乙醇水溶液提取玉米胚芽油的工艺优化

为了解决水酶法提取玉米胚芽油生产成本高、提取时间长的缺点,该文采用乙醇水溶液作为提取剂提取玉米胚芽油。通过对粒径、料液比、温度、乙醇体积分数、p H值和时间等条件对油在油相、水相和渣相中分布的研究发现,物料粒径和乙醇体积分数对提高清油得率具有显著(P0.05)的影响,而提取时间对清油得率的影响最小(P0.05)。在单因素试验的基础上通过正交试验,得出乙醇水溶液提取玉米胚芽油的最佳工艺参数为:物料细粉4次(此时粒径为49.18μm)、料液比1∶7 g/m L、温度70℃、乙醇体积分数30%、p H值9.0、提取时间2 h。在该条件下,清油的得率为94.05%±0.32%,水相含油量为3.49%±0.77%,渣相含油量为2.55%±0.82%。分析乙醇水溶液提取的玉米胚芽毛油酸价、过氧化值和含水率等指标发现,该毛油的质量优于国标规定的玉米原油,并且和压榨一级成品油指标接近,只需要经过简单精炼就可以达到食用油要求。研究结果为乙醇水溶液工业化生产玉米胚芽油提供参考。     

Cross‐Sectional Staining and Surface Properties of DDGS Particles and Their Influence on Flowability

With the U.S. fuel ethanol industry projected to grow during the next several years, supplies of distillers dried grains with solubles (DDGS) are anticipated to continue to grow as well. DDGS is used primarily as livestock feed. Much of the DDGS must be shipped, often over large distances, outside the Corn Belt (which is where most of the corn‐based ethanol plants are currently located). Stickiness and caking among particles is a common issue for DDGS, and it often leads to flowability problems. To address this, the objective of this study was to understand the cross‐sectional and surface natures of DDGS particles from five ethanol plants, and how they interact with DDGS properties. This study examined the distribution patterns of chemical components within cross‐sections, within section edges (i.e., surface layers), and on surfaces using standard staining techniques; chemical composition was determined using standard protocols; and physical and flowability properties were also determined. Crude protein in the samples was 28.33–30.65% db, crude fat was 9.40–10.98% db, and neutral detergent fiber (NDF) was 31.84–39.90% db. Moisture contents were 4.61–8.08% db, and geometric mean diameters were 0.37–0.52 mm. Cross‐sectional staining showed protein levels of 19.57–40.39%, and carbohydrate levels of 22.17–43.06%, depending on the particle size examined and the production plant from which the DDGS was sampled. Staining of DDGS particles indicated a higher amount of surface layer protein compared with carbohydrate thickness in DDGS particles that had a lower flow function index (which indicated potential flow issues). Additionally, surface fat staining suggested that higher surface fat also occurred in samples with worse flow problems. This study represents another step toward understanding why DDGS particles stick together during storage and transport, and will hopefully help to improve DDGS material handling strategies.     

Effect of Additional Separation and Grinding on the Chemical and Physical Properties of Selected Corn Dry-Milled Streams

Three streams of corn dry-milled products (corn grits, corn cones, and corn flour) from three different commercial corn dry-millers were further separated by particle size according to the major portion of each stream. They were separated into corn grits (1.190 and 0.841 mm), corn cones (0.595, 0.420, and 0.297 mm), and corn flour (0.297 and 0.210 mm). Besides separation, corn grits were also ground and then separated into ground corn grits (0.297 and 0.210 mm). The original streams, streams with additional separation, and streams with additional grinding were analyzed for protein content, ash content, crude fat content, and color properties. Duncan's significant difference tests (P < 0.01) showed that additional separation and grinding of the commercial corn grits, corn cones, and corn flour affected protein, crude fat content, and color parameter (L, a, and b) distribution of the products. The tristimulus parameters (L, a, and b) were good indicators of the protein content of the corn dry-milled streams studied.     

