Extraction and Film Properties of Kafirin from Coarse Sorghum and Sorghum DDGS by Percolation

The high cost of kafirin and zein restricts their use for bioplastic and food applications. Effective, simple, and rapid kafirin/zein isolation processes are required. Here a percolation‐type aqueous ethanol solvent extraction process from coarse meals (grits) and coarse sorghum distillers dried grains and solubles (DDGS) for kafirin and zein isolation employing a low ratio of extractant to meal (2.5:1) was investigated, which is potentially applicable in the grain bioethanol industry. Postextraction filtration times were more than twice as fast using coarse meals compared with fine flours. Washing the meals prior to extraction to remove starch improved protein preparation purity to 73–85% compared with 68–72% for unwashed meals. Hence, no subsequent filtration or centrifugation step is required to clean up the kafirin/zein solution prior to solvent evaporation. With a single extraction step, kafirin/zein yields were 48% (protein basis) for DDGS and 53–70% for washed sorghum/maize meals. Cast films were used as a model bioplastic system to evaluate extracted kafirin/zein functional properties. DDGS kafirin films had rough surfaces but had the lowest water uptake and in vitro digestibility, owing to heat‐induced disulfide crosslinking during DDGS processing. Extraction by percolation using coarse meal/DDGS has potential to improve kafirin/zein viability.     

Sorghum Bran as a Potential Source of Kafirin

Sorghum bran, a coproduct of sorghum dry milling, could be a source of protein for industrial applications. Condensed tannin‐free red and white sorghum samples were decorticated by abrasion until ≈10 or 25% grain by weight was removed. Kafirin was then extracted from the milling fractions using an aqueous ethanol based solvent system. The brans were darker and considerably higher in protein and fat compared with the whole grain flours and decorticated grain flours, with the 25% bran having higher protein than the 10% bran. This is due to increased contamination of the bran with protein‐dense, corneous endosperm. The protein extracted from all the milling fractions, including the brans, was pure kafirin. However, the yield of kafirin from the brans (15.9–26.7% of total protein present) was somewhat lower than that from whole grain and decorticated grain flours (45.0–57.9% of total protein present), due to the fact that kafirin is located solely in the endosperm. Also, the kafirin from bran was more contaminated with fat, polyphenols, and other substances, and more highly colored, particularly the kafirin from red sorghum. Thus, sorghum bran could be used as a source of kafirin but further purification steps may be necessary.     

Physical,Mechanical, and Barrier Properties of Kafirin Films from Red and White Sorghum Milling Fractions

Fractions from the sorghum dry milling industry, including bran, are a potential source of kafirin. Free‐standing plasticized cast films were prepared from defatted kafirin preparations from red and white sorghum flour and bran fractions, and from commercial zein. All the kafirin preparations were able to form films. However, there were differences in film thickness, clarity, flexibility, surface texture, odor, and color between the different kafirin films. Bran kafirin films were highly colored, less flexible with a less smooth surface texture compared with films from flour, probably due to higher levels of contaminants in the bran kafirins. The strong color of the bran films could limit their use in certain coating applications. The kafirin films had much higher tensile strength and lower extensibility than zein film, probably because of the presence of β‐ and γ‐kafirins in the kafirin, giving high levels of disulfide cross‐linking in the kafirin films. The kafirin films had poorer water barrier properties than zein film, possibly due to greater thickness or to poorer flexibility, which may have caused microcracks.     

Transgenic sorghum with altered kafirin synthesis: kafirin solubility, polymerization, and protein digestion

Transgenic sorghum (TG) lines with altered kafirin synthesis, particularly suppression of γ-kafirin synthesis, and improved protein quality have been developed. The proportion of kafirin extracted with 60% tert-butyl alcohol alone was greatly increased in the TG lines. However, the total amount of kafirin remained unchanged. Further, in the TG lines, the kafirin was much less polymerized by disulfide bonding. There was also evidence of compensatory synthesis of other kafirin proteins. Cooked protein digestibility was increased in the TG form, even after removal of interfering starch. The TG protein bodies were intermediate in appearance between the normal type and the invaginated high digestibility mutants. Hence, the increased protein digestibility of these TG lines is probably related to their lower levels of disulfide-bonded kafirin polymerization, allowing better access of proteases. This work appears to confirm that disulfide bond formation in kafirin is responsible for the reduced protein digestibility of cooked sorghum.     

