IMPROVED FEED INGREDIENT FROM DRIED DISTILLERS GRAINS USING DRY TRIBO-ELECTROSTATIC SEPARATION

Abstract

An improved ingredient for animal feed produced from distillers grains using a tribo-electro static belt separation process is disclosed.

Claims

1. An animal feed ingredient comprising dried distillers grains comprising a crude protein content of at least about 39% by weight on a dry matter basis and a fat content greater than 5% and having a true metabolizable energy (TME.sub.n) greater than about 3600 kcal/kg DM.

2.-3. (canceled)

4. The animal feed ingredient of claim 1, wherein the dry matter crude protein content is at least about 40%.

5. The animal feed ingredient of claim 1, wherein the dry matter crude protein content is at least about 45%.

6. The animal feed ingredient of claim 5, wherein the fat content is greater than 4%.

7. The animal feed ingredient of claim 1, wherein the dry matter crude protein content is at least about 48%.

8. The animal feed ingredient of claim 1, wherein the dry matter crude protein content is at least about 50%.

9. The animal feed ingredient of claim 8, wherein the fat content is greater than 2%.

10. The animal feed ingredient of claim 1, wherein the gross energy content is greater than 5000 kcal/kg DM.

11. (canceled)

12. The animal feed ingredient claim 1, having a true metabolizable energy (TME.sub.n) of greater than about 3800 kcal/kg DM.

13. The animal feed ingredient claim 1, having a true metabolizable energy (TME.sub.n) of greater than about 4000 kcal/kg DM.

14. The animal feed ingredient claim 1, having a true metabolizable energy (TME.sub.n) of greater than about 4500 kcal/kg DM.

15. The animal feed ingredient of claim 1, further comprising a fiber content of at least about 3%.

16. The animal feed ingredient of claim 1, further comprising a fiber content of at least about 10%.

17. The animal feed ingredient of claim 1, further comprising a fat content of no more than about 8%.

18. The animal feed ingredient of claim 1, wherein the meal is a feed supplement.

19. The animal feed ingredient of claim 18, wherein the meal is a supplement to the feed having an inclusion level ranging from about 10% to 30% inclusion level.

20. The animal feed ingredient of claim 19, wherein the meal is a supplement to the feed having an inclusion level ranging from about 10% to 20% inclusion level.

21. The animal feed ingredient of claim 19, wherein the meal is a supplement to the feed having an inclusion level ranging of about 20% inclusion level.

22. The animal feed ingredient of claim 18, wherein the feed further comprises one or more of: fish oil, fish meal, L-Lysine, monocalcium phosphate, poultry by- product, vitamin C, other vitamin, wheat gluten meal, corn protein concentrate, soy meal, soy protein concentrate, rapeseed meal and sunflower meal.

23. The animal feed ingredient of claim 18, wherein the feed is provided for aquaculture.

24. The animal feed ingredient of claim 18, wherein the feed is fish feed, i.e. trout feed.

25. The animal feed ingredient of claim 18, wherein the feed is provided for a mono-gastric animal.

26. The animal feed ingredient of claim 25, wherein the feed is provided for beef cattle, dairy cattle, equine, sheep, swine, chickens, ducks, geese, turkey, rabbits, goats, or as pet food for companion animals.

27. The animal feed ingredient of claim 1, produced via fractionation of a feed mixture derived from dried distiller's grains (DDG) or distiller's dried grains and mixed with solubles (DDGS) using a tribo-electrostatic separation (TBS) process.

28. The animal feed ingredient of claim 27, wherein the DDG or DDGS is corn-based.

29. The animal feed ingredient of claim 27, wherein the tribo-electrostatic separation process is a single-step process.

30. The animal feed ingredient 1 of claim 27, wherein the fractionation process comprises: a. milling the DDG or DDGS feed mixture to a specified particle size; b. supplying said milled DDG or DDGS feed mixture to a tribo-electrostatic separator; and c. simultaneously charging and separating said DDG or DDGS feed mixture into at least two subfractions, with one of the subfractions having a protein content and/or a true metabolizable energy level (TME.sub.n) higher than the DDG or DDGS feed mixture and higher than that could be obtained otherwise.