Flowability Properties of Commercial Distillers Dried Grains with Solubles (DDGS)

Distillers dried grains with solubles (DDGS), the major coproduct from the corn‐based fuel ethanol industry, is primarily used as livestock feed. Due to high protein, fiber, and energy contents, there is a high demand for DDGS. Flowability of DDGS is often hindered due the phenomenon of caking. Shipping and handling of DDGS has thus become a major issue due to bridge formation between the DDGS particles. The objective of this investigation was to measure flowability characteristics of DDGS samples from five ethanol plants in the north central region of the United States. Carr and Jenike tests were performed and the resulting data were mathematically compared with a previously developed empirical model. The largest particles had an average geometric mean diameter (GMD) of 1.19 mm, while the lowest particle size had an average GMD of 0.5 mm. Soluble solid levels were ≈10.5–14.8% (db). The effective angle of friction (δ) was 43.00–57.00°. Additionally, a few parameters exhibited fairly high linear correlations, including aerated and packed bulk densities (r = 0.97), geometric standard deviation and Carr compressibility (r = 0.71), geometric standard deviation and Hausner ratio (r = –0.70). Overall flowability assessment indicated that the commercial DDGS samples did have the potential for flow problems, although no samples exhibited complete bridging. Quantifying DDGS flowability is a necessary step toward overcoming this logistical challenge facing the fuel ethanol industry.     

Effect of Harvest Moisture Content on Selected Yellow Dent Corn: Dry‐Grind Fermentation Characteristics and DDGS Composition

Efficiently utilizing the nongrain portion of the corn plant as ruminant food and the grain for ethanol will allow the optimization of both food and fuel production. Corn and corn stover could be more effectively used if they were harvested earlier before dry down. Corn harvested at different moisture contents (MCs) may exhibit different processing characteristics for the ethanol industry, because of differences in physical and chemical properties. Therefore, the objective of this study was to investigate the effect of corn harvest MC on dry‐grind fermentation characteristics and dried distillers grains with solubles (DDGS) composition. Pioneer hybrid 32D78 was harvested at seven different dates from August 21 to November 23, 2009, with harvest MCs ranging from 73 to 21% (wb). The corn samples with different harvest MCs were evaluated by a conventional dry‐grind process. Final ethanol concentration from the corn with harvest MC of 54% (kernel dent stage) was 17.9% (v/v), which was significantly higher (0.5–1.2 percentage points) than the mature corn with lower harvest MCs (P < 0.05). Ethanol conversion efficiencies for the corn with harvest MCs of 73 and 54% (wb) were 98.5 and 93.2%, respectively, whereas ethanol conversion efficiencies for the corn with lower harvest MCs were significantly lower (P < 0.05), ranging between 83.2 and 88.3%. For DDGS composition, with corn harvest MC decreasing from 73 to 21% (wb), the residual starch concentration increased from 7.7 to 15.2%, the crude protein concentration decreased from 29.4 to 24.9%, and the neutral detergent fiber concentration decreased from 26.6 to 20.6%.     

Physical and Chemical Characterization of Fuel Ethanol Coproducts Relevant to Value‐Added Uses

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 properties of the DDGS included crude ash (5.0–21.93%), neutral detergent fiber (NDF) (26.32–43.50%), acid detergent fiber (ADF) (10.82–20.05%), crude fiber (CF) (8.14–12.82%), crude protein (27.4–31.7%), crude fat (7.4–11.6%), and total starch (9.19–14.04%). Physical properties of the DDGS included moisture content (3.54–8.21%), A_w (0.42–0.53), bulk density (467.7–509.38 kg/m³), thermal conductivity (0.05–0.07 W/m·°C), thermal diffusivity (0.1–0.17 mm²/sec), color L* (36.56–50.17), a* (5.2–10.79), b* (12.53–23.36), and angle of repose (25.7–47.04°). These properties were also determined for DWG and DDG. We also conducted image analysis and size determination of the DDGS particles. Carbon group characterization in the DDGS and DDG samples were determined using NMR spectroscopy; O‐alkyl comprised >50% of all DDGS samples. Results from this study showed several possibilities for using DDGS in applications other than animal feed. Possibilities include harvesting residual sugars, producing additional ethanol, producing value‐added compounds, using as food‐grade additives, or even using as inert fillers for biocomposites.     

