Source: UNIVERSITY OF TENNESSEE submitted to NRP
PRODUCTION AND VALORIZATION OF HEMICELLULOSIC BIOREFINING STREAMS AS FUNCTIONAL FEED INGREDIENTS FOR THE POULTRY INDUSTRY
Sponsoring Institution
National Institute of Food and Agriculture
Project Status
ACTIVE
Funding Source
Reporting Frequency
Annual
Accession No.
1030628
Grant No.
2023-67021-39644
Cumulative Award Amt.
$626,713.00
Proposal No.
2022-10844
Multistate No.
(N/A)
Project Start Date
Jan 1, 2023
Project End Date
Dec 31, 2025
Grant Year
2023
Program Code
[A1531]- Biorefining and Biomanufacturing
Recipient Organization
UNIVERSITY OF TENNESSEE
2621 MORGAN CIR
KNOXVILLE,TN 37996-4540
Performing Department
Center for Renewable Carbon
Non Technical Summary
This project aims to valorize agricultural residues through development of scalable isolation approaches of underutilized hemicellulose-enriched biorefinery streams for novel application as functional feed additives. Hemicellulose-derived sugars like xylooligosaccharides (XOS) have significant potential as non-antibiotic promoters for chicken growth performance and health, which are currently needed in the prebiotic feed additives market. Moreover, in 2021, demand for non-antibiotic animal feed additives in the U.S. was ~ 8 million ton, whereas the supply of XOS-like functional ingredients was only 150 ton. The value chain of hemicellulose-derived XOS products is hampered by high costs associated with energy consumption for XOS separation and lack of high-quality XOS formulations with consistent efficacy in improving chicken productivity. Therefore, our long-term goal is to develop an economically and environmentally viable approach for large-scale production of XOS with proven efficacy for promoting poultry health and growth and stimulate the utilization of hemicellulosic sugars in the functional feed additive industry. To achieve this goal, we propose to 1) Engineer XOS process streams with tunable chemical composition from agricultural feedstocks, 2) Evaluate and validate XOS for enhanced growth performance and pathogen resistance in broiler chickens, and 3) Develop a cost-effective and scalable process to mass-produce validated XOS formulations. Our project will energize the U.S. bioproducts manufacturing (from pulp mills to ag-fiber industry), create resilient animal feed supply chains, and improve the nation's health and the environment. Ultimately, our project has the dual advantages of multiplying the revenue streams of biorefineries and improving the sustainability of poultry production.
Animal Health Component
50%
Research Effort Categories
Basic
34%
Applied
50%
Developmental
16%
Classification