Characterization of Kafirins in Algerian Sorghum Cultivars

The prolamins in seven Algerian Sahara sorghum cultivars of varying seed shape and color were investigated. Protein contents ranged from 12 to 16%. Prolamins were the major protein fraction. They could be separated according to degree of disulfide cross‐linking. Kafirin monomers and low molecular weight polymers could be extracted with 70% ethanol, whereas highly cross‐linked kafirins additionally needed a reducing agent to become extractable. Kafirin monomers of α‐, β‐ and γ‐type were purified and N‐terminally sequenced. For the first time, δ‐kafirin was identified at the protein level. The study clearly revealed intercultivar differences between protein levels. The joint use of SDS‐PAGE, SE‐HPLC, and RP‐HPLC allowed discriminating among cultivars based on the differences in prolamin levels and composition.     

Improvement in water stability and other related functional properties of thin cast kafirin protein films

Improvement in the water stability and other related functional properties of thin (<50 μm) kafirin protein films was investigated. Thin conventional kafirin films and kafirin microparticle films were prepared by casting in acetic acid solution. Thin kafirin films cast from microparticles were more stable in water than conventional cast kafirin films. Treatment of kafirin microparticles with heat and transglutaminase resulted in slightly thicker films with reduced tensile strength. In contrast, glutaraldehyde treatment resulted in up to a 43% increase in film tensile strength. The films prepared from microparticles treated with glutaraldehyde were quite stable in ambient temperature water, despite the loss of plasticizer. This was probably due to the formation of covalent cross-linking between free amino groups of the kafirin polypeptides and carbonyl groups of the aldehyde. Thus, such thin glutaraldehyde-treated kafirin microparticle films appear to have good potential for use as biomaterials in aqueous applications.     

Effect of Decorticating Sorghum on Ethanol Production and Composition of DDGS

The use of a renewable biomass that contains considerable amounts of starch and cellulose could provide a sugar platform for the production of numerous bioproducts. Pretreatment technologies have been developed to increase the bioconversion rate for both starch and cellulosic‐based biomass. This study investigated the effect of decortication as a pretreatment method on ethanol production from sorghum, as well as investigating its impact on quality of distillers' dry grains with solubles (DDGS). Eight sorghum hybrids with 0, 10, and 20% of their outer layers removed were used as raw materials for ethanol production. The decorticated samples were fermented to ethanol using Saccharomyces cerevisiae. Removal of germ and fiber before fermentation allowed for greater starch loading for ethanol fermentation and resulted in increased ethanol production. Ethanol yields increased as the percentage of decortication increased. The decortication process resulted in DDGS with higher protein content and lower fiber content, which may improve the feed quality.     

Ethanol Production from Pearl Millet Using Saccharomyces cerevisiae

Four pearl millet genotypes were tested for their potential as raw material for fuel ethanol production in this study. Ethanol fermentation was performed both in flasks on a rotary shaker and in a 5‐L bioreactor using Saccharomyces cerevisiae (ATCC 24860). For rotary‐shaker fermentation, the final ethanol yields were 8.7–16.8% (v/v) at dry mass concentrations of 20–35%, and the ethanol fermentation efficiencies were 90.0–95.6%. Ethanol fermentation efficiency at 30% dry mass on a 5‐L bioreactor reached 94.2%, which was greater than that from fermentation in the rotary shaker (92.9%). Results showed that the fermentation efficiencies of pearl millets, on a starch basis, were comparable to those of corn and grain sorghum. Because pearl millets have greater protein and lipid contents, distillers dried grains with solubles (DDGS) from pearl millets also had greater protein content and energy levels than did DDGS from corn and grain sorghum. Therefore, pearl millets could be a potential feedstock for fuel ethanol production in areas too dry to grow corn and grain sorghum.     