REVIEW: Zein Extraction from Corn,Corn Products,and Coproducts and Modifications for Various Applications: A Review

Corn can be fractioned to produce starch, fiber, oil, and protein in relatively pure forms. The corn kernel contains 9–12% protein, but half of this is an industrially useful protein called zein. Dry milled corn (DMC), corn gluten meal (CGM), and distiller's dried grains with solubles (DDGS) are all coproducts from corn that contain zein and are used for zein extraction. Because it is insoluble in water, zein has found uses in many products such as coatings, plastics, textiles, and adhesives. Newer applications are taking advantage of zein's biological properties for supporting growing cells, delivering drugs, producing degradable sutures, and producing biodegradable plastics. This review covers zein characteristics and nomenclature, past and current practices in processing and extraction of zein from corn products and coproducts, and the modifications of zein for various applications.     

Modeling Distillers Dried Grains with Solubles (DDGS) Mass Flow Rate as Affected by Drying and Storage Conditions

Ethanol production in 2015 was over 15 million gallons in the United States, and it is projected to increase in the next few years to meet market demands. With the continued growth in the ethanol industry, there has been enormous expansion in distillers grains production. Because the local market for distillers dried grains with solubles (DDGS) is often saturated, it is essential to transport DDGS long distances, across the United States and to international markets. Caking and agglomeration of DDGS particles in hoppers and other storage structures are typical during transportation. The current study deals with DDGS prepared by combining condensed distillers solubles (CDS) with distillers wet grains and then drying at varying temperatures. DDGS was stored in conical hoppers under varying ambient temperature, consolidation pressure, and time conditions. We investigated the effects of CDS (10, 15, and 20% wb), drying temperature (100, 200, and 300°C), drying time (20, 40, and 60 min), cooling temperature (0, 25, and 50°C), consolidation pressure (0, 1.72, and 3.43 kPa), and consolidation time (0, 3, and 6 days) levels on various flow parameters. To examine these factors, Taguchi's experimental design with an L ₁₈ orthogonal array was implemented. Response surface modeling yielded mass flow rate = f (Hausner ratio, angle of repose) with R ² = 0.99, and it predicted moisture content for good, fair, and poor flow. Results showed that drying temperature, drying time, and cooling type were the main factors in predicting mass flow rate. The Johansson model for predicted mass flow rate was calibrated with experimental data, and a new parameter, compressibility factor, with a value of 0.96 g²/(min cm³), was determined to quantify the divergence of compressible and cohesive materials (such as DDGS) for free‐flowing bulk solids. Thus, the predicted models may be beneficial for quantitative understanding of DDGS flow.     

Particle Segregation Within a Pile of Bulk Distillers Dried Grains with Solubles (DDGS) and Variability of Nutrient Content

Piling Dried Distillers's Grains with Solubles (DDGS) using gravity discharge is common in the corn‐ethanol industry. This study investigated the occurrence of particle segregation within piles of DDGS formed by gravity discharge and subsequent spatial nutrient variability. Particle segregation tests were performed in a laboratory study where piles of DDGS were formed using samples collected from two fuel ethanol plants (an “old” and a “new” generation plant), and a plant study performed on piles of DDGS formed at the same two fuel ethanol plants. In both the laboratory and plant studies, the piles were formed by gravity‐driven discharge and sampled at various categorized sections from the center of the pile to the periphery. Our results gave similar conclusions to a prior bench‐scale study and confirmed that particle segregation does result in significant differences in particle size at the sampled locations of the pile. Particle size expressed as the geometric mean diameter (d_gw) increased from the core of the pile to the periphery. Of all the nutrient composition tested, only crude protein and moisture correlated with particle size. While the correlation of crude protein with particle size was not consistent and clearly discernible in all the piles sampled in both the bench‐scale and plant studies, the correlation of particle size with moisture showed a strong positive correlation. Based on these findings, we recommend the development of a standard sampling protocol following good sampling practices for bulk granular solids.     

