Alcohol Education and Processing
Effects of Small Grains
Craig Pilgrim
Global Marketing Manager
EPAC conference
Billings, Montana
June 26, 2012
Outline
• Lallemand (brief overview)
• Educational Aspects
 Schools and learning
• Example of training
• Small grains

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

Production values
Composition
Starch and Non Starch Polysaccharides
Enzymes and viscosity
Processing issues
Fermentation issues
• Summary
Lallemand in 2012
• Develops, produces and markets yeasts, bacteria
and other ingredients derived from those
microorganisms for:
 bakeries (65% of sales)
 wine, beer and alcohol producers (as well as fuel
ethanol industry)
 animal and human nutrition industries,
pharmaceutical industry
 other food and agricultural industries
• Over 2500 employees (of which 70+ in R&D)
in over 35 countries on 5 continents
Our core activity
Development, production and marketing of…
Yeast
…and their derivatives
Bacteria
Ethanol Technology Institute
Publications
Educational Activities
The Alcohol School – Toulouse/Montreal
• Now in 31st year of running this class
• Organized by Prof Graeme Walker,
Ethanol Technology Institute
• Non-commercial
• Mix of internal and reputable guest
speakers
• Directed towards:
 Senior operational staff
 Laboratory staff
 Experienced operators/Shift leads
• Agenda covers whole process at mid
to high level
• Some new technology/developmental
topics included
The Operators’ School
•
•
•
•
•
In fourth year of operation.
Mix of lectures and hands on demonstrations
Organized by the Ethanol Technology Institute
Non-commercial
Directed towards operators and less experienced
managers/shift leads
• Predominantly in house trainers
• Agenda covers complete process including both batch and
continuous
• Significant aspect of troubleshooting including worked
examples/role play
The Alcohol Textbook
Ethanol Technology Institute
publishes “The Alcohol
Textbook”
• The most comprehensive book
on alcohol production.
• Team of internal and external
writers. Edited by Dr. Mike
Ingledew, Glen Austin and
Dave Kelsall.
• 5th edition recently published.
Example of educational training
• Why training and educational aspect?
 Been a part of landscape for more than 30 years
 Focus on increasing operations knowledge, better trained
personnel
• Focus on Montreal is more North America and related
grain processing
 Corn as main substrate
• Focus in Toulouse is more on Rest of World
 Small grains is the main topic
• The rest of this presentation will discuss aspects of small
grain processing and those educational opportunities.
Global Small Grain Production
United States Department of Agriculture, Avg. 2008-2010 Crop Years
Raw material usage in US
• Corn is KING!
• Majority of ethanol producing facilities are
using corn.
• Some plants, based on locations are
using milo, sorghum, barley or wheat.
• Inherent issues using small grains
 Depending on grain, starch content might
be less
 Processing could be a bit more difficult
 Equipment usage and wear
 Viscosity
• However, in other parts of the world,
small grains are prevalent.
Raw Material Usage for EU
• Mostly wheat,
sugar beet juice,
barley and
maize.
• Small grains
effect production
costs.
• To minimize
costs, blends of
products may be
used.
Source: eBio
Grain Composition
Wheat
Triticale
Rye
Barley
Corn
Sorghum
Small grain challenge
The small grains contain high concentrations of Non Starchy Polysaccharides (NSPs)
which, have high water-binding capacity leading to increased mash viscosity
Protein matrix
Protein
middle
The
small grains contain high
Starch
concentrations of NSPs which,
granules
have high water-binding
capacity leading to increased
mash viscosity
Outer wall
(-Glucan and
pentosan)
lamella
Inner cell wall
(-Glucan)
Endosperm Cell Structure
Source: Novozymes
Grain Composition
Component
% content of dry matter
Corn
Wheat
Barley
Rye
Sorghum
Millet
Protein
9-12
12–14
10-11
10-15
11-12
15.4
Fat
4.5
3.0
2.5-3.0
2.0-3.0
3.6
3.9
65-72
67-70
52-64
55-65
72-75
70.8
Ash
1.5
2.0
2.3
2.0
1.7
1.2
Total cell wall material
9.6
11.4
14.0
14.6
n/a
n/a
Starch
Water extractable non-starchy polysaccharides:
Arabinoxylans
0.03
0.6
0.3
1.4
nil
nil
Beta-glucans
0.05
0.14
2.4
0.8
nil
nil
Starch Structure
High rigidity
Amylose
High viscosity
Amylopectin
Starch breakdown
• “Normal” starch breakdown is relatively easy using heat
and enzymes.
• Long chained polymers known as “dextrins” are broken
down with alpha amylase. This reduces viscosity fairly
quickly and easily.
• Once that happens, another enzyme is added at
fermentation known as glucoamylase.
• This breaks down the long chains into single glucose
units.
• Glucose is the primary and preferred source of sugar
used by yeast to convert to ethanol.
Non Starch Polysaccharides of Cereal Grains
• Arabinoxylan:
Especially in wheat, rye and barley.
Xylan backbone with
L-arabinofuranose (L-arabinose
in 5-atom ring form)
• Beta-glucan:
Linear unbranched beta-D-glucose
with one beta-1,3 every 3 or 4
beta-1,4 linkages; in bran of grains
Cereal Grain Non-starch Polysaccharides
Cell wall components % DM
Need enzymes
Need enzymes
8
7
% of NSP
6
5
4
Insoluble pentosans
3
Cellulose
2
soluble β-glucan
soluble pentosans
1
Insoluble β-glucan
0
Wheat
Source: Novozymes
Rye
Corn
Barley
Viscosity Reducing Enzymes Composition of Grains
•
•
Beta Glucans and Pentosans are the main cause of high mash viscosities
These “Hemicelluloses” also create problems in thin stillage evaporation
and dewatering of fermentation solids
Needs
Xylanase
Needs
Beta Glucanase
Can be converted
to fermentable
sugars
Source: Genencor
NSP Comparison in various grains
% Water-extractable NSP
3
Beta-glucaner
2.5
Arabinoxylaner
2
1.5
1
0.5
0
Wheat
Barley
Rye
Corn
Non Starch Polysaccharides of Grains
-Impact on processing grains to ethanol• Grains like rye, barley, triticale and wheat contain high levels of
hemicelluloses (Beta Glucans, Pentosans) = high viscosity due to
high water-binding capacity
• Consequences: This reduces the efficiency of
 Heat exchange operation