Effect of Microwave Heating of Kafirin on the Functional Properties of Kafirin Films

To improve the functional properties of cast kafirin films, dry kafirin, extracted with an aqueous ethanol‐based solvent at 70°C, was microwave‐heated. No effect on film tensile properties was found. Two strategies were employed to improve the effect of microwaving: extraction of kafirin using an aqueous tert‐butanol‐based solvent at ambient temperature to minimize temperature‐induced denaturation and wetting the kafirin to increase its dielectric properties. Microwave heating this kafirin to 90 or 96°C and holding for 1–2 min more than doubled maximum tensile strength and Young's modulus, and decreased strain by about one‐third compared with films made from nonmicrowaved kafirin. Film water vapor permeability was reduced by at least one‐third. Digestibility of microwaved kafirin and films was also substantially decreased, and film biodegradability was slowed slightly. Microwave heating gave a film microstructure with fewer and smaller size pores. SDS‐PAGE showed microwave‐induced intermolecular cross‐linking of the kafirin monomers, which was possibly responsible for the modification of film properties. Microwave heating of kafirin can be used to modify kafirin film properties, but the kafirin must be microwaved wet and be as close as possible to its native state.     

Improvement of Sorghum-Wheat Composite Dough Rheological Properties and Breadmaking Quality Through Zein Addition

Addition of sorghum flour to wheat flour produces marked negative effects on rheological properties of dough and loaf volume. Although there are notable differences in the chemical composition of sorghum proteins (kafirins) compared with wheat gluten that might imply poor functionality in breadmaking systems, a larger constraint may be the unavailability of kafirins due to encapsulation in protein bodies. In this study, zein, the analogous maize prolamin to kafirin, was used to determine the potential effects of protein-body-free prolamins on dough rheology and baking quality of wheat-sorghum composite flour. Mixograms run at 35°C (above the glass transition temperature of zein) were significantly (P < 0.01) improved with addition of zein. Mixogram peak heights increased while mixing time decreased uniformly with addition of zein. Dough extensibility studies showed an increase in maximum tensile stress, while baking studies showed an increase in loaf volume with increasing amounts of added zein. These data are supported by a previous study showing that, in a model system, zein mixed with starch can form viscoelastic networks, and suggest that kafirin, if made available, could contribute to dough formation.     

Effect of preparation conditions on protein secondary structure and biofilm formation of kafirin

Various extraction and drying conditions for the isolation of kafirin from dry-milled, whole grain sorghum have been investigated, with a view to optimizing extraction of the protein for commercial food coatings and packaging films. The addition of sodium hydroxide to an aqueous ethanol extractant increased the yield and solubility of kafirin. Subsequent heat drying at 40 degrees C was shown to cause the kafirin to aggregate as indicated by an increase in intermolecular beta-sheets. Extraction of the flour using ethanol (70%, w/w) with 0.5% (w/w) sodium metabisulfite and 0.35% (w/w) sodium hydroxide at 70 degrees C followed by freeze-drying of the protein was found to produce a yield of 54% kafirin with good film-forming properties. The kafirin films were assessed for their sensory properties, tensile strength, strain, and water vapor permeability. Fourier transform infrared spectroscopy was used to study the secondary structure of the extracted kafirins. The best films were made with kafirin containing a large proportion of nativelike alpha-helical structures with little intermolecular beta-sheet content as indicated by the Fourier transform infrared reflectance peak intensity ratios associated with these secondary structures. The principal factor affecting the secondary structure of the protein appeared to be the temperature at which the protein was dried. Heat drying resulted in a greater proportion of intermolecular beta-sheets. Any industrial-scale extraction must therefore minimize protein aggregation and maximize native alpha-helical structures to achieve optimal film quality.     

