Engineering Commons^™

Fractionation Of Distillers Dried Grains With Solubles (Ddgs) Through A Narrowing Of Particle Size Distribution Followed By Aspiration, Rafael A. Garcia, Kurt A. Rosentrater

Kurt A. Rosentrater

Distiller's dried grains with solubles (DDGS) may have more value and utility if they can be separated into high protein and high fiber fractions. A variety of such separation processes have been proposed; two of the most promising processes involve three screening and three air classification unit operations. In the present study, an alternative process involving fewer unit operations is demonstrated. DDGS are subjected to a single screening, and the oversize particles are processed in a mill setup so that it narrows the particle size distribution of the oversize fraction. The milled DDGS is then processed in an air classification …

Twin-Screw Extrusion Processing Of Distillers Dried Grains With Solubles (Ddgs)-Based Yellow Perch (Perca Flavescens) Feeds, Ferouz Y. Ayadi, Kurt A. Rosentrater, Kasiviswanathan Muthukumarappan, Michael L. Brown

Kurt A. Rosentrater

Increases in global aquaculture production, compounded with limited availabilities of fish meal for fish feed, has created the need for alternative protein sources. Twin-screw extrusion studies were performed to investigate the production of nutritionally balanced feeds for juvenile yellow perch (Perca flavescens). Five isocaloric (~3.06 kcal/g) ingredient blends, adjusted to a target protein content of 36.7% db, were formulated with 0%, 10%, 20%, 30%, and 40% distillers dried grains with solubles (DDGS) at an initial moisture content of 5–7% db, with appropriate amounts of fish meal, fish oil, whole wheat flour, corn gluten meal, and vitamin and mineral premixes. During …

Nutritional Composition And Use Of Common Carp Muscle In Yellow Perch Diets, Travis W. Schaeffer, Matthew J. Hennen, Michael L. Brown, Kurt A. Rosentrater

Kurt A. Rosentrater

High market demand for marine fish meals coupled with increasing costs and questionable sustainability of wild stocks have led researchers to investigate a variety of alternative plant and animal protein sources for aquaculture feeds. Our objective was to evaluate the use of common carp Cyprinus carpio, a locally abundant, nonnative fish species, to offset the cost of marine fish meal in fish feed. We completed analyses of common carp whole muscle, formulated diets containing combinations of carp and Gulf menhaden Brevoortia patronus fish meal, and then evaluated test diets in a feeding trial with yellow perch Perca flavescens. Composition (dry …

Overview Of Fuel Ethanol Production And Distillers Grains, Kurt A. Rosentrater

Kurt A. Rosentrater

Modern societies face many challenges, including growing populations, increased demands for food, clothing, housing, consumer goods, and the concomitant raw materials required to produce all of these. Additionally, there is a growing need for energy, which is most easily met by use of fossil fuels (e.g., coal, natural gas, and petroleum). In 2008, the overall U.S. demand for energy was 99.3 x 1015 Btu (1.05 x 1014 MJ); 84% of this was supplied by fossil sources (U.S. EIA, 2009). Transportation fuels accounted for 28% of all energy consumed during this time, and nearly 97% of this came from fossil sources. …

Manufacturing Of Fuel Ethanol And Distillers Grains—Current And Evolving Processes, Kurt A. Rosentrater, Klein Ileleji, David B. Johnson

Kurt A. Rosentrater

Before examining all of the different possible uses of distillers dried grains with solubles (DDGS), a discussion regarding ethanol and DDGS production methods is warranted. This chapter will cover current production processes and some of the new practices that have been developed and are being adopted at plants, including front-end fractionation and back-end fractionation. Additionally, standard coproduct definitions will be discussed, as they govern the marketing and sales of these materials.