Effect of the corn breaking method on oil distribution between stillage phases of dry-grind corn ethanol production

The majority of fuel ethanol in the United States is produced by using the dry-grind corn ethanol process. The corn oil that is contained in the coproduct, distillers' dried grains with solubles (DDGS), can be recovered for use as a biodiesel feedstock. Oil removal will also improve the feed quality of DDGS. The most economical way to remove oil is considered to be at the centrifugation step for separating thin stillage (liquid) from coarse solids after distilling the ethanol. The more oil there is in the liquid, the more it can be recovered by centrifugation. Therefore, we studied the effects of corn preparation and grinding methods on oil distribution between liquid and solid phases. Grinding the corn to three different particle sizes, flaking, flaking and grinding, and flaking and extruding were used to break up the corn kernel before fermentation, and their effects on oil distribution between the liquid and solid phases were examined by simulating an industrial decanter centrifuge. Total oil contents were measured in the liquid and solids after centrifugation. Dry matter yield and oil partitioning in the thin stillage were highly positively correlated. Flaking slightly reduced bound fat. The flaked and then extruded corn meal released the highest amount of free oil, about 25% compared to 7% for the average of the other treatments. The freed oil from flaking, however, became nonextractable after the flaked corn was ground. Fine grinding alone had little effect on oil partitioning.     

Hydrocyclone Separation of Dry-Milled Corn

Corn milled to <1 mm using a screen mill was sieved and the particles >590 μm were soaked for 1 hr in solutions with a range of glucose concentration providing liquid specific gravities above and below that of the lighter fraction (corn germ). A suspension of these particles was pumped through a hydrocyclone to separate the germ particles and to rinse watersoluble compounds from the corn. The specific gravity of the hydrocyclone streams (suspensions), as well as liquid phase (after solids settling) was measured, and product compositions and particle sizes were determined. This work shows that a germ-enriched fraction of corn ground to <1 mm, can be separated with a hydrocyclone. To enable computer simulation of the corn-treatment process, the experimental data was used to construct a two-component model of the hydrocyclone separation of the milled corn. In the model, the milled and sieved corn is virtually separated into germ and endosperm streams that are fed to paired hydrocyclone models. Hydrocyclone bypassing streams that simulate particles entrained to the contrary outlet (underflow for germ and overflow for endosperm particles) were included in the simulation to bring the model into agreement with the experimental product compositions.     

Influence of soil particle size and grinding on bray‐2 extractable phosphorus

Abstract

The influence of soil particle size and soil fine grinding on Bray‐2 extractable phosphorus (Bray‐2P) was studied. Air‐dried and 2‐mm mesh‐sieved soil was separated into six particle size classes: <0.075, 0.075–0.106, 0.106–0.25, 0.25–0.425, 0.425–0.85, and 0.85–2 mm. The lowest amounts of Bray‐2P were found in the 0.425–0.85 and 0.85–2 mm fractions and the highest in <0.075 mm fraction. When ground for 3 min, the amount of Bray‐2P increased in the fractions larger than 0.25 mm, whereas it decreased in the fractions smaller than 0.25 mm. In the large fraction (0.425–0.85 mm), grinding for 1 to 3 min led to an increase in the amount of Bray‐2P, but grinding for 9 to 18 min caused a decrease. In contrast, in the small fraction (<0.075 mm), the amount of Bray‐2P decreased by grinding for 1 min. The large and small fractions that were ground absorbed P in proportion to the grinding time during the extraction‐filtration period.     