31. The animal feed ingredient of claim 30, wherein the method further comprises optionally drying the milled DDG or DDGS feed mixture to a specified moisture level depending on the specified particle size.

32. The animal feed ingredient of claim 30, wherein the milled DDG or DDGS feed mixture is dried if the specified median particle size is at least about, e.g. 100-125 micron or greater.

33. The animal feed ingredient of claim 27, wherein the DDG or DDGS feed mixture is characterized by a protein level of between about 30-45%, an oil content of less than about 20%, and/or a moisture content of less than about 30%.

34. The animal feed ingredient of claim 33, wherein the protein level of the DDG or DDGS feed mixture is in a range of from about 30% to about 35%.

35. The animal feed ingredient of claim 33, wherein the protein level of one of the sub-fractions is enriched to be anywhere in a range of from about 35% to about 55%, e.g. from about 40% to about 55%.

36. The animal feed ingredient of claim 33, wherein the protein level of one of the subfractions is enriched by at least an absolute protein increase of about 5%, e.g. an absolute protein increase of from about 10% to about 25%.

37. The animal feed ingredient of claim 30, wherein the specified particle size is associated with a fine (e.g. about 50-75 micron or less), medium (e.g. about 100-125 micron) or coarse (e.g. about 225-250 micron or greater) particle size.

38. The animal feed ingredient of claim 33, wherein the feed moisture content is from about 0% to about 12%.

39. The animal feed ingredient of claim 33, wherein the feed oil content is from about 0.7% to about 12.0%.

40. The animal feed ingredient of claim 30, wherein fat content of one of the subfractions is not significantly reduced, i.e. wherein a decrease in fat content of one of the subfractions is less than 2% absolute.

41.-44. (canceled)

45. The animal feed ingredient of claim 30, wherein the DDG or DDGS feed mixture is milled to a specified median particle size of about 225-250 micron or greater and then dried in order to achieve an absolute protein increase of at least about 10%.

46. The animal feed ingredient of claim 45, wherein the milled DDG or DDGS feed mixture is dried in order to achieve a moisture content of about 6.4% or less.

47. The animal feed ingredient of claim 30, wherein the DDG or DDGS feed mixture is milled to a specified median particle size of less than 125 microns.

48. The animal feed ingredient of claim 47, wherein the feed mixture moisture content is less than about 5.8%.

49. The animal feed ingredient of claim 47, wherein the milled DDG or DDGS feed mixture need not be dried in order to achieve an absolute protein increase of at least about 10%.

50. The animal feed ingredient of claim 30, wherein the DDG or DDGS feed mixture is milled to a specified median particle size of about 50-75 micron or less.

51. The animal feed ingredient of claim 50, wherein the milled DDG or DDGS feed mixture need not be dried in order to achieve an absolute protein increase of at least about 10%.

52.-98. (canceled)

Description

BRIEF DESCRIPTION OF DRAWINGS

[0074] Certain illustrative features and examples are described below with reference to the accompanying figures in which:

[0075] FIG. 1 is a schematic of a prior art tribo-electric belt separator system.

[0076] The advantages of the aspect and embodiments of this disclosure may be better understood by referring to the following description when taken in conjunction with the drawings. The drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component that is illustrated in various figures is represented by a like numeral. For purposes of clarity, not every component may be labeled in every drawing. It will be recognized by the person of ordinary skill in the art, given the benefit of this disclosure, that the dimensions, sizes, components, and views shown in the figures are for illustrative purposes. Other dimensions, representations, features, and components may also be included in the embodiments disclosed herein without departing from the scope of the description.

DETAILED DESCRIPTION

[0077] The disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. Aspects of the disclosure are capable of other embodiments and of being practiced or of being carried out in various ways. Also, the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having,” “containing”, “involving”, and variations thereof herein, is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. At least one aspect of the present disclosure is directed to the improved animal feed ingredient produced using a tribo-electric enrichment process and system for the enrichment of protein and true metabolizable energy content from low value by-products such as, for example, those resulting from distillation industries i.e. dried distiller's grains with or without solubles (DDGS or DDG) and to the resulting products from the process, particularly the product that is enriched in protein. The enriched products can have increased value as an ingredient in animal feed formulations.