Alternative Protein Sources For Aquaculture Feeds, Ferouz Y. Ayadi, Kurt A. Rosentrater, Kasiviswanathan Muthukumarappan

Kurt A. Rosentrater

With a global seafood production of about 51.7 million ton in 2006 and an annual growth rate of 6.9% from 1970-2006, aquaculture is one of the fastest growing sectors in the food industry. Feed represents 40-70% of operating costs for aquaculture operations. Fish diets typically contain between 20 and 55% crude protein, depending on the fish species. High quantities of fish meal are commonly used in these feeds to supply fish with essential proteins, amino acids and fatty acids. However, during the last 3 years prices for fish meal have remained above $1000 ton-1 and have even approached $2000 ton-1 …

Surface Roughness And Diametral Consistency Of Holes Drilled Into Ddgs/Phenolic Resin Blends, J. W. Shanafield, A. W. Otieno, R. A. Tatara, D. J. Schroeder, Kurt A. Rosentrater

Kurt A. Rosentrater

In this study, corn-based distillers dried grains with solubles (DDGS) has been utilized as a filler and blended with phenolic resin. The blends were compression molded into rectangular test specimens, into which holes have been machined using a standard 9.52 mm (3/8 in) diameter, two-fluted twist drill. A series of tests was then conducted to examine the effects of DDGS content, cutting speed, and feed rate upon the surface finish (roughness) of the interior hole slot, as well as the consistency of the drilled hole diameter. DDGS content was 0, 25, 50, and 75%, by weight. Cutting speed was 17, …

Toward A Scientific Understanding Of Ddgs, Keshun Liu, Kurt A. Rosentrater

Kurt A. Rosentrater

Recently, many people have asked what the fuel ethanol industry is going to do about the growing piles of nonfermented leftovers. Actually this question has been around for quite some time. As early as the 1940s, one report stated that "Grain distillers have developed equipment and an attractive market for their recovered grains" (Boruff, 1947), while another report described that "Distillers are recovering, drying, and marketing their destarched grain stillage as distillers dried grains and dried solubles" (Boruff, 1952). So it appears that a viable solution had already been developed as far back as the 1940s. And by the early …

Extruded Aquafeeds Containing Distillers Dried Grains With Solubles: Effects On Extrudate Properties And Processing Behaviour, Kamal Mjoun, Kurt A. Rosentrater

Kurt A. Rosentrater

BACKGROUND: The tremendous supply and low cost of distillers dried grains with solubles (DDGS) make it an attractive feedstuff for aquaculture diets. Also, several studies have shown that DDGS can be successfully fed to various finfish. The objective of this study was to evaluate the effects of inclusion rate of DDGS (0, 250, 500 g kg−1), feed moisture content (350, 450 g kg−1) and die opening area (die A = 18.85 mm2, die B = 3988.45 mm2) on the properties of the extrudates and on processing behaviour using a single-screw extruder.

RESULTS: Increasing the inclusion rate of DDGS resulted in …

Artificial Neural Network Modeling Of Ddgs Flowability With Varying Process And Storage Parameters, Rumela Bhadra, K. Muthukumarappan, Kurt A. Rosentrater

Kurt A. Rosentrater

Neural Network (NN) modeling techniques were used to predict flowability behavior of distillers dried grains with solubles (DDGS) prepared with varying condensed distillers soluble (10, 15, and 20%, wb), drying temperature (100, 200, and 300°C), cooling temperature (-12, 0, and 35°C) and cooling time (0 and 1 month) levels. Response variables were selected based on our previous research results, and included aerated bulk density, Hausner Ratio, angle of repose, Total Flowability Index, and Jenike Flow Function. Various neural network models were developed using multiple input variables in order to predict single response variables or multiple response variables simultaneously. The NN …

Effects Of Conditioner Steam, Extruder Water And Screw Speed On Physical Properties Of Ddgs-Based Extrudates In Twin-Screw Extrusion, Parisa Fallahi, Kurt A. Rosentrater, Kasiviswanathan Muthukumarappan, Mehmet Tulbek