Air and Moisture Transport Properties of Low‐Oil DDGS

Distillers dried grains with solubles (DDGS) are widely used as feed for cattle, dairy, and swine because of their protein, fiber, amino acids, fat, and other vital nutrients. Corn ethanol plants in the United States recently have started extracting oil from DDGS to gain additional profit, thus producing low‐oil DDGS. So far, there has been no comprehensive study reported with bulk handling and flowability properties of low‐oil DDGS. We measured the air resistance, moisture diffusivity, and air permeability properties for low‐oil DDGS at different temperature and relative humidity conditions, along with some important physical and chemical properties. Physical property comparisons between regular and low‐oil DDGS showed differences in key properties such as particle size, color, density, porosity, and angle of repose. The modified Henderson model predicted the equilibrium moisture content (EMC)–equilibrium relative humidity (ERH) relationship of low‐oil DDGS with a low standard error of regression value (0.008); it showed no pattern in the residuals and was judged the most appropriate model tested for EMC‐ERH predictions. Results of EMC‐ERH nonlinear modeling were used to define conditions for moisture diffusivity. Moisture diffusivities of low‐oil DDGS at varying drying temperatures ranged from 0.74 × 10⁻¹¹ to 1.77 ×10⁻¹¹m²/s. The properties are important for understanding and modeling heat and moisture transport through and flow properties of low‐oil DDGS.     

Effects of Varying CDS Levels and Drying and Cooling Temperatures on Flowability Properties of DDGS

Demand for alternative fuels and the need to reduce dependence on fossil fuels have triggered the growth of corn‐based ethanol production, which is expected to rise in future years. Transportation of the coproduct distillers dried grains with solubles (DDGS) from this industry occurs under various environmental conditions. Transporting DDGS is often problematic, because caking between the particles can lead to flow problems. In this study, we have prepared DDGS by combining condensed distillers solubles (CDS) with distillers wet grains and then drying. We investigated the effects of CDS level (10, 15, and 20%, wb), drying temperature (100, 200, and 300°C), and cooling temperature (–12, 25, and 35°C) on the flowability of the resulting DDGS. Statistical analyses of the resulting data found significant differences among the cooling temperature levels for angle of repose, total flow and flood indices, dispersibility, water activity, and protein dispersibility index. Additionally, significant interaction effects between CDS, drying temperature, and cooling temperature levels for angle of repose, total flow and flood indices, dispersibility, and protein dispersibility index were observed. Response surface regression on selected dimensionless flowability parameters was also applied. However, multivariate PLS regression yielded better results (R² > 0.8) than response surface plots. Understanding the effects of drying and cooling temperatures as well as CDS levels can be used to help improve the industrial processing of DDGS and improve storage and transportation.     

Evaluation of Operating Conditions for Surface Lipid Extraction from Rice Using a Soxtec System

The degree of milling (DOM) of rice is a measure of how well the germ and bran layers are removed from the surface of rice kernels during milling. Because the majority of rice kernel lipids are found on the surface, measuring the surface lipid content (SLC) of rice after milling may be one way to quantify the DOM of rice. While there are several methods to measure the lipid content (LC) of rice, there is not an established standard method for determining the SLC of milled rice. The objective of this study was to evaluate the primary operating variables of a Soxtec apparatus in measuring the SLC of milled rice. This was accomplished by varying the preextraction drying, boiling, rinsing, and postextraction drying durations, as well as the solvent used for extraction, to achieve the maximum extraction of lipids from rice. Experiments were performed on stored Oryza sativa L. ‘Cypress’ and ‘Bengal’ rice milled for 10, 30, and 60 sec. Results showed that durations of 1 hr of preextraction, 20 min of boiling, 30 min of rinsing, and 30 min of postextraction drying provided the maximum lipid extraction from milled head rice with petroleum ether. Of the three solvents tested, petroleum ether, and ethyl ether yielded similar extraction results.     