[0078] In particular, at least one embodiment of the process includes supplying a DDGS/DDG feed mixture to a tribo-electric separator and charging and separating the feed mixture into at least two sub-fractions, with one of the subfractions enriched in protein and true metabolizable energy and having a composition different than the feed mixture. In at least one embodiment, the protein concentration of one of the products of the separator apparatus and process is higher than would otherwise be achievable with the prior art processes or that is naturally occurring.

[0079] Examples of separation results obtained from dried distillers grains are detailed below.

Example 1: Enrichment of Protein from DDGS

[0080] A sample of corn-based distillers dried grains with solubles (DDGS) was prepared for testing using the TBS apparatus and process to demonstrate the capability of the TBS apparatus and process to simultaneously charge and separate distinct protein and starch particles using the TBS apparatus and process in a single step. Feed sample was prepared at three different particle sizes using an impact-type mill—coarse grind with a median (D50) particle size: 225-250 micron, medium grind (D50) with a median particle size: 100-125 micron, and fine grind with a median (D50) particle size: 50-75 micron. The results are described below:

Medium Grind:

[0081] The sample was milled using an impact-type mill to a median particle size of approximately 100-125 micron, contained approx. 8% moisture after milling. The feed sample was fed as-received, with no adjustment to the moisture content, into the TBS separator at a rate of 17 tonne per hour per meter of TBS electrode width. The TBS belt speed was set at 15 feet per second, and 12 kV was applied across the TBS electrode gap to produce an electric field strength of 1390 kV/m. Two resulting products were collected from the two ends of the separator. There was no middling fraction that needed to be re-processed. Table 1 shows the mass yields of the two products, the composition of the feed and the products, achieved in a first pass. For purposes of this example, first pass refers to the feed material having been processed through the separator once.

TABLE-US-00001 TABLE 1 Results from testing corn-based DDGS (medium grind, first pass) Product 1 Product 2 (Enriched (Enriched Feed Fiber) Protein) Mass  100% .sup. 71% .sup. 29% Protein (dry basis) 34.8% 30.0% 46.8% Moisture  7.9% — — Crude Fiber  6.9%  9.0%  3.8% Fiber (ADF) 11.3% 11.8% 11.0% Fiber (NDF) 26.6% 34.8% 14.0% Oil  7.2%  7.1%  7.6% Protein Recovery .sup. 51% .sup. 49%

[0082] The high-protein product from the first pass was then processed through the separator again (second pass) and further protein increase was achieved. The results are shown in Table 2.

TABLE-US-00002 TABLE 2 Results from testing corn-based DDGS (medium grind, second pass) Product 1 Product 2 (Enriched (Enriched Feed Fiber) Protein) Mass 100% .sup. 55% .sup. 45% Protein (dry basis) 46.8%  42.7% 51.8% Moisture  7.9% — — Fiber (ADF) 11.1%  8.9% Fiber (NDF) 19.3% 13.0% Oil  7.7%  7.8% Protein Recovery 50.3% 49.7%

[0083] The effect of moisture on medium grind feed by drying was tested, and no significant effect on protein separation was found.

Fine Grind:

[0084] The sample was milled using an impact-type mill to a median particle size of approximately 50-75 micron, contained approx. 6% moisture after milling. The feed sample was fed as-received, with no adjustment to the moisture content, into the TBS separator at a rate of 17 tonne per hour per meter of TBS electrode width. The TBS belt speed was set at 15 feet per second, and 12 kV was applied across the TBS electrode gap to produce an electric field strength of 1390 kV/m. Table 3 shows the mass yields of the two products, the protein content of the feed and the products.