Kurt A. Rosentrater

A fractional factorial design with a replicated central composite point was used to investigate the effects of extrusion processing on physical properties of DDGS–based aquafeeds using a twin screw extruder. Extrusion cooking trials were performed using an ingredient blend for Nile tilapia, with 2 levels of screw speed (350 and 450 rpm), 2 levels of extruder water (0.236 and 0.302 kg/min) and 2 levels of conditioner steam (0.1 and 0.15 kg/min). The central point was 400 rpm screw speed, 0.271 kg/min extruder water, and 0.12 kg/min conditioner steam. Effects of these processing conditions on extrudate characteristics were extensively analyzed, and …

Quantification Of Physical And Chemical Properties, And Identification Of Potentially Valuable Components From Fuel Ethanol Process Streams, Christine Wood, Kurt A. Rosentrater, Zhengrong Gu, Kasiviswanathan Muthukumarappan

Kurt A. Rosentrater

Wider exploration of ethanol coproducts is required as the ethanol industry continues to expand. Currently, process streams such as thin stillage and condensed distillers solubles (CDS) are processed into DDGS and used as animal feeds, but other higher value opportunities may exist. The objective of this study was to identify chemical components in CDS and thin stillage and to quantify physical properties. Analysis of protein, organic acid, and sugar profiles was explored. Physical properties including density, thermal conductivity, thermal diffusivity, and moisture were also examined. CDS had an average density of 1.02 g/cm 3 , while thin stillage had 1.08 …

Single-Screw Extrusion Modeling Effects On Extrusion Processing Parameters And Physical Properties Of Ddgs-Based Nile Tilapia ( Oreochromis Niloticus ) Feeds, Ferouz Y. Ayadi, Parisa Fallahi, Kurt A. Rosentrater, Kasiviswanathan Muthukumarappan

Kurt A. Rosentrater

A single-screw laboratory extruder was used to conduct an L 18 (2 2 X 3 6 ) Taguchi fractional factorial study of aquafeed processing. The ingredients were based on a formulation for nutritionally-balanced Nile tilapia diets containing distillers dried grains with solubles (DDGS) and soybean meal as the main protein sources, in addition to constant amounts of corn flour, whey, and fish meal. The effects of three levels of DDGS (20, 30 and 40%), soybean meal (30, 40 and 50%), ingredient moisture content (20, 30 and 40% db), screw speed (100, 150 and 200 rpm), barrel temperatures (80-100-100°C, 80-120-120°C and …

Using Alternative Flours As Partial Replacement In Barbari Bread (Traditional Iranian Bread) Formulation, Shirin Pourafshar, Padmanaban G. Krishnan, Kurt A. Rosentrater

Kurt A. Rosentrater

Since cereals and cereal-based products are a cheap source of energy, they are highly consumed in all of countries. Wheat is the major cereal, consumed in different food products, especially bread. Today, whole wheat flour is being consumed in most of the breads because of its nutrient components but still different problems are associated with this flour, such as allergies and loss of nutrient components due to milling and refining. Thus, to find different sources to fortify products made with wheat flour as their major ingredient, especially bread is important. In this study, five different flours (20% of each flour …

Overview Of Corn-Based Fuel Ethanol Coproducts: Production And Use, Kurt A. Rosentrater

Kurt A. Rosentrater

Modern societies face many challenges, including growing populations, increased demands for food, clothing, housing, consumer goods, and the raw materials required to produce all of these. Additionally, there is a growing need for energy, which is most easily met by use of fossil fuels (e.g., coal, natural gas, petroleum). For example, in 2008, the overall U.S. demand for energy was 99.3 x 1015 Btu (1.05 x 1014 MJ); 84% of this was supplied by fossil sources. Transportation fuels accounted for 28% of all energy consumed during this time, and nearly 97% of this came from fossil sources. Domestic production of …

Twin-Screw Extrusion Processing Of Rainbow Trout (Oncorhynchus Mykiss) Feeds Using Various Levels Of Corn-Based Distillers Dried Grains With Solubles (Ddgs), Ferouz Y. Ayadi, Kasiviswanathan Muthukumarappan, Kurt A. Rosentrater, Michael L. Brown

