pre-diluted with water at the factory. What Was or Could be Its Impact? This research has already had impact in U.S. sugar manufacture. One factory has already stopped using low activity alpha-amylase, and several factories have stopped applying high temperature stable alpha-amylases. Several factories are now applying working solutions of high activity alpha-amylase to syrups and more are expected. 4b List other significant research accomplishment(s), if any. Evaluated of the Effect of Different Sugarcane Trash Components on Industrial Processing Specific
accomplishment Evaluated the processing quality of juice from different tissues of two commercial Louisiana sugarcane varieties: LCP 85-384 and HoCP 96-540, and ascertained the effect of chemical ripener on different tissues of the plant. Generally, with ripener treatment there are more brown leaves and soluble solid impurities. Brown leaves significantly reduce the quality of clarified juice in the factory. Problem the accomplishment addresses Currently there is a dramatic shift in the U.S. from harvesting burnt to unburnt (green) sugarcane. Unfortunately, this has meant that more trash, i.e., leaves and tops, is being delivered to factories putting added burdens on processors to deal with and remove the trash. The effect of green sugarcane harvesting on processing has not been properly or fully characterized and, therefore, few solutions to alleviate the detrimental repercussions have been found. What was done? Juice was extracted from lower stalk, middle stalk, growing point
region, green leaves, and brown leaves, 27 and 53 days after polado (TM) ripener application. Juice was also extracted from sugarcane with 0 to 25% addition of either green or brown leaves. All the juice was evaluated for processing ability, including heat transfer characteristics and clarification performance. What Was or Could be Its Impact? This research will underpin efforts to alleviate the increased detrimental effect of trash being delivered to the factory and, therefore, increase processing efficiency and factory profits. 4d Progress report. The following research was conducted under two reimbursable agreements between ARS and the American Sugar Cane League, 6435-41000-074-02T and 6435-41000-074-03T, which provides support to this in-house project. 6435-41000-074-02T: Factory studies to optimize the application of dextranase enzyme (a compound that speeds up the breakdown of dextran polymer) in sugarcane juices were completed. Increasing the temperature of juice from 90 to
120 degrees Fahrenheit markedly improves the application and is economical to the factory. A cost-effective enzymatic method was developed to measure mannitol in cane juices as a sensitive measure of cane deterioration. The method can indirectly measure dextran (sugar polymer) in juices. The threshold level of mannitol that detrimentally affects factory processing was ascertained. Mannitol does not degrade on processing but is not always at high levels in raw sugar when deteriorated sugarcane is processed. Mannitol was shown to impede evaporation. 6435-41000-074-03T: Amylase application in sugarcane factories to breakdown starch from trash was optimized. The processing quality of juice from different tissues of two commercial Louisiana sugarcane varieties: LCP 85-384 and HoCP 96-540 was evaluated, as well as the effect of chemical ripener on different tissues of the plant. Generally, with ripener treatment there are more brown leaves and soluble solid impurities. Brown leaves
significantly reduce the quality of clarified juice in the factory. Brown, dried leaves can still be metabolically active and of greater detriment to sugarcane processing than previously considered. 5. Describe the major accomplishments to date and their predicted or actual impact. In 2006 more sugarcane processing factories used results from detailed factory studies on the efficiency of intermediate temperature and hot temperature lime clarification processes, compared to the traditional cold temperature lime process. From 1999-2006, 100% of Louisiana factories have adopted intermediate or hot lime clarification processes. Additionally, two factories in Florida have adopted hot lime clarification, and one in Texas. It has been conservatively estimated that from sugar loss and lime consumption savings alone, there is currently $3,815,200 in dollar savings per year in Louisiana from the impact of this research. Mannitol a product from the deterioration of cane from Leuconostoc
bacteria, has been proven to be a sensitve indicator of Leuconostoc activity and cane deterioration. Mannitol can be measured by sugarcane processors at the factory using a developed enzymatic method that is easy, rapid, inexpensive and reliable. Furthermore, mannitol is equal to, if not better than dextran (a sugar polymer), at predicting factory processing problems associated with high viscosity and low filterabilty. Mannitol can also be more easily measured than dextran at the factory. The quantitative enzymatic method to measure mannitol has potential impact to be used to measure cane deterioration in cane method payment formulas for growers. This research has already had impact with Brazilian sugar technologists using mannitol as an indicator of bacterial contamination in alcohol yeast fermentations. Sugar technologists in Reunion Island (Indian Ocean) are using the method to monitor deterioration in sugarcane in 2005. Optimized the application of dextranase enzyme in U.S.
