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POTENTIAL USES FOR

DISTILLERS GRAINS

Compiled by:
John Bonnardeaux
Department of Agriculture and Food
Western Australia
3 Baron-Hay Court
SOUTH PERTH WA 6151

MARCH 2007
DISCLAIMER

While all reasonable care has been taken in the preparation of the material in this
document, the Western Australian Government and its officers accept no
responsibility for any errors or omissions it may contain, whether caused by
negligence, or otherwise or for any loss, however caused, sustained by any
person who relies on it.

© State of Western Australia, 2007


Potential Uses for Distillers Grains

TABLE OF CONTENTS
1. INTRODUCTION 1

2. BACKGROUND 1

3. ANIMAL NUTRITION 3

4. FOOD USES 6

5. INDUSTRIAL USES FOR DDGS 7

6. CONCLUSIONS 8

7. REFERENCES 9

List of Tables
Table 1. Average percentage of available protein in selected feed supplements 4

Table 2. Essential amino acids profile 4

Table 3. Average price of available protein from selected feed supplements 4

Table 4. Average and range of available energy content* from DDGS, grains and canola
meal for each animal, expressed in MJ/kg, as Metabolizable Energy (ME) for ruminants,
Apparent Metabolizable Energy (AME) for poultry and Digestible Energy (DE) for pigs
5

Table 5. Average price of available energy from DDGS, grains and canola meal for
various animal 5

Table 6. Feeding value of DDGS in livestock rations 6

List of Figures
Figure 1. Distillers grains flowchart 2

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Potential Uses for Distillers Grains

1. INTRODUCTION
Distillers grains are produced as a co-product from ethanol production from grain. It is a
non-animal based, high protein livestock feed supplement, produced from the distillation and
dehydration process during ethanol production.

Ethanol is derived from the fermentation of sugars and starch derived mainly from vegetable
material such as grain or sugar cane. The fermentation produces alcohol, which can then be
blended with petrol or used as a pure fuel in certain engines (these are flexi vehicles and are
not currently available in WA).

Distillers grain can be sold wet or solid: Wet Distillers Grains (WDG), Distillers' Dried Grains
(DDG), Distillers' Dried Solubles (DDS) and Distillers' Dried Grains with Solubles (DDGS) are
all variations for the co-product from ethanol production and they all vary due to the different
types of treatments at the ethanol plant.

In Western Australia, there is the possibility of significant expansion of the ethanol industry in
the next couple of years which could result in a major increase in volume of distillers’ grains.
Currently, there is no other industry than the livestock industry to absorb the distillers grains.

With a small feedlot industry in Western Australia, alternative uses and markets for distillers
grains will be necessary when proposed ethanol plants become commercial from 2008
onwards. Alternative markets for distillers grains will become important in the future because
there will be an over-supply of the product which could affect the future viability of the ethanol
industry.

This report examines potential uses for distillers grains, including the livestock and human
consumption industries and industrial uses.

2. BACKGROUND
Ethanol production from grain involves the conversion of starch to alcohol (ethanol) through
fermentation. The by-products of the fermentation process are wet distillers grains and thin
stillage (Figure 1). The difference between these two by-products are:
• Wet distillers grains is made of coarse grain particles.
• The thin stillage contains yeast cells, soluble nutrients and very small grain particles.

Thin stillage is often called distillers solubles. However, this is a misnomer, because much of
the material is not really soluble, but is instead a suspension of fine particles.

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Potential Uses for Distillers Grains

GRAIN

Fermentation followed by
Distillation

Slurry +
WHOLE STILLAGE

ETHANOL
The whole stillage is
screened and pressed
or centrifuged

Liquid fraction
THIN STILLAGE +

Coarse grain particles


WET DISTILLERS GRAINS
WDG

The thin stillage is


evaporated Option 1: Only the coarse
grain particles are dried

Condensed thin stillage, syrup-like product


DRIED DISTILLERS GRAINS
CONDENSED DISTILLERS SOLUBLES
DDG
CDS

Option 2: The coarse grain


particles are dried with the
condensed thin stillage

DRIED DISTILLERS GRAINS


with SOLUBLES
DDGS

Figure 1. Distillers grains flowchart

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Potential Uses for Distillers Grains