Kurt A. Rosentrater

Increasing demand for seafood products and rising demand for fish meal for commercial fish feeds is driving the search for effective alternative protein sources. Twin-screw extrusion trials were conducted to study the production of nutritionally balanced feeds for rainbow trout fingerlings (Oncorhynchus mykiss). Six isocaloric (≈4.61 kcal/g) ingredient blends with a target protein content of >45% db were formulated with 0, 10, 20, 30, 40, and 50% distillers dried grains with solubles (DDGS) and other feed ingredients. The moisture contents of the diets were initially adjusted to 5–7% db, and then extruded at 250 rpm using dual 1.9 mm dies …

Developing Criteria For Evaluating The Sustainability Of Emerging Energy, Kurt A. Rosentrater, Elif Kongar

Kurt A. Rosentrater

Over the last decade, the interest in and production of biofuels has grown rapidly. Renewable transportation fuels can be produced from a variety of substrates, using various processing strategies. Feedstock preference and factory scale are geographic dependent. However, it is important to understand the implications of deploying these types of systems on a large scale, both throughout the U.S. as well as globally. To assess the sustainability of various biofuel options, it is crucial to evaluate their performance according to a number of attributes. This has been done using Life Cycle Assessment (LCA). Even so, comparisons among biofuel options are …

Single-Screw Extrusion Processing Of Distillers Dried Grains With Solubles (Ddgs)-Based Yellow Perch (Perca Flavescens) Feeds, Ferouz Y. Ayadi, Kasiviswanathan Muthukumarappan, Kurt A. Rosentrater, Michael R. Brown

Kurt A. Rosentrater

This study was conducted to investigate the production of balanced diets for juvenile yellow perch (Perca flavescens) feeds. Six isocaloric (≈3.21 kcal/g), isonitrogenous (30.1 ± 0.4% db) ingredient blends were formulated with 0, 10, 20, 30, 40, and 50% distillers dried grains with solubles (DDGS), and appropriate amounts of soybean meal, fish meal, vitamins, and minerals. Extrusion cooking was performed using a laboratory-scale single-screw extruder at a constant barrel temperature profile of 40–90–100°C, and a constant screw speed of 230 rpm (24.1 rad/sec). The mass flow rate was determined during processing; it generally increased with progressively higher DDGS content. Additionally, …

Effect Of Starch Sources And Protein Content On Extruded Aquaculture Feed Containing Ddgs, Sankaranandh Kannadhason, Kasiviswanathan Muthukumarappan, Kurt A. Rosentrater

Kurt A. Rosentrater

A 3 × 3 × 3 completely randomized design was used to investigate extrusion cooking behavior and product characteristics of distillers dried grains with solubles (DDGS), protein levels, and various starch sources in a laboratory scale single screw extruder. Cassava, corn, and potato starches with varying levels of DDGS (20%, 30%, and 40% wet basis (wb)) were extruded with three different proportions of protein levels (28%, 30%, and 32% wb). The extrusion cooking was performed at a constant feed moisture content of 20% wb, barrel temperature of 120 °C, and a preset screw speed of 130 rpm (13.6 rad/s). Extrudate …

Effects Of Dietary Distillers Dried Grains With Solubles And Soybean Meal On Extruded Pellet Characteristics And Growth Responses Of Juvenile Yellow Perch, Travis W. Schaeffer, Michael L. Brown, Kurt A. Rosentrater

Kurt A. Rosentrater

A 126-d feeding trial was performed to investigate graded combinations of distillers dried grains with solubles (DDGS) and soybean meal (SBM) in diets formulated for yellow perch Perca flavescens. Six experimental diets contained DDGS and SBM at 0 and 31.5% (dry matter basis), respectively (0/31.5 diet), 10 and 26% (10/26), 20 and 20.5% (20/20.5), 30 and 15% (30/15), 40 and 9.5% (40/9.5), and 50 and 4% (50/4) to obtain similar levels of crude protein (mean ± SE = 30.1 ± 0.2%), crude lipid (16.7 ± 0.7%), and digestible energy (13.5 ± 0.2 kJ/g). Fourteen fish (initial individual weight = 19.1 …