sugar processing. This research has already had impact in U.S. sugar manufacture. Several factories are now successfully using a simple titration (mixing of chemicals) method, developed for the determination of the relative activity of dextranases to a) economically compare activities of different commercial dextranases, b) measure the activity of delivered batches and c) monitor the changing activities on factory storage. Several Louisiana and Florida factories are now using "concentrated" dextranase over the traditional "non-concentrated" dextranases and more are expected. 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? Critical information on the differences in the factory performance of cold, intermediate, and hot lime clarification processes
was communicated to processors and scientists through a presentation at the 2006 International Society of Sugar Cane Technologists Processing Workshop in Baton Rouge, LA. This work has had significant impact in the U.S. sugarcane industry. Critical information on how to measure dextranase and alpha-amylase enzyme activities at the factory, as well as how and where to add these different enzymes in the factory was communicated to farmers, processors, and scientists through invited presentations at the meeting of the American Society of Sugar Cane Technologists in Baton Rouge, LA and an Industrial Enzyme Symposium at the national meeting of the American Chemical Society in Washington, DC. A major constraint to the full adoption of this technology is the highly conservative nature of the sugar industry. Critical information on the effect of sugarcane trash on processing ability and the optimization of alpha-amylase application in the factory was presented to the research committee of a
sugar cane industrial league. A $10,000 grant was awarded to further study these effects across the 2006 grinding season. Critical information on the effect of sugarcane trash on viscosity of industrial products was presented to the research committee of a sugar cane industrial league. An $18,900 grant was awarded to purchase a specialized deformation rheometer (measures visocity) for this study in 2006. 7. List your most important publications in the popular press and presentations to organizations and articles written about your work. (NOTE: List your peer reviewed publications below). Spillman, A. September, 2003. Raising Cane. ARS Research Benefits Sugarcane Growers and Processors. Agricultural Research, 4-7. Eggleston, G. 2004. Uniform and Easy Measurement of the Activity of Dextranases at the Sugarcane Factory/Refinery. Presented at the American Society of Sugar Cane Technologists meeting, St. Petersburg, FL. June 2004. Eggleston, G., Pollach, G., Triche, R. 2004.
Differentiating Cane White Sugar from Beet White Sugar using ion Chromatography Profiles. Proc. 2004 Sugar Processing Res. Conf., Atlanta, GA, U.S.A., 209-214. Eggleston G, and Monge A. (2004). Optimization of Factory Applications of Dextranases in the U.S. Proc. 2004 Sugar Processing Res. Conf., Atlanta, GA, U.S.A., 371-394.
Impacts
(N/A)
Publications
- Eggleston, G., Doyle, J.P. 2006. Polysaccharides: molecules, clusters, networks and interactions. Oxford University Press. Chapter 2, pp. 19-35.
- Eggleston, G., Harper, W.D. 2006. Determination of sugarcane deterioration at the factory: development of a rapid, easy and inexpensive enzymatic method to measure mannitol. Food Chemistry. 98(2):366-372.
- Eggleston, G., Monge, A. 2005. Minimization of seasonal sucrose losses across robert's type evaporators in raw sugar manufacture by ph optimizationl. Journal of Agriculture and Food Chemistry. 53(16):5332- 6339.
- Grisham, M.P., Hoy, J.W., Godshall, M.A., Eggleston, G. 2005. Effect of Sugarcane Yellow Leaf Virus on Sugarcane Yield and Juice Quality of LCP 85- 384 and Ho 95-988 [abstract]. Journal of the American Society of Sugar Cane Technologists. 25:110-111. Available: http://www.assct. org/journal/journal.htm
- Eggleston, G., Monge, A. 2006. Differences in the factory performance of cold, intermediate, and hot lime clarification processes in raw sugar manufacture. (Abstract). 2006 International Society of Sugar Cane Technologists Processing Workshop. p. 14.