TABLE-US-00003 TABLE 3 Results from testing corn-based DDGS (fine grind) Product 1 Product 2 (Enriched (Enriched Feed Fiber) Protein) Mass 100% .sup. 70% .sup. 30% Protein (dry basis) 33.9%  28.8% 45.9% Moisture  5.8% — —

Coarse Grind:

[0085] The sample was milled using an impact-type mill to a median particle size of approximately 225-250 micron, contained approx. 10% moisture after milling. The feed sample was fed as-received, with no adjustment to the moisture content, into the TBS separator at a rate of 17 tonne per hour per meter of TBS electrode width. The TBS belt speed was set at 65 feet per second, and 12 kV was applied across the TBS electrode gap to produce an electric field strength of 1390 kV/m. Table 4 shows the mass yields of the two products, the protein content of the feed and the products.

TABLE-US-00004 TABLE 4 Results from testing corn-based DDGS (coarse grind) Product 1 Product 2 (Enriched (Enriched Feed Fiber) Protein) Mass  100% .sup. 84% .sup. 16% Protein (dry basis) 34.1% 33.5% 39.0% Moisture 10.3% — —

[0086] Effect of moisture was investigated on coarse grind feed by drying. Table 5 shows the mass yields of the two products, and protein content of the feed and the products upon reduction of moisture content. In comparison to Table 4, results showed that the protein separation improved significantly at similar mass yields compared to the un-dried feed for coarse grind feed.

TABLE-US-00005 TABLE 5 Results from testing corn-based DDGS (coarse grind, dried) Product 1 Product 2 (Enriched (Enriched Feed Fiber) Protein) Mass 100% 85.1% 14.9% Protein (dry basis) 34.1%  32.5% 44.1% Moisture  6.4% — —

[0087] It was demonstrated that in order to achieve substantial protein increase (≥10% absolute) the feed material must be milled to a particle size with median (D50): 100-125 micron, or milled to finer particle size with median (D50): 50-75 micron, or milled to coarse particle size with median (D50): 225-250 micron and then dried, for example, to 6.4%. It is reasonable to conclude that drying is also useful for particle sizes of greater than 225-250 micron. For example, coarse milled feed material may need to be dried in order to achieve at least about a 10% absolute increase in protein content. Drying does not appear to be required for particle sizes of 100-125 micron or finer. In at least some embodiments, DDG or DDGS with a particle size equal to or less than about median (D50): 100-125 micron need not be dried in order to still achieve at least about a 10% absolute increase in protein content.

[0088] This example demonstrates the capability of TBS process to effectively tribo-charge and separate distinct protein and fiber particles in a single step from a DDGS feed sample in fine dry powder form, generating product streams enriched in each component.

[0089] Feed ingredient performance for mono-gastric and aquatic animals for the enhanced sub-fraction obtained using the TBS process are detailed in the following examples.

EXAMPLE 2

Energy Content in High Protein DDGS Fractions Obtained by Rooster Assays

[0090] Reflecting the rapid growth of the fuel ethanol industry in the early 2000s, corn-based DDGS has found an application in animal feed especially for monogastric animal such as poultry and swine. In such feed formulation, energy, digestible amino acid and phosphorus values are the determining factors of its quality, most of which are available in DDGS. Not only is corn-based DDGS nutritionally ideal for poultry feed but also its low price and availability offer an economical advantage. Furthermore, technological advancement in the fuel ethanol industry enabled to partially remove oil throughout the process resulting in low-fat DDGS. The low-fat DDGS contains 3%-7% fat as compared to the traditional DDGS which contains up to 10% fat. Other example of processing innovation is the production of high protein DDGS which contains significantly higher protein content of 50% compared to the conventional DDGS at around 35% protein. DDGS with various fat contents and its effects on feed quality has been researched extensively yet few research high protein corn-based DDGS.