Use of SDS to Extract Sorghum and Maize Proteins for Free Zone Capillary Electrophoresis (FZCE) Analysis

Two different extraction methods for extracting sorghum (Sorghum bicolor L. Moench.) storage proteins for free zone capillary electrophoresis (FZCE) analysis were compared. A traditional solvent based on 60% t‐butanol was compared with a pH 10 borate buffer containing the anionic detergent SDS followed by precipitation of nonkafirins using 60% t‐butanol. FZCE analysis of both types of extracts showed identical patterns, despite the fact that the SDS should have given all proteins equal charge‐to‐mass ratios. This methodology was also successfully applied to maize proteins. The use of t‐butanol to precipitate nonkafirins, combined with electrophoresis at low pH, is thought to have removed the SDS from the storage proteins. The SDS extraction procedure produced more stable extracts for FZCE analysis. These extracts could also be used directly for SDS capillary electrophoresis (SDS‐CE) separations. Kafirins from 15 genotypes were extracted with this procedure and analyzed by FZCE and SDS‐CE. Resolution of the kafirins by FZCE was much higher than the SDS‐CE, demonstrating that the kafirin proteins possessed a high level of charge density variability within a relatively small molecular size distribution. Two distinct groups of α‐kafirins could be seen in the FZCE electropherograms.     

Impacts of Kafirin Allelic Diversity,Starch Content,and Protein Digestibility on Ethanol Conversion Efficiency in Grain Sorghum

Seed protein and starch composition determine the efficiency of the fermentation process in the production of grain‐based ethanol. Sorghum, a highly water‐ and nutrient‐efficient plant, provides an alternative to fuel crops with greater irrigation and fertilizer requirements, such as maize. However, sorghum grain is generally less digestible because of extensive disulfide cross‐linking among sulfur‐rich storage proteins in the protein– starch matrix. Thus, the fine structure and composition of the seed endosperm directly impact grain end use, including fermentation performance. To test the hypothesis that kafirin (prolamin) seed storage proteins specifically influence the efficiency of ethanol production from sorghum, 10 diverse genetic lines with allelic variation in the β‐, γ‐, and (δ‐kafirins, including three β‐kafirin null mutants, were tested for ethanol yield and fermentation efficiency. Our selected lines showed wide variation in grain biochemical features, including total protein (9.96–16.47%), starch (65.52–74.29%), and free amino nitrogen (FAN) (32.84–73.51 mg/L). Total ethanol yield (ranging from 384 to 426 L/metric ton), was positively correlated to starch content (R² = 0.74), and there was a slight positive correlation between protein digestibility and ethanol yield (R² = 0.52). Increases in FAN content enhanced fermentation efficiency (R² = 0.65). The highest ethanol producer was elite staygreen breeding line B923296, and the line with the highest fermentation efficiency at the 72 h time point was inbred BT×623. A large‐seeded genotype, KS115, carrying a novel γ‐kafirin allele, was rich in FAN and exhibited excellent short‐term fermentation efficiency at 85.68% at the 20 h time point. However, the overall ethanol yield from this line was comparatively low at 384 L/metric ton, because of insufficient starch, low digestibility, and high crude protein. Multivariate analysis indicated an association between the β‐kafirin allele and variation in grain digestibility (P = 0.042) and FAN (P = 0.036), with subsequent effects on ethanol yield. Reversed‐phase HPLC profiling of the alcohol‐soluble kafirin protein fraction revealed diversity in protein content and composition across the lines, with similarities in peak distribution profiles among β‐kafirin null mutants compared with normal lines.     