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Progress 10/01/04 to 09/30/05
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? In recent years in the U.S., there has been a dramatic shift from the harvesting of whole-stalk to billeted (15-21cm long pieces) sugarcane, and from burnt to unburnt (or green) sugarcane. While this has meant an increase in sugar yields per acre, these production practices have also often reduced the quality of the processed sugarcane and made processing much more difficult. The two major sources of reduced quality sugarcane are from deterioration reactions and the delivery of extraneous matter or trash, i.e., leaves and plant tops, with the green sugarcane to the factory. Sugarcane burning has often been used to remove trash, but pressure from the public and environmental agencies is mounting against open field burning, especially near urban areas, and is expected to be curtailed in the next few
years. For sugarcane processors there is an urgent need for factory measurements to indicate and predict sugarcane quality problems associated with deteriorated and green sugarcane. In this project it is proposed to develop and deliver tests to factory personnel, which can be used to measure sugarcane quality indicator compounds that can predict future processing problems. The physical and chemical quality and processing ability of different components of trash will be characterized. Trash quality parameters will be further evaluated for their effect on factory performance in a large field and factory study. Finally, in collaboration with process managers and designers, the negative impact of green impurities on the efficiency of specific industrial processes will be reduced by improving process controls and designs and the use of processing aids. The project has two objectives: 1) to determine the physical and chemical properties of juice from sugarcane varieties subjected to
new harvesting and storage practices, and develop makers/indicators of deteriorated and green (unburnt) sugarcane, that can be used to predict processing problems, and 2) to determine the levels and effects of green trash that impact sugar processing, and improve harvest and processing methods to increase efficiency and reduce sugar losses. This research supports National Program 306 B Quality and Utilization of Agricultural Products. It directly addresses the NP 306 Action Plan, Component 1, Quality Characterization, Preservation and Enhancement, Problem area 1b "Methods to evaluate and predict quality," and 1c "Factors and processes that affect quality." 2. List the milestones (indicators of progress) from your Project Plan. FY 2005 Milestones: 1) A new mannitol (a small sugar alcohol) factory assay to measure sugarcane deterioration will have been developed. 2) A study on the use of mannitol and D-lactic acid (a naturally occurring organic acid) at the factory will have begun. 3)
Planting of sugarcane will have been accomplished to evaluate the processing quality of differentiated sugarcane tissue. 4) Planting of sugarcane will have been accomplished to evaluate the processing quality of dried, dead leaves compared to fresh, green leaves. 5) Preliminary studies on the impact of green sugarcane on factory unit processes will have been undertaken. FY 2006 Milestones: 1) The evaluation of the use of mannitol and D-lactic acid at the factory to measure sugarcane deterioration will have been completed. 2) Differences in the processing quality of differentiated sugarcane tissue will have been determined. 3) The processing quality of dried, dead leaves compared to fresh, green leaves will have been evaluated. 4) Planting of sugarcane will have been accomplished for a FY 2008 study on the evaluation of the trash components of different sugarcane varieties on processing. 5) Preliminary studies on the factory performance of green versus burnt billeted (15-21 cm long
pieces) sugarcane will have been undertaken. 6) Factory studies for the determination of the impact of green sugarcane on factory unit processes will have begun. FY 2007 Milestones: 1) The evaluation of the trash components of different sugarcane varieties on processing will have been completed. 2) Planting of sugarcane will have been accomplished for a FY 2008 large factory study on the factory performance of green versus burnt billeted sugarcane. 3) Determination of the effects of trash on the boiling ability of juices will have begun. 4) Factory studies for the determination of the impact of green sugarcane on factory unit processes will have continued. FY 2008 Milestones: 1) A large factory study to determine the factory performance of green versus burnt billeted sugarcane will have been conducted. 2) Determination of the effects of trash on the boiling ability of juices will have continued. 3) Factory studies for the determination of the impact of green sugarcane on factory unit