[0091] A rooster assay utilizing cecectomized roosters was conducted to determine true metabolizable energy (TME.sub.n) using a fine-ground, corn-based high protein DDGS processed by the triboelectric belt separator (TBS). TME.sub.n is defined as its gross energy minus the energy in feces and urine derived from the same quantity of that diet (Equation A). A testing procedure approved by the Institutional Animal Care and Use committee was followed to determine the TME.sub.n: After 24 hours of feed withdrawal 5 cecectomized adult Comb White Leghorn roosters were tube-fed approximately 30g of high protein DDGS. Another 5 roosters were fasted for additional 48 hours. Excreta from each bird were then collected for 48 hours and analyzed for gross energy using an adiabatic oxygen bomb calorimeter standardized with benzoic acid and then TME.sub.n was calculated as equation shown below (Equation A):

[00001]$\mathrm{TMEn}=\frac{\mathrm{FEf}-\left(\mathrm{EEf}+8.22Nf\right)+\left(\mathrm{EEu}+8.22Nu\right)}{\mathrm{FC}}$

where FE.sub.f equals the gross energy of the total feed consumed; EE.sub.f and EE.sub.u equals the energy in the excreta collected from the fed birds and fasted birds, respectively; N.sub.f and N.sub.u equals the gram nitrogen retained by the fed birds and fasted birds, respectively; and FC equals the grams of dry feed consumed (Parsons et al. 1982).

[0092] Dry matter, crude protein, crude fat, gross energy, and TME.sub.n values of the high protein DDGS processed with TBS (TBS 50% protein DDGS or TBS DDGS) along with conventional DDGS and commercially available 50% protein corn meal product produced using the process described in U.S. Pat. Nos. 10,233,404 and 10,519,398 (high protein Corn Meal Product) are shown in the Table 6. Compared to the conventional milled DDGS where the crude fat content is similar to the TBS 50% protein DDGS, the TBS DDGS has shown 916 kcal/Kg DM (or 24%) increase in TME.sub.n value. The crude protein of the TBS DDGS was 18.2% DM higher than the conventional milled DDGS. Comparing to the existing high protein Corn Meal Product to TBS DDGS, TBS DDGS contained 0.9% DM lower crude protein, 5.8% DM higher crude fat and 725 kcal/Kg DM (or 19%) higher TME.sub.n value.

[0093] The in vivo rooster assay demonstrated the additional benefit of TBS process minimizing a fat reduction while enriching protein resulting in a unique high protein DDGS with fat content equivalent to the conventional DDGS. The TBS DDGS showed a drastic increase in true metabolizable energy compared to both conventional DDGS and High Protein Corn Meal Product providing additional value as a feed ingredient.

TABLE-US-00006 TABLE 6 Dry matter, crude protein, crude fat and true metabolizable energy comparison of conventional DDGS, TBS high protein DDGS, TBS low protein DDGS and commercially available High protein Corn Meal Product. Gross Dry Crude Crude Energy TME.sub.n Matter protein fat Kcal/g (kcal/Kg Sample (%) (% DM) (% DM) DM DM) Conventional DDGS 89.4 33.5 8.9 4594 2909 feed (no milling) Conventional DDGS 93.7 33.3 8.9 4591 2941 milled feed TBS DDGS high 92.5 51.5 7.8 5416 3857 protein sample 1 TBS DDGS high 92.8 43.7 NA 4744 3663 protein sample 2 TBS DDGS low 93.6 28.9 NA 4543 2879 protein sample 2 High protein corn meal 93.7 52.4 2.0 NA 3132 product.sup.1 .sup.1Source: Specification of product presented in U.S. Pat. No. 8778433

EXAMPLE 3

Approximate Growth Performance in Fish Diet Formulated with TBS High Protein DDGS Obtained by Trout Digestibility Trial

[0094] A 35 day trout feeding trial with experimental fish diet formulated with TBS high protein (HP)-DDGS was conducted to determine the effect of TBS HP-DDGS in feed digestibility, growth performance and feed intake. TBS HP-DDGS at 48% (DM) protein content was used (Table 7). Female rainbow trout were fed with formulated fish diets containing TBS HP-DDGS at 0, 10, 20 and 30% inclusion levels (Table 8). Diets were formulated to meet nutritional requirement of rainbow trout at given HP-DDGS inclusion levels (NRC, 2011). Trout that have been fed with commercial diet were put into an acclimation period over a week prior to the trial. Commercial diet was transitioned into experimental diet every two days in the ratio of 25:75, 50:50, 75:50, and 100:0. Each diet was tested in three circular digestibility tanks in which data including water condition, growth performance and fecal matter were collected for 35 days. Feed conversion ratio (FCR) was calculated as the weight of feed divided by biomass gain achieved in the same tank during the same period.