The two most common versions of distillers grains consumed by the livestock are Wet
Distillers Grains and Dried Distillers Grains and these are described below:
• Wet Distillers Grains (WDG) contains primarily unfermented grain residues (protein,
fibre, fat and up to 70 per cent moisture. WDG has a shelf life of four to five days and
involves the transport of 70 per cent water by weight of total product. WDG supply
transport is economically viable usually within a 200 km radius from the ethanol
production facility. These facts are important as they affect both profitability and
logistic issues.
• Dried Distillers Grains with Solubles (DDGS) is WDG that has been dried with the
concentrated thin stillage to 10-12 per cent moisture (Figure 1). DDGS have an almost
indefinite shelf life and may be sold and shipped to any market regardless of its vicinity
to an ethanol plant. Drying is costly, as it requires the input of further energy.

The conversion rate of grains to ethanol and distillers grains varies with the different types of
grains and the process used. The details are outlined below:
• The conversion rate of corn to distillers grains is: One tonne of corn produces 378 L of
ethanol and 479 kg WDG (70% moisture content), or 309 kg of DDGS (10% moisture
content).
• The conversion rate of wheat to distillers grains is: one tonne of wheat produces 372 L
of ethanol and 457 kg WDG (70% moisture content), or 295 kg of DDGS (10%
moisture content).

The nutrient composition of distillers grains, depends on the type, variety and quality of Dry
mill ethanol processing creates wet and dry forms of distillers grains. WDG and DDGS are
the two most common versions of distillers grains consumed by the livestock industry:
• WDG is processed grain mash that contains approximately 70 per cent moisture. Wet
distillers grain has a shelf life of 4-5 days and involves the transport of 70 per cent
water by weight of total product. Wet distillers grain supply transport is economically
viable usually within a 200 km radius from the ethanol production facility. These facts
are important as they affect both profitability and logistic issues.
• DDGS is WDG that has been dried to 10-12 per cent moisture. DDGS have an almost
indefinite shelf life and may be sold and shipped to any market regardless of its vicinity
to an ethanol plant. Drying is costly, as it requires the input of further energy. In the
US, it is packaged and traded as a commodity product

3. ANIMAL NUTRITION
The variety of decisions regarding the production and marketing of distillers’ grains are very
important for ethanol-producing plants. Next to ethanol, DDGS accounts for the second
largest source of income for the plant. In the United States (US), DDGS typically makes up
10-20 per cent of total income depending on inputs and outputs prices, Federal and State
incentives, plant size and whether a plant has income from CO2.

The Chairman of Australian Ethanol Ltd stated that: “The future of ethanol in Australia is in
grain alcohol adopting the US model where the fuel ethanol revenue pays the bills and the
profit comes from the distillers’ grain by-product. With a strong cattle industry and
continuous demand for Australian red meat; fuel ethanol from grain is the future”.

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Potential Uses for Distillers Grains

The nutrient composition of distillers grains, depends on the type, variety and quality of the
grains used, as well as the efficiency of starch conversion and the processing technique.
Colour and handling properties of DDGS can also change substantially between
manufacturing plants.

Table 1 illustrates the protein levels in DDGS, different grain types and canola meal. DDGS
has the second highest protein content and has a higher protein content that the grain from
which it was produced.
Table 1. Average percentage of available protein in selected feed supplements
Canola
Feed Unit DDGS Wheat Barley Sorghum Lupins
meal
Protein content (range) % DM 30-32 7.5-14.5 20-32 35-37
Protein content (average) % DM 31.00 12.00 11.00 9.00 30.00 36.00
Source: University of Minnesota and the Department of Agriculture and Food, WA (DAFWA).