Utilization Of Diets Containing Graded Levels Of Ethanol Production Co-Products By Nile Tilapia, Travis W. Schaeffer, Michael L. Brown, Kurt A. Rosentrater, Kasiviswanathan Muthukumarappan

Kurt A. Rosentrater

A feeding trial was performed to investigate inclusion levels of distillers dried grains with solubles (DDGS) as a fishmeal replacement for juvenile Nile tilapia (Oreochromis niloticus). On a dry matter basis, five isocaloric [19.3 ± 0.4 kJ/g (mean ± SE)], isonitrogenous (39.1 ± 0.5% crude protein) diets were formulated to contain 17.5%, 20%, 22.5%, 25%, and 27.5% DDGS and compared against a 0% DDGS, reference diet (gross energy = 14.5 kJ/g; crude protein = 39.8%). The reference diet resulted in significantly higher body weight gain (BWG), food conversion ratio (FCR), and protein efficiency ratio (PER) than experimental diets except that …

Granular Packing Influences Bulk Density Of Ddgs, Christine Keierleber, Kurt A. Rosentrater

Kurt A. Rosentrater

As the quantity of ethanol produced continues to increase, the amount of distillers dried grains with solubles (DDGS), the primary coproduct of ethanol manufacturing, has become more widely available. Currently, the main consumer of DDGS is the livestock industry, but new value-added uses are garnering interest. With the increase in the availability of, and demand for DDGS, transportation has become an important issue because DDGS must be shipped increasingly long distances using railways. Rail transportation is expensive, especially considering the quantities of DDGS that can be loaded onto unit trains. DDGS often has low bulk density and poor flowability characteristics. …

Artificial Neural Network Modeling Of Ddgs Flowability With Varying Process And Storage Parameters, Rumela Bhadra, K. Muthukumarappan, Kurt A. Rosentrater

Kurt A. Rosentrater

Neural Network (NN) modeling techniques were used to predict flowability behavior in distillers dried grains with solubles (DDGS) prepared with varying CDS (10, 15, and 20%, wb), drying temperature (100, 200, and 300°C), cooling temperature (-12, 0, and 35°C) and cooling time (0 and 1 month) levels. Response variables were selected based on our previous research results, and included aerated bulk density, Hausner Ratio, Angle of Repose, Total Flowability Index, and Jenike Flow Function. Various neural network models were developed using multiple input variables in order to predict single response variables or multiple response variables simultaneously. The NN models were …

Tilapia: Profile And Economic Importance, Kamal Mjoun, Kurt A. Rosentrater, Michael L. Brown

Kurt A. Rosentrater

Tilapia is the common name broadly applied to a group of cichlid fishes native to Africa, the Mediterranean, and the Middle East. Tilapia are some of the oldest cultured fishes, as depicted in line drawings found in Egyptian tombs that date back to 2000 BC. This group consists of three economically important genera, which are taxonomically distinguished according to their reproductive behaviors: Tilapia, Oreochromis, and Sarotherodon, all are commonly known as “tilapia.” Tilapia are biparental caring-substrate spawners; Oreochromis are generally maternal mouth brooders; and Sarotherodon are generally paternal or biparental mouth brooders. Currently, Nile tilapia (Oreochromis niloticus; fig. 1) and …

Tilapia: Environmental Biology And Nutritional Requirements, Kamal Mjoun, Kurt A. Rosentrater, Michael L. Brown

Kurt A. Rosentrater

Tilapia is one of the most widely cultured fish in the world. Currently, farmed tilapia represents more than 75% of world tilapia production (FAO, 2009), and this contribution has been exponentially growing in recent years. Several factors have contributed to the rapid global growth of tilapia. Tilapia are easily cultured and highly adaptable to a wide range of environmental conditions. Tilapia feed on a wide variety of dietary sources, including phytoplankton, periphyton, zooplanktons, larval fish, and detritus. Adult tilapia are principally herbivorous but readily adapt to complete commercial diets based on plant and animal protein sources. In the United States, …