Knowledge Area (KA)Subject of Investigation (SOI)Field of Science (FOS)Percent
51117992020100%
Goals / Objectives
Our long-term goal is to develop an economically and environmentally viable approach for large-scale production of xylooligossacharides (XOS) with proven efficacy for promoting poultry health and growth, and stimulate the utilization of hemicellulosic sugars in the functional feed additive industry. Our cross-cutting approach will encompass the following interdisciplinary objectives:Obj.1: Engineer XOS process streams with tunable chemical composition from agricultural feedstocks. We will combine hydrothermal biomass fractionation with advanced separation technology based upon membranes and adsorbents to maximize the output of XOS with specific composition and functionality. We will use wheat straw as our agricultural biomass model and comprehensively characterize the resulting hemicellulosic streams to aid in the fractionation of XOS using environmentally safe solvents and scalable approaches.Obj.2: Evaluate and validate XOS for enhanced growth performance and pathogen resistance in broiler chickens. We will test our XOS fractions with different molecular weight and functionality for their efficacy in improving chicken growth rate, gut microbial diversity, and host resistance to reduce colonization of significant pathogens in the intestine. Promising XOS fraction(s) will serve as a model for further process optimization.Obj.3: Develop a cost-effective and scalable process to mass-produce validated XOS formulations. We will build and simulate complete process flowsheets for XOS production. Different process flow scenarios will be evaluated by techno-economic analysis for the co-production of XOS in a biorefinery and the selection of a cost-effective process.
Project Methods
We will use a combined severity factor to optimize the autohydrolysis conditions and maximize XOS production. We will test 7 seveity conditions and repeat each experiment in triplicate. The composition and purity of XOS will be determined based on the total amount of monosaccharides and polysaccharides present per gram of the liquid process sample using the National Renewable Energy Laboratory's standardized protocols.For the chicken feeding studies, XOS produced using the optimized autohydrolysis conditions will be subjected to dewatering and then fractionated according to molecular weight and chemical functionality. To handle the harsh conditions at the front end of this process, we will demonstrate the use of graphene oxide nanofiltration (GO NF) membranes with tuned molecular weight cutoff (MWCO) in the range of 300-400 Da to retain XOS (and some fraction of the by-products) and produce a retentate product with a total solids content of 30% (w/v) while permeating water, inorganic contaminants, and some by-products. Then, commercial ultrafiltration membranes with 1.2 kDa or higher MWCO will be used to separate XOS larger than DP 9 from the concentrated NF retentate after a necessary pH adjustment.The XOS fractions will be evaluated in vivo in broiler chickens by the following method. Sixty chicks that are one day of age will be assigned into 4 groups (15 birds per group in a single floor pen). The birds in the control group will receive only water while those in the three treatment groups will receive an XOS fraction as oral supplement, once a day for 56 days.Each bird in the experimental groups will be orally gavaged with a treatment (an XOS fraction or water) at a dose of 20 mg/kg body weight per day. During the 56-day experiment, the birds will be weighed weekly to record the body weight (BW) and subsequently the body weight gain (BWG). Upon termination (using our standardized animal study protocols), ileal and cecal contents will be collected from each bird, and subjected to microbiome analysis as described in our previous publications.We will use well-established chicken models to determine C. jejuni colonization as detailed in our publications. For this task, 60 one-day-old chicks will be assigned into 4 groups (15 birds per group in wired cages). The chickens in each group will receive only water or specific XOS fraction on a daily basis via oral gavage. On day 15, each bird will be challenged with C. jejuni NCTC 11168 (dose of 105 CFU/chicken). To assess colonization of C.jejuni in the intestine, cloacal swabs will be collected every 2 days for the next 10 days. Swabs will be plated on Mueller Hinton agar containing selective supplement (SR117E; Oxoid) for enumeration of Campylobacter cells. Percentage of chickens colonized by C. jejuni and the shedding level of Campylobacter in chickens colonized by C. jejuni will be determined. Two-way ANOVA followed by least significant difference test will be used to assess the significance of difference among the percentages and shedding levels of the groups at each sampling point.We will use the Aspen Plus process simulator together with the non-random two-liquid model thermodynamic package and Henry gaseous components to design a process flow and simulate commercial-scale XOS production using data generated in the project. We will extend the process simulations to the selected XOS candidates from our poultry prebiotic evaluations. Custom models developed at Georgia Tech for membrane separation and adsorption units will be coupled to Aspen Plus via a MATLAB-Excel-Aspen interface, as implemented recently in our modified kraft process flowsheet. The mass and energy balances obtained from the simulations will be used as the input data for the technoeconomic analysis. Detailed costing, cash-flow calculations, and sensitivity analysis will be performed using information from both the CAPCOST package and the Aspen economic analysis modules. Quantifiable sustainability indicators such as overall greenhouse emission savings and energy consumption will also be tracked.

Progress 01/01/24 to 12/31/24

Outputs
Target Audience:The intended audience for this project duration included members of the science and engineering community, collaborators within the pulp/fiber manufacturers, and poultry industries in the United States. The project holds particular significance for individuals engaged in the conversion of the biomass components into value-added materials and chemicals. Our primary focus revolved around advancing Research & Development endeavors. Additionally we aim to demonstrate the potential of hemicellulose-derived XOS (xylooligosaccharides) as non antibiotic sources of functional feed additives and to develop a feasible methodology for XOS isolation and production such that it will ultimately facilitate the integrated utilization of lignocellulosic feedstock in biorefineries. Changes/Problems:No major changes however there aresome delays in the project due to the need to acquire a new extraction system to produce the crude fractions for the study. What opportunities for training and professional development has the project provided?The project's post doc had the opportunity to attend a three-days training program to operate a new bio-digester needed for the project, which features a capacity of 20 liters and is equipped with two vessels to generate large amount of XOS crude extracts. The training was focused on understanding the system's functionality, handling procedures, and optimizing its performance for bio-digestion process. How have the results been disseminated to communities of interest?The research findings that address the production of hemicellulose and potential applications were disseminated at the Circular Bioeconomy System: A Workshop held at University of Tennessee, Knoxville, TN, where it attracted the interest of biorefineries, process engineers, and researchers who are involved in the biomass-based chemicals, fuels, and materials development. Kamboj, G., Labbé, N., Lin, J., D'Souza, D., Wang, S., Nair, S., Rajan, K. Production and valorization of hemicellulose biorefining streams as a functional feed ingredients for poultry industry, CBS (Circular Bioeconomy System) Knoxville, TN., 9th May, 2024. What do you plan to do during the next reporting period to accomplish the goals?During the upcoming project period, the team will produce three fractions of XOS: I) a crude XOS without any purification, II) a high molecular weight XOS mixture (≥DP 10) free of significant by-products, and III) a highly pure low molecular weight XOS mixture (≤DP 9). Additionally, Co-PDs Lin and D'Souza's team will test the performance of these three XOS fractions produced in vivo chicken models. The birds in the control group will receive only water (along with normal feed) while those in the three treatment groups will additionally receive an XOS as a oral supplement. The team will ascertain the ideal XOS fraction (with known chemical composition and molecular weight) that is suitable for chicken body weight gain and resistance toC. jejunicolonization, and as prebiotics for probiotic growth. We also expect to determine the mechanism by which XOS components promote beneficial gut microbiota in the broiler chicken.