The chemical composition and amino acid profiles are given in Table 2 for wheat and wheat
DDGS. Wheat DDGS has higher amino acid concentrations compared to wheat. Therefore
distillers grains are a valuable source of protein for feed livestock.
Table 2. Essential amino acids profile
Wheat Wheat DDGS
Isoleucine (per cent) 0.363 1.165
Leucine (per cent) 0.719 2.257
Lysine (per cent) 0.321 0.679
Methionine (per cent) 0.178 0.568
Phenylalanine (per cent) 0.505 1.602
Threonine (per cent) 0.540 1.783
Trytophan (per cent) 0.163 0.283
Valine (per cent) 0.475 1.517
Source: International Distillers Grains Conference 2006, Minneapolis.

Table 3 shows the price of grains, DDGS and canola meal per tonne and then converts it to a
price per unit of protein. When comparing the price per unit of protein, DDGS is at least half
the price of its next competitor. DDGS are not only a valuable source of protein, they are
also the cheapest source of protein (Table 3).
Table 3. Average price of available protein from selected feed supplements
Canola
Feed Unit DDGS Wheat Barley Sorghum Lupins
meal

Price range $/t 120-130 184-238 160-300 280-400

Average $/t 125 211 181 177 230 345


Protein content
% DM 31.00 12.00 11.00 9.00 30.00 36.00
(average)
Protein price $/kg
0.40 1.76 1.65 1.97 0.77 0.96
(average) protein
Source: University of Minnesota and the Department of Agriculture and Food, WA (DAFWA).

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Potential Uses for Distillers Grains

However, feedlots purchase grain on energy basis − not protein concentration. Table 4
shows DDGS contain as much energy as the different grain types particularly for ruminants
and pigs and to a lesser degree broilers.
Table 4. Average and range of available energy content* from DDGS, grains and canola
meal for each animal, expressed in MJ/kg, as Metabolizable Energy (ME) for ruminants,
Apparent Metabolizable Energy (AME) for poultry and Digestible Energy (DE) for pigs
Canola
Feed DDGS2 Wheat1,5 Barley1,5 Oats1 Triticale1,5 Sorghum1,5 Lupins4
meal3
Sheep at
12.8- 11.5- 11.2- 10.0-
maintenance 12.3-13.4 13.6-14.3
13.7 13.9 15.7 13.0
(ME)
Average ME 15.00 13.25 12.70 13.45 12.85 13.95 11.50 12.20
Cattle ad 12.2- 12.2- 10.8-
12.9-13.2 10.2-13.1
libitum (ME) 13.1 13.2 13.4
Average ME 13.72 12.65 12.70 12.10 13.05 11.65 13.00 10.37
14.3- 12.4- 10.6- 12.0-
Pig DE 0 12.3-16.5 15.5-16.6
14.8 15.0 14.7 17.0
Average DE 14.60 13.70 12.65 N/A 13.05 14.45 14.50 13.00
8.74- 11.2- 11.3- 10.0-
Broiler AME 9.9-12.3 9.7-13.0 13.3-14.9
10.11 14.0 12.8 10.7
Average AME 9.45 12.60 11.10 12.05 11.35 14.10 10.35 8.36
* All values are based on 90% dry matter.
Source: 1GRDC; 2University of Minnesota, US; 3Canola Council of Canada; 4DAFWA; 5Pork CRC.

DDGS also appear to be the most economical energy source for feeding most livestock
except broilers where sorghum is slightly cheaper (Table 5).
Table 5. Average price of available energy from DDGS, grains and canola meal for various
animal
Canola
Feed Unit DDGS Wheat Barley Sorghum Lupins
meal
Price range $/t 120-130 184-238 160-300 280-400
Average $/t 125 211 181 177 230 345
Sheep at
cent/MJ of ME 0.83 1.60 1.43 1.27 2.00 2.83
maintenance
Cattle ad libitum cent/MJ of ME 0.91 1.67 1.43 1.52 1.77 3.33
Pig DE cent/MJ of DE 0.86 1.54 1.43 1.22 1.59 2.65
Broiler AME cent/MJ of AME 1.32 1.68 1.63 1.26 2.22 4.13

The energy in DDGS is mainly in the form of protein, whereas grains energy are in the form
of starch. Protein as a source of energy is less efficient than starch (65%).