processes will have continued. FY 2009 Milestones: 1) Determination of the effects of trash on the boiling ability of juices will have been completed. 2) Factory studies for the determination of the impact of green sugarcane on factory unit processes will have been completed. 3a List the milestones that were scheduled to be addressed in FY 2005. For each milestone, indicate the status: fully met, substantially met, or not met. If not met, why. 1. A new mannitol factory assay to measure sugarcane deterioration will have been developed. Milestone Fully Met 2. A study on the use of mannitol and D-lactic acid at the factory will have begun. Milestone Fully Met 3. Planting of sugarcane will have been accomplished to evaluate the processing quality of differentiated sugarcane tissue. Milestone Fully Met 4. Planting of sugarcane will have been accomplished to evaluate the processing quality of dried, dead leaves compared to fresh, green leaves. Milestone Substantially Met 5. Preliminary
studies on the impact of green sugarcane on factory unit processes will have been undertaken. Milestone Substantially Met 3b List the milestones that you expect to address over the next 3 years (FY 2006, 2007, and 2008). What do you expect to accomplish, year by year, over the next 3 years under each milestone? The next 3 year milestones for the new project are listed below with a description of the anticipated outcomes. FY 2006 Milestones: Complete the factory evaluation of mannitol as a predictor of deteriorated sugarcane and processing problems, using the rapid, economic and simple enzymatic method developed in FY 2005. Characterize the extra impurities of green, unburnt cane that are detrimentally affecting processing, and improve target unit process efficiencies to overcome these effects. FY 2007 Milestones: Complete the characterization of the extra impurities associated with differentiated sugarcane tissue that detrimentally affect processing. Evaluate the effects of trash
impurities associated with green, unburnt sugarcane on the boiling and crystallization ability of juices, and improve target unit process efficiencies to overcome these effects. FY 2008 Milestones: Conduct a large multi-disciplinary factory study to determine the factory performance of green versus burnt billeted sugarcane. Improve target unit process efficiencies to overcome the detrimental affects of impurities associated with green sugarcane being delivered to the factories. The potential impact of this research is improved process efficiencies when processing green cane. 4a What was the single most significant accomplishment this past year? Development and Evaluation of Mannitol Method to Predict Processing Problems in U.S. Sugar Manufacture. Specific accomplishment: Developed an enzymatic method to measure mannitol at the factory that is quick, easy, inexpensive, and reliable. The method was evaluated at two sugarcane factories across the 2004 Louisiana processing season, and
was observed to predict dextran (a long chain sugar that forms on sugarcane deterioration which causes unwanted high viscosity in juices and syrup products in factory processing) problems in juices as well as other deterioration problems. Problem the accomplishment addresses: The mechanical harvesting of billeted (15-21cm long pieces) cane is now more predominant than the harvesting of whole-stalk cane in the U.S., but billeted cane deteriorates faster so there is now a more urgent need to have a reliable test of the extent of cane deterioration, including freeze deterioration, at the factory. What was done? An enzymatic method was developed to measure mannitol in cane juices as a measure of cane deterioration, and was evaluated at two sugarcane factories. What Was or Could be Its Impact? This research has already had impact with Brazilian sugar technologists using mannitol as an indicator of bacterial contamination in alcohol yeast fermentations. Sugar technologists in Reunion
Island are using the method to monitor deterioration in sugarcane in 2005. The quantitative mannitol method has the potential to be used to measure cane deterioration in cane method payment formulas for growers. 4b List other significant accomplishments, if any. Factory Evaluation and Optimization of the Use of Dextranases to Breakdown Dextran in U.S. Sugar Manufacture. Specific accomplishment: Evaluated and optimized the application of dextranase (an enzyme that breaks down dextran) at two Louisiana sugarcane factories in the 2004 processing season. Problem the accomplishment addresses: The application of dextranase enzymes to breakdown unwanted dextran (a very long chain sugar) in U.S. sugar factories is not optimized, partly because of misinformation about which enzyme to use and where to add the enzyme. Previous laboratory studies showed that commercial U.S. dextranases exist as traditional non-concentrated or concentrated forms, and it is uneconomical to apply them to syrups