Impacts
What was accomplished under these goals? This project aims to develop an economically and environmentally viable approach for large scale production of xylooligosaccharides (XOS) with proven efficacy for promoting poultry health and growth, and thus stimulate the utilization of hemicellulose sugars in the functional feed additive industry. Agricultural residues are valuable sources of hemicellulose-derived xylooligosaccharides (XOS), which are emerging as a prebiotic feed additives. During the project period 2024, PD-Labbé lab conducted major investigation on the effect of temperature and time on the hydrolysate composition of five different biomass sources (switchgrass, wheat straw, miscanthus, pine, and hybrid poplar). High performance liquid chromatography analysis was conducted to identify and quantify the monosaccharides (xylose, glucose, mannose, glactose), oligosaccharides (xylobiose, xylotriose, xylotetraose, arabinobiose), and byproducts (lactic acid, formic acid, acetic acid, furfural) from all authydrolysis hydrolysates. The frozen hydrolyzates were shared with partners at Georgia Tech University for graphene oxide (GO) membrane nanofiltration (NF) process to separate the water from the hemicellulose rich flow. Co-PD Nair's team are working on the GO NF membrane for the rejection of lignin along with molecular weight cutoff (MWCO) ~360 Da. In the base case scenario, the crude NF concentration will be the end product, while in upgraded scenario, additional steps are included to obtain XOS products with targeted molecular weights. The concentrated hemicellulose hydrolysates will pass through ultrfiltration membrane to fractionate high-MW XOS products known as ultrafiltration retentate and low- MW XOS (ultrafiltration crude permeate containing by products). The latter stream will then be sent to selective carbon-based adsorption process to remove/modulate co-products like organic acids and phenolic components. Our goal is to identify hydrothermal fractionation conditions that produce high hemicellulose extraction efficiency and high XOS yield from feedstock. We will utilize these crude and/or purified XOS fragments as poultry feed additives by determining their growth and health-promoting effects in poultry and as value-added prebiotics for growth of select probiotics. Co-PD Nair group has begun evaluation of initial suitable adsorbents for separation of purified XOS streams from the crude XOS extract, based on the chemical compositions of the crude extract provided by the Labbé group. Furthermore, initial membrane nanofiltration of the crude extract is being performed as an initial separation unit operation, and the compositions of the permeate and retentate steams are being analyzed in detail.

Publications


    Progress 01/01/23 to 12/31/23

    Outputs
    Target Audience:The intended audience for this project duration included members of the science and engineering community, collaborators within the pulp, paper, farmers, and poultry feed industry in the United States. The project holds particular significance for individual engaged in the conversion of the biomass components into valuable materials. Changes/Problems: Nothing Reported What opportunities for training and professional development has the project provided?One postdoctoral researcher was hired to process and trained in the pre-processing and characterization of the lignocellulosic feedstocks. How have the results been disseminated to communities of interest?We are actively working on disseminating our results to the communities of interest. We are in the planning phase of hosting a workshop and conference to ensure that our findings will reach a wise audience. These events will provide valuable opportunities for discussion, sharing knowledge, and collaboration. We are also committed to continue to develop meaningful connection with our industrial partners. What do you plan to do during the next reporting period to accomplish the goals?During the upcoming project period, the team will optimize the autohydrolysis process to maximize the XOS production. Additionally, we will characterize the composition and purity of XOS which will be determined based on the total amount of monosaccharides and polysaccharides available per gram of the hydrolyzate. We will also demonstrate the use of the graphene oxide nanofiltration (GO NF) membrane with tuned molecular weight cutoff (MWCO) in the range of 300-400 Da, to retain XOS and produce a retentate product with a total solid content of 30% (w/v) while permeating water, inorganic contaminants, and some by-products. We will evulate and validate XOS for growth performance and the pathogen resistance in broiler chickens.

    Impacts
    What was accomplished under these goals? The approval ofIACUC was submitted to USDA in May 2023 and we received a USDA amendement that releases the fundingin December 2023. Therefore we did not spend any funds in 2023, however, we initiatedsome preliminary work. We conducted a study involving the extraction of extractives present in wheat straw, our model biomass. This step is needed to remove non-structural components, such as free sugars, phenolics, and ash, prior to the extraction of hemicellulose. Sized-reduced biomass was added to an in-house constructed 10L bioreactor and extracted with 2.5 L of water at 100 °C for one hour. The same process was repeated with ethanol, and this was done 18 times to comprehensively assess the variability of the extracted material and generate a large batch of extractives-free biomass. Following the extraction process, the biomass was air-dried and conditioned for the production of hemicellulosic materials for the remaining tasks and objectives of the project.

    Publications