When purchasing DDGS, feedlots will need to consider its higher protein content. Excess
protein in the diet increases animal energy utilisation. This is because the animals must use
energy to degrade and excrete the excess protein. Table 6 illustrates the maximum quantity
of DDGS that can be fed to livestock.

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Potential Uses for Distillers Grains

Table 6. Feeding value of DDGS in livestock rations


Max % of DDGS in
Animal
rations
Pigs
Nursery Pigs 25%
Sows 20-50%
Boars 50%
Poultry
Broilers 10%
Chicken Layers 15%
Turkeys 10%
Ruminants
Dairy Cattle 20%
Beef Cattle 20%
Aquaculture
Catfish up to 20%
Trout up to 8%
Salmon up to 8%
Freshwater Prawns up to 6%
Shrimps up to 5%
Tilapia up to 10%
Source: Dr Jerry Shurson, University of Minnesota’s Department of Animal Science, 2006.

The current price of DDGS, its protein and its energy content, makes DDGS an excellent
feed supplement for livestock.

4. FOOD USES
Distillers grain can also be used for human consumption. There is some research that is
currently being conducted in this area which is discussed below.

DDGS contain a high concentration of dietary fibre and protein, and have potential for
increased value if used as a flour supplement in baked goods.

A great deal of research was done on DDGS at the Institute for Food Science and
Technology at the University of Washington in the late 1980s. The premise for this was that
fuel ethanol production from wheat could not be profitable unless a high value use, such as
human food, was found. Distillers grains are chemically and microbiologically safe as a food
ingredient. Distillers grains are also high in protein and dietary fibre content and could be
used as a high protein and high dietary fibre food ingredient.

In 1987, researchers, Rasco and co-workers at the Institute for Food Science & Technology,
University of Washington, in Seattle, substituted 30 per cent of the all-purpose flour in white
bread, whole wheat bread, chocolate chip cookies and banana bread with DDGS. The
cookies and banana bread received ratings from sensory panels that were as good as those
for the controls containing no DDGS. The breads were rated acceptable to good. When
DDGS was added to fish batter, replacing 25 per cent of the all-purpose flour, the product
was acceptable to panelists despite the darker colour, and in fact a number of panelists
preferred the yeasty flavour which resulted.

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Potential Uses for Distillers Grains

In 1989, Rasco, McBurney and Edmonds, patented a human food product which they
produced from DDGS. The primary drawbacks to the utilisation of DDGS in human food
were smell and taste. A number of researchers had attempted to alleviate these problems
with little success until Rasco and associates developed their process which involves
adjusting the pH of the silage using organic and inorganic acids and neutralisation with
selected hydroxides or oxides before drying to a moisture content of 5-10 per cent. The
drying temperature must be kept low so as not to adversely affect colour or flavour. The
product could be used in baked goods such as brownies, cookies, pasta, yeast breads and
quick breads at concentrations ranging from 10-50 per cent, depending on the product.

Other researchers looked at the use of dried distiller grains (DDG) in extruded snack
products. Extrusion cooking involves the cooking of moist starchy or proteinaceous materials
in tubes by a combination of pressure, heat and mechanical shearing (Hauck, 1980). The
extrudate is generally formed by passing it through different shapes of openings in the final
die. Wheat DDG was found to be one of the more successful materials for extrusion when
compared to corn, oats, barley, rye and sorghum.

Dr Victor Wu and his associates (1984) at the Biopolymer Research Unit, National Centre for
Agricultural Utilisation Research (USDA) looked at the by-products formed when hard and
soft wheats and their flours were fermented to produce ethanol. In addition to the energy
costs associated with drying silage to concentrate the solubles, they found problems with
denaturation of the protein that could interfere with use in food products. Wu (1987) used
reverse osmosis and ultra-filtration to fractionate the silage into different components, leaving
a permeate that could be recycled through the system. The process was less costly than
evaporation and produced a product that had potential for incorporation into foods such as
baked goods.