compared to juices. What was done? Factory studies were undertaken to optimize the addition of concentrated dextranase to juices. It was found that greater amounts of dextran in the factory juices improved degradation because of better contact between the dextran and dextranase. Contact can be improved by adding working solutions of the concentrated dextranase that have been prediluted with either water or a sugar solution; in tap or distilled water the working solutions are stable up to 48 hours and in sugar solutions they can by stable up to 140 hours. What Was or Could be Its Impact? This research has already had impact in U.S. sugar manufacture. Several factories are now successfully using a simple chemical method, developed for the determination of the relative activity of dextranases to a) economically compare activities of different commercial dextranases, b) measure the activity of delivered batches and c) monitor the changing activities on factory storage. Three Louisiana
factories are now using concentrated dextranase over the traditional non-concentrated dextranases and more are expected. 4d Progress report. This report serves to document research conducted under a Reimbursable Agreement between ARS and the American Sugar Cane League, 6435-41000-095- 02T. Two factory studies to optimize the application of dextranase enzyme in sugarcane juices were conducted. The greater the amount of dextran in factory juices the easier it was to breakdown because of better contact between the dextran and dextranase. The addition of working solutions of concentrated dextranase were shown to improve contact. A cost-effective enzymatic method was developed to measure mannitol in cane juices as a measure of cane deterioration and was evaluated at two sugarcane factories. The method can indirectly measure dextran in juices. The threshold level of mannitol that detrimentally affects factory processing was found. Mannitol was shown to impede evaporation. This report
also serves to document research conducted under a Specific Cooperative Agreement between ARS and the Sugar Processing Research Institute, 6435-41000-095-01S. The addition of polyaluminium compounds (compounds with multiple aluminium molecules) to improve clarification process was studied and cost-effectiveness studies need to be addressed next. Enzymes were found to remove content of polysaccharides (very long chain sugars) and colorants (compounds that are strongly colored) and cost-effectiveness studies need to be addressed next. Colloidal (gel forming) material in raw sugar was discovered to filter plugs in refineries and affect refined sugar quality. A dextran collaborative study was completed. 5. Describe the major accomplishments over the life of the project, including their predicted or actual impact. In 2005 more sugarcane processing factories used results from detailed factory studies on the efficiency of intermediate temperature and hot temperature lime clarification
processes, compared to the traditional cold temperature lime process. From 1999-2005, 92% of Louisiana factories have adopted intermediate or hot lime clarification processes. Additionally, U.S. Sugars company in Florida have adopted hot lime clarification. It has been conservatively estimated that from sugar loss and lime consumption savings alone, there is currently $2,808,000 in dollar savings per year in Louisiana from the impact of this research. Mannitol a product from the deterioration of cane from Leuconostoc bacteria (a bacteria producing acid) has been proven to be a sensitive indicator of Leuconostoc activity and cane deterioration. Mannitol can be measured by sugarcane processors at the factory using a developed enzymatic method that is easy, rapid, inexpensive, and reliable. Furthermore, mannitol is equal to, if not better than, dextran (a sugar polymer) at predicting factory processing problems associated with high viscosity and low filterabilty. Mannitol can also be
more easily measured than dextran at the factory. The quantitative enzymatic method to measure mannitol has potential impact to be used to measure cane deterioration in cane method payment formulas for growers. The impact of this research is improved processing efficiencies when handling green cane. The research directly addresses the National Program 306 Action Plan by focusing on "methods to evaluate and predict quality" and on "factors and processes that effect quality." 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? Critical information on where sucrose losses occur, how much, and how to reduce such losses across sugarcane factories was communicated to processors and scientists through an invited presentation at the 26th meeting of Fermente in