Turbidity Assay for Rapid and Efficient Identification of High Protein Digestibility Sorghum Lines

Recently, our laboratory reported a protein digestibility assay based on SDS‐PAGE that distinguishes mutant high protein digestibility from wild‐type sorghum lines. Using that assay, high protein digestibility sorghum lines were identified both qualitatively (visual observation) and quantitatively by measuring the SDS‐PAGE band intensity of the undigested α‐kafirin protein. Here, we report on a new turbidity assay that can be used for an even quicker quantitation of the undigested proteins with much higher throughput for screening purposes. Proteins remaining after 1 hr of pepsin digestion were extracted with a buffer of SDS, 2‐mercaptoethanol, and borate and an aliquot of the extract was precipitated using 72% trichloroacetic acid (TCA). Absorbance of the resulting turbid solution was then read at 562 nm. Lower readings corresponded to more digestible lines. The turbidity of the suspensions developed quickly and reached a plateau at ≈5 min for high protein digestibility lines and 10 min for wild‐type lines. The turbid solutions remained stable for at least 1 hr. Two distinct groups, wild‐type and high protein digestibility sorghum lines, were obtained when the assay was compared with a standard pepsin digestibility procedure and to our recently developed SDS‐PAGE assay. A comparison with the bicinchoninic acid (BCA) assay of protein quantitation indicated that the turbidity assay is more efficient in differentiating between wild‐type and high protein digestibility sorghum lines. We have further refined the turbidity assay for microtiter plate analysis making it possible for a single operator to analyze ≈200 sorghum lines per day, compared to 60 lines when using the SDS‐PAGE assay.     

Alteration of kafirin and kafirin film structure by heating with microwave energy and tannin complexation

Heating with microwave energy and tannin complexation of kafirin both increase the tensile strength of cast kafirin bioplastic films. The effects of these treatments on the molecular structure of kafirin and of kafirin in the film were investigated. SDS-PAGE of heated wet kafirin showed an increase in kafirin oligomers. Disulfide groups increased in heated kafirin and in films made from the heated kafirin. Fourier transform infrared (FTIR) spectroscopy of heated kafirin and films made from the heated kafirin indicated an increase in beta-sheet conformation. In contrast, kafirin complexation with tannic acid (TA) and sorghum condensed tannin (SCT) resulted in a slight decrease in beta-sheet conformation in the kafirin and a larger decrease in the kafirin in the films. Raman spectroscopy showed that, with TA, there was a shift in peak from 1710 to 1728 cm(-1) for kafirin-tannic acid complexes, indicating kafirin and tannic acid interaction. The protein conformational changes presumably facilitated cross-linking between kafirin molecules and/or between kafirin and the tannins. Thus, although both heating with microwave energy and tannin complexation cause cross-linking of kafirin to increase film tensile strength, their effects on kafirin structure appear to be different.     

A Rapid Protein Digestibility Assay for Identifying Highly Digestible Sorghum Lines

Protein digestibility in sorghum (Sorghum bicolor (L.) Moench) lines was determined using two standard procedures (pepsin digestibility and pH‐stat) and compared with a newly developed, rapid electrophoresis‐based screening assay. The new assay was based on the rate of α‐kafirin disappearance after pepsin digestion. α‐Kafirin, the major sorghum storage protein, makes up ≈60–70% of the total protein in the grain. In the new assay, samples were first digested with pepsin for 1 hr, and undigested proteins were then analyzed by SDS‐PAGE. The intensitizes of the undigested α‐kafirin bands were measured. Higher band intensity indicated lower protein digestibility. The new assay was significantly correlated with the standard pepsin digestibility assay (r = −0.96, n = 16) after which it was patterned. The same was true of the pH‐stat procedure (r = −0.85, n = 16). This implies that the new assay is comparable to existing procedures and can be used for screening sorghum lines for protein digestibility. Two groups consisting of high‐protein digestibility and wild‐type sorghum lines were identified when the new assay was tested on 48 sorghum lines derived from crosses of wild‐type and mutant high protein digestibility lines, indicating that the new assay was efficient in differentiating between the two groups. Advantages of the new assay over the standard procedures include considerable reduction in analysis time and sample size required for the analysis. For example, analysis time was reduced by 20% and sample size by 10% when the new assay was used as compared with the pH‐stat procedure. We estimate that ≈60 sorghum lines can be screened in a day by a single operator using the new assay.     