To date, however, no commercial food products incorporate DDG. In order for viable
products to be successfully manufactured, additional research is needed, especially in
methods for processing DDG into food grade ingredients:
• Pre-treatments such as separation and concentration of proteins, fibres, lipids, or other
compounds.
• Washing, cleaning, and quality upgrading.
• Bleaching, deodorising, and sterilising.
• Milling into flour.
• Development of specific food products such as bakery goods, noodles, pastas, or other
low carbohydrate, high protein, high fibre foods.
• Storability, shelf life, and preservation assessment; and
• Sensory analysis and acceptability testing.

5. INDUSTRIAL USES FOR DDGS


There has also been research into industrial uses of DDGS for agriculture, fractionation,
energy and in the pre-fermentation in the ethanol manufacturing process.

Initial trials to develop value-added applications of DDGS have been conducted in agriculture
and included investigating the effects of DDGS applications on soils physical and chemical
properties. Theoretically, this co-product can be used in agriculture due to its high organic
matter and plant nutrient contents. While DDGS application had positive effects on the

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Potential Uses for Distillers Grains

nitrogen and organic matter contents of the soils, its overall effect on soil fertility was
negative due to the relatively high levels of sulfur present in DDGS.

Fractionation is a technology that separates grains into fractions, such as fibre, germ and
endosperm. In addition, through fractionation, proteins can be extracted from the grain as a
pre-fermentation step. The technology is gaining momentum in the ethanol industry. A
typical ethanol plant today takes the grain, grinds it into a fine powder and ferments the
starch into ethanol. Everything else − the oil, fibre and protein − ends up in DDGS.
Alternatively, fractionation works in a different manner. Only the endosperm is fermented to
create ethanol, while the remaining fractions are converted into new value-added products
such as wheat germ oil, used in natural skin care products as a carrier oil. The new process
results in increased ethanol yields and decreased energy consumption.

The distillers grains could also be fed into a biodigester to produce methane gas. Anaerobic
digesters convert solid and liquid biomass wastes by using bacteria operating in an
environment without the presence of oxygen to produce combustible gas (biogas) similar to
natural gas and a liquid effluent stream containing solids (raw fertiliser) which is used as a
fertiliser.

The breakdown of organic material involves a number of biological steps, each step involving
a well-defined class of bacteria which absorb energy for their survival from gradually
decomposing biomass which is finally converted to water, carbon dioxide and methane. The
biogas can fuel internal combustion engines driving electrical generators for heat and
electricity.

Depending on the specific composition of the organic material, between 105 and 130 cubic
metres of biogas are produced per tonne of biomass. In energy terms, this corresponds to
about 70 litres of petrol. The anaerobic digestor process enables ethanol plants to be totally
self sufficient for power generation and surplus electricity can be sold to the electricity grid
and are eligible for Renewable Energy Certificates.

The bodies of exhausted bacteria, mixed with organics more difficult to digest such as woody
materials, constitute the residual digested fertiliser sludge. The sludge is converted to liquid
ammonia, and potassium and phosphorous fertiliser, all saleable by-products.

6. CONCLUSIONS
With the emerging ethanol industry in Western Australia and indeed the world, there will be
an abundance of distillers grains in the coming years. It is currently mainly used as a feed
grain to livestock. However, the livestock industry in WA is small and it will only have the
capacity to consume less than 10 per cent of the total distillers grains potentially produced.
Therefore large surpluses of distiller grains will need to find alternative markets and uses to
be developed.

Distillers grains, in wet or dry form, is a material rich in fibres and proteins. It can be
incorporated in baked goods for human consumption although its smell and taste may not be
immediately acceptable to a great majority of consumers.

There are also a range of potential industrial uses for distillers grains. This includes uses as
a soil conditioner in agriculture, fractionation where fractions of the grain are utilised in the
pre-fermentation process for ethanol production, anaerobic digestion where the distillers
grains is converted into biogas and fertiliser, and re-using the distillers grains with the
addition of enzymes to convert the sugars to starch which can then be used in ethanol
production.

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Potential Uses for Distillers Grains

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Potential Uses for Distillers Grains

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