TABLE-US-00007 TABLE 7 Composition of TBS HP-DDGS used for feed formulation Composition Unit HP-DDGS Dry Matter % 95.5 Crude Protein % DM 47.7 Crude Fat % DM 8.1 Crude Fiber % DM 3.1 Ash % DM 5.5 Neutral Detergent Fiber (NDF) % DM 26.7 Acid Detergent Fiber (ADF) % DM 23.4

TABLE-US-00008 TABLE 8 Feed formulation of the four experimental diets with graded inclusion of HP-DDGS fed to rainbow trout Inclusion (% as-fed) A B C D Ingredients (Reference) (10HP) (20HP) (30HP) Corn protein concentrate 10.00 9.00 8.00 7.00 Fish oil herring 10.74 9.67 8.59 7.52 Fish meal herring 30.00 27.00 24.00 21.00 L-Lysine 0.03 0.03 0.03 0.02 Monocalcium Phosphate 3.43 3.08 2.74 2.40 (21% P) Poultry by-product meal 20.00 18.00 16.00 14.00 Low ash Stabilized vitamin in c 0.30 0.27 0.24 0.21 (Stay-C) Vitamin & mineral premix 0.50 0.45 0.40 0.35 Wheat gluten meal 10.00 9.00 8.00 7.00 Wheat flour 14.50 13.00 11.50 10.00 TBS HP-DDGS (HP) 0.00 10.00 20.00 30.00 Titanium dioxide 0.50 0.50 0.50 0.50 Total 100 100 100 100

[0095] Preliminary data including initial body weight (IBW), final body weight (FBW), weigh gain (WG), growth rate measured as thermal-unit growth coefficient (TGC), feed intake (FI), and feed conversion ratio (FCR) obtained from 35 days of feeding period are shown in Table 9. The experimental diet with TBS HP-DDGS showed positive effects on growth performance and feed efficiency within the length of trial. Diet with 30% TBS HP-DDGS inclusion showed 21% higher weight gain compared to the reference diet. Feed intake of diet with 30% inclusion showed 29% higher feed intake compared to the reference diet. These results imply that there is a correlation between palatability and growth performance. Little difference between 20% and 30% TBS HP-DDGS inclusion levels was observed.

[0096] The approximate growth rate and feed intake results relative to TBS HP-DDGS inclusion levels strongly indicates the potential of TBS HP-DDGS as a value-added ingredient for aquafeed.

TABLE-US-00009 TABLE 9 Initial body weight (IBW), final body weight (FBW), weight gain (WG), growth rate measured as thermal-unit growth coefficient (TGC), feed intake (FI), and feed conversion ratio (FCR) of Rainbow trout fed the experimental diets containing different High Protein Distillers Dried Grains with Solubles (HP-DDGS) IBW FBW WG TGC FI Diet (g fish.sup.−1) (g fish.sup.−1) (g fish.sup.−1) [g.sup.1/3 (° C. .Math. d.sup.−1)] (g fish.sup.−1) FCR Day 0-35 A (0% HP-DDGS) 35.23 (0.50) 73.86 (0.37) 38.62 (0.28) 0.182 (0.002) 40.06 (0.46) 1.04 (0.02) B (10% HP-DDGS) 34.79 (0.15) 75.08 (0.43) 40.29 (0.34) 0.190 (0.001) 46.22 (0.19) 1.15 (0.01) C (20% HP-DDGS) 34.82 (0.42) 78.73 (2.56) 43.91 (2.18) 0.203 (0.007) 47.20 (2.16) 1.08 (0.02) D (30% HP-DDGS) 34.53 (0.26) 81.16 (1.31) 46.62 (1.23) 0.213 (0.004) 51.75 (0.82) 1.11 (0.02) Average values with Standard Deviation in parenthesis