丁香酚对高粱醇溶蛋白可食性膜结构及性能的影响

为开发天然的可降解、可食性包装材料,以高粱醇溶蛋白为原料,采用溶液共混的方法制备可食性丁香酚/高粱醇溶蛋白复合膜,分析不同浓度丁香酚对可食性高粱醇溶蛋白膜物理性能及微观结构的影响并探讨其变化机理。结果表明,添加4%丁香酚可优化蛋白膜的机械性能,提升膜的拉伸强度(TS)和断裂伸长率(EAB);添加丁香酚不影响蛋白膜的水蒸气透过系数(WVP),但略微提高了蛋白膜的溶解度;添加4%丁香酚可增加蛋白膜对紫外光和可见光的吸光度值,即增强膜的光阻隔性能。DSC测量显示,添加丁香酚后降低了高粱醇溶蛋白的玻璃态转变温度(Tg),表明丁香酚提高了丁香酚/高粱醇溶蛋白复合膜的延展性;FTIR分析结果表明,添加丁香酚后使得高粱醇溶蛋白二级结构中的α-螺旋、无规则卷曲转变为β-折叠、β-转角,表明丁香酚有助于提高丁香酚/高粱醇溶蛋白复合膜的机械性能;SEM结果显示,4%丁香酚与高粱醇溶蛋白的相容性良好,制备的复合膜截面光滑紧致。本研究结果为可降解、可食性膜新材料的研究及应用推广提供了理论参考。     

Evaluation of Nebraska Waxy Sorghum Hybrids for Ethanol Production

To evaluate the ethanol production performance of waxy sorghum hybrids and the effects of location and harvest year on ethanol yield, samples of four waxy sorghum hybrids collected from two Nebraska locations (Mead and Lincoln) in both 2009 and 2010 were tested for ethanol production in a dry‐grind process. No significant difference (P = 0.216) in starch contents was observed among the four hybrids, but starch contents of the hybrids were significantly affected by growth location (P = 0.0001) and harvest year (P = 0.0258). Location, hybrid, and harvest year all had significant effects on ethanol fermentation efficiency in the dry‐grind process. Lincoln sorghum samples showed higher (P = 0.022) ethanol fermentation efficiency (90.4%) than did Mead sorghum samples (90.0%). Sorghums harvested in 2010 had higher (P < 0.001) ethanol fermentation efficiency (91.1%) than those harvested in 2009 (89.3%). The 2009 sorghum flours had more amylose‐lipid complexes than the 2010 samples did, and amylose‐lipid complexes as previously reported had adverse effects on ethanol fermentation. Residual starch contents in distillers dried grains with solubles (DDGS) were significantly affected by hybrid and harvest year (P < 0.0001), but we observed no difference in protein content in DDGS from the four hybrids.     

Sorghum Protein Extraction by Sonication and Its Relationship to Ethanol Fermentation

The objectives of this research were to develop a rapid method for extracting proteins from mashed and nonmashed sorghum meal using sonication (ultrasound), and to determine the relationships between the levels of extractable proteins and ethanol fermentation properties. Nine grain sorghum hybrids with a broad range of ethanol fermentation efficiencies were used. Proteins were extracted in an alkaline borate buffer using sonication and characterized and quantified by size‐exclusion HPLC. A 30‐sec sonication treatment extracted a lower level of proteins from nonmashed sorghum meal than extracting the proteins for 24 hr with buffer only (no sonication). However, more protein was extracted by sonication from the mashed samples than from the buffer‐only 24‐hr extraction. In addition, sonication extracted more polymeric proteins from both the mashed and nonmashed samples compared with the buffer‐only extraction method. Confocal laser‐scanning microscopy images showed that the web‐like protein microstructures were disrupted during sonication. The results showed that there were strong relationships between extractable proteins and fermentation parameters. Ethanol yield increased and conversion efficiency improved significantly as the amount of extractable proteins from sonication of mashed samples increased. The absolute amount of polymeric proteins extracted through sonication were also highly related to ethanol fermentation. Thus, the SE‐HPLC area of proteins extracted from mashed sorghum using sonication could be used as an indicator for predicting fermentation quality of sorghum.