Sao Pedro, Sao Paulo State, Brazil. Critical information on the differences in the factory performance of cold, intermediate, and hot lime clarification processes was communicated to processors and scientists through an invited presentation at the 26th meeting of Fermentec in Sao Pedro, Sao Paulo State, Brazil. Critical information on how to measure dextranase enzyme activities at the factory, as well as how and where to add dextranases in the factory, was communicated to farmers, processors, and scientists through invited presentations at meetings of the American Society of Sugar Cane Technologists in Baton Rouge, LA, and Belle Glade, FL, as well as at Belle Ksiri factory in Morocco. Constraints to the full adoption of this technology is the highly conservative nature of the sugar industry. An easy, cheap, and reliable method to measure dextranase activity by factory staff in order to allow them to better decide which commercial dextranase to use was successfully transferred to
processors by holding four factory workshops in Florida and Louisiana. The discovery of mannitol as a sensitive indicator of sugarcane deterioration; and the development of a rapid, easy, inexpensive and reliable enzymatic method to measure mannitol at the factory was communicated to processors and scientists through presentations at the Congress of the International Society of Sugar Cane Technologists in Guatemala City, Guatemala, the annual meeting of the American Society of Sugar Cane Technologists in Panama City, FL, and Belle Ksiri factory in Morocco. The mannitol method was also demonstrated to processors at Belle Ksiri factory in Morocco and to a Reunion Island scientist in New Orleans. The development of a rapid, easy, inexpensive, and reliable enzymatic method to measure mannitol at the factory was presented to the research committee of a sugar cane industrial league. A $15,000 grant was awarded to assess the viability of the method at two factories across the 2005 grinding
season. Critical information on the trash components in differentiated portions of sugarcane and their effect on processing ability was presented to the research committee of a sugar cane industrial league. A $10,000 grant was awarded to study this in 2005/06. 7. List your most important publications in the popular press and presentations to organizations and articles written about your work. (NOTE: List your peer reviewed publications below). Spillman, A. September, 2003. Raising Cane. ARS Research benefits Sugarcane Growers and Processors. Agricultural Research, 4-7. Eggleston, G. 2004. Uniform and easy measurement of the activity of dextranases at the sugarcane factory/refinery. Presented at the American Society of Sugar Cane Technologists meeting, St. Petersburg, FL. June 2004. Eggleston, G., Pollach, G., Triche, R. 2004. Differentiating cane white sugar from beet white sugar using ion chromatography profiles. Proc. 2004 Sugar Processing Res. Conf., Atlanta, U.S.A., 209-214.
Eggleston, G., Damms, M., Monge, A., Endres, T. 2004. New Insights on sucrose losses across factory evaporators and juice and syrup clarifiers. Proc. 2004 Sugar Processing Res. Conf., Atlanta, U.S.A., 349-370. Eggleston G, Monge A. (2004). Optimization of factory applications of dextranases in the U.S. Proc. 2004 Sugar Processing Res. Conf., Atlanta, U.S.A., 371-394.
Impacts
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Publications
- Eggleston, G., Pollach, G., Triche, R. 2005. Use of ion chromatography profiles to differentiate cane white sugar from beet white sugar. Zuckerindustrie. 130:611-616.
- Eggleston, G., Monge, A. 2004. Optimization of sugarcane factory application of commercial dextranases in the U.S. Process Biochemistry. 40(5):1881-1894
- Eggleston, G., Monge, A., Stewart, D., Montes, B. 2005. Optimization of applications of dextranases in sugarcane factories [abstract]. Sugar Journal. 68(1): 33.
- Eggleston, G., Monge, A., Ogier, B. 2005. Calagem a quente (101 degrees C) e suas vantagens na producao de acucar [abstract]. Session 3, 26th meeting of Fermentec, Sao Pedro, Sao Paulo State, Brazil, March, 2005, Fermentec Publication. p. 2-3.
- Eggleston, G. 2005. Razoes para a destruicao de acucar durante o processamento de cana [abstract]. Session 3, 26th meeting of Fermentec, Sao Pedro, Sao Paulo State, Brazil, March, 2005, Fermentec Publication. p. 4-5.
- Eggleston, G., Pollach, G., Triche, R. 2004. Differentiating cane white sugar from beet white sugar using ion chromatography profiles [abstract]. ACS 228th Ntl. Mtg, Philedelphia. CARB 050.
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