Physical And Chemical Characterization Of Fuel Ethanol Coproducts Relevant To Value-Added Uses, Rumela Bhadra, Kurt A. Rosentrater, Kasiviswanathan Muthukumarappan

Kurt A. Rosentrater

One of the fastest growing industries in the United States is the fuel ethanol industry. In terms of ethanol production capability, the industry has grown by more than 600% since the year 2000. The major coproducts from corn-based ethanol include distillers dried grains with solubles (DDGS) and carbon dioxide. DDGS is used as a livestock feed because it contains high quantities of protein, fiber, amino acids, and other nutrients. The goal of this study was to quantify various chemical and physical properties of DDGS, distillers wet grains (DWG), and distillers dried grain (DDG) from several plants in South Dakota. Chemical …

Insect-Damaged Corn Stalks Decompose At Rates Similar To Bt-Protected, Non-Damaged Corn Stalks, R. Michael Lehman, Shannon L. Osborne, Deirdre A. Prischmann-Voldseth, Kurt A. Rosentrater

Kurt A. Rosentrater

The relative decomposability of corn (Zea mays L.) residues from insect (Bt)-protected hybrids and conventional hybrids cultivated under insect pressure was investigated in two studies. Above-ground biomass, residue macromolecular composition, and stalk physical strength were also measured. In the first decomposition study, chopped residues (stalks and leaves) were used from a corn rootworm-protected (Cry3Bb1) hybrid and its non-Bt near isoline that were grown in replicated plots infested with corn rootworms (Diabrotica spp.). In the second study, residue (intact stalk sections) was used from three European corn borer (ECB, Ostrinia nubilalis Hübner)-resistant (Cry1Ab) hybrids representing different seed manufacturer/maturity date series, their …

A Review Of Alternatives To Wheat Flour, Shirin Pourafshar, Kurt A. Rosentrater, Padmanaban Krishnan

Kurt A. Rosentrater

For centuries, cereals have been major food stuffs used all around the world; because of that, there are many different kinds of breads produced from different types of flours. Despite the variety of flours available, there are still many challenges to produce ingredients which maximize nutrient components, and with which healthier breads and other products can be produced. As studies have shown, traditional wheat flour has some nutritional deficiencies (although this is a matter of perspective), which depend on the level of consumption. Additionally, gluten intolerance and Celiac disease are growing problems. The nutritional value of breads can be enhanced …

Malnutrition, A Global Problem, Shirin Pourafshar, Kurt A. Rosentrater, Padmanaban Krishnan

Kurt A. Rosentrater

Malnutrition is a general term for medical conditions caused by an inadequate diet and poor nutrition. Hunger and malnutrition are among the major difficulties confronting many countries around the world. Malnutrition can be caused by several factors, such as the sharp increase in population (current world population is approximately 6,800,000,000), poor distribution of foods, lack of access to highly nutritious foods, and most important, lack of knowledge about healthy diets. Malnutrition can lead to other problems, such as reduced school attendance, learning capacity, spread of HIV/AIDS, malaria and other diseases, and it can have a negative effect on a nation’s …

Effects Of Varying Cds, Drying And Cooling Temperatures On Glass Transition Temperature Of Ddgs, Rumela Bhadra, Kurt A. Rosentrater, Kasiviswanathan Muthukumarappan

Kurt A. Rosentrater

Distillers dried grains with solubles (DDGS), a co product of the corn-based fuel ethanol industry, is used widely as an animal feed. Due to increased demand for DDGS in livestock markets it has become essential to transport DDGS over long distances. Flowability problems in DDGS, due to particle caking, often create nuisance in storage and transportation. Materials above the glass transition temperature (Tg) can exist in a “rubbery state,” this condition can often be responsible for structural collapse, particle agglomeration, and caking of materials. This study investigated the effects of varying CDS (10, 15, and 20%, wb), drying (100, 200, …