Centrifugal separation of solids
Evaporation
Mass transfer in fermentation
• Limited solids concentration in mashing
• Negative effect on the energy balance of the process.
(lower solids, higher water content, lower ethanol yield, etc.)
• Residual Hemicelluloses may contribute to fouling of heat
exchangers and distillation equipment
Source: Genencor
Composition of Non Starch Polysaccharides of
Cereal Grains
Common
Name
Water
soluble
Specific
viscosity
Primary
monomer
Beta Glucan
Yes*
High
Glucose
Cellulose
No
Low
Glucose
β 1,4
β 1,4
β 1,3 + β 1,2
β 2,6 + β 2,1
Arabinoxylan
Yes*
High
Xylose,
Arabinose
Fructan
Yes
Low
Fructose
* Depending on extraction conditions and specific composition
Linkage
β 1,4 +
β 1,3
Monomer
fermentable
Yes
Yes
No
Yes
Summary - Processing Small Grains
• Milling may be slightly different on equipment wear
depending on substrate and variety.
• Because of viscosity issues with NSP’s, secondary
enzymes will have to be used. (Barley and rye definitely,
wheat, depending on variety).
• Because of viscosity issues, % solids in fermentation may
have to be lower than compared to corn.
• Dryhouse may have to be equipped to handle slightly
larger volumes and lowers solids syrup.
• Seasonal and strain differences in substrate will effect
processing more than compared to corn (fairly constant)
Fermentation
• Should be fairly comparable to corn or any other starch
substrate fermentation.
• Things to look for include:
 Lower solids fermentations.
 Foaming may vary due to substrate and age
 Because small grains composition, fermentation yield may
decrease because of availability of fermentable sugars.
Fermentation
• Time
• Nutrients
• Antifoam
Fermentation
• Time
 May take slightly longer due to viscosity
issues, mass transfer issues, sugar
composition, etc.
 May be offset due to lower solids required in
some cases.
• Nutrients
• Antifoam
Fermentation
• Time
• Nutrients
 Usually
comparable to
corn, but nutrient
package may
have to be used
as well
• Antifoam
FAN (mg/L Mash)
Total
Usable
Wheat
82
64
Barley
84
62
Hulless Barley
124
100
Oats
193
159
Hulless Oats
184
130
Rye
103
83
Corn
70
58
Starch Slurry
~0
~0
FAN values normalized to 20% DS
Thomas and Ingledew, 2006
Fermentation
• Time
• Nutrients
• Antifoam
 Due to lower inherent oil levels in these
substrates, foaming may be an issue.
 Antifoams may have to be used in
fermentation.
Corn oil could be used as well. Depending on
what DDGS are used for.
Summary
• Small grains can be used for ethanol production
• Not prevalent in US, but could be used if necessary.
 Dependant on areas of US that could grow the crops.
• There are some inherent challenges to using small
grains.
 Mainly viscosity issues and starch content
• Small grains are successfully used in other parts of the
world for biofuels production.
Summary
• Education and Training are key in understanding various
processes and substrates.
• This is type of presentation you would see in our various
schools.
• For more information, please see www.ethanoltech.com