Maize Proximate Composition and Physical Properties Correlations to Dry‐Grind Ethanol Concentrations

Dry‐grind ethanol plants incur economic losses because of seasonal variations in ethanol yields. One possible cause associated with ethanol yield variability is incoming grain quality. There is little published information on factors causing variation in dry‐grind ethanol concentrations. The objective of this study was to determine relationships between rapidly measurable corn quality attributes (physical parameters and chemical composition) and dry‐grind ethanol concentrations. Corn samples obtained from a Midwestern ethanol plant were analyzed for physical quality parameters (test weight, kernel weight, true density, percent stress cracks, and moisture content) and composition (starch, protein, oil, and soluble sugars contents) and then processed with a laboratory‐scale dry‐grind procedure. There were significant (P < 0.05) variations in corn quality parameters and ethanol concentrations. Correlation coefficients were significant (P < 0.05) but low (–0.50 < r < 0.50) between starch content and final ethanol concentrations (72 h) and total soluble sugar content and ethanol concentrations at 72 and 48 h. Ethanol concentrations (at 24, 48, and 72 h) were predicted as a function of a combination of grain quality factors using multiple regression methods; however, the R² values obtained were low. Variations in ethanol concentrations were not related to physical and chemical composition quality factors. Other factors, such as structural and physiologic attributes of corn grain, need to be evaluated.     

Economics of Fiber Separation from Distillers Dried Grains with Solubles (DDGS) Using Sieving and Elutriation

Separation of fiber from distillers dried grains with solubles (DDGS) provides two valuable coproducts: 1) enhanced DDGS with reduced fiber, increased fat and increased protein contents and 2) fiber. Recently, the elusieve process, a combination of sieving and elutriation was found to be effective in separating fiber from two commercial samples of DDGS (DDGS‐1 and DDGS‐2). Separation of fiber decreased the quantity of DDGS, but increased the value of DDGS by increasing protein content and produced a new coproduct with higher fiber content. Economic analysis was conducted to determine the payback period, net present value (NPV), and internal rate of return (IRR) of the elusieve process. The dependence of animal foodstuff prices on their protein content was determined. Equipment prices were obtained from industrial manufacturers. Relative to crude protein content of original DDGS, crude protein content of enhanced DDGS was higher by 8.0% for DDGS‐1 and by 6.3% for DDGS‐2. For a dry‐grind plant processing corn at the rate of 2,030 metric tonnes/day (80,000 bushels/day), increase in revenue due to the elusieve process would be $0.4 to 0.7M/year. Total capital investment for the elusieve process would be $1.4M and operating cost would be $0.1M/year. Payback period was estimated to be 2.5–4.6 years, NPV was $1.2–3.4M, and IRR was 20.5–39.5%.     

Effects of Thermomechanical Extrusion and Particle Size Reduction on Bioconversion Rate of Corn Fiber for Ethanol Production

The objective of this research was to evaluate the effect of thermomechanical extrusion and particle size (PS) reduction on the bioconversion rate of corn fiber for ethanol production. Extrusion was conducted at a screw speed of 300 rpm, feed rate of 120 g/min, feed moisture content of 30%, melt temperature of 140°C, and die diameter of 3 mm. Raw and extruded corn fiber were separated into three different PSs (1 > PS ≥ 0.5, 0.5 > PS ≥ 0.3, and 0.3 > PS ≥ 0.15 mm) with a wire sieve. Extrusion pretreatment and PS reduction resulted in a significant (P < 0.05) difference in physical properties and color values of extruded corn fiber as a result of accelerated degradation of corn fiber structure. Significant increase in water solubility index of extruded corn fiber at 0.3 > PS ≥ 0.15 mm was an indication of high degradation of starch during extrusion for higher release of polysaccharides. Moreover, extruded corn fiber at PS reduction 0.3 > PS ≥ 0.15 mm also significantly increased (P < 0.05) ethanol yield (69.11 g/L) and conversion (68.18%) by increasing protein digestibility and free amino nitrogen, which are essential for higher fermentation efficiency.     

Effect of Moisture Content and Soluble Level on the Physical,Chemical, and Flow Properties of Distillers Dried Grains with Solubles (DDGS)

Distillers dried grains with solubles (DDGS) is a bulk material that has been widely used as a protein source for ruminants and nonruminants for more than two decades. DDGS is the nonfermentable processing residue (i.e., protein, fiber, fat, and ash) from fuel ethanol manufacturing. With the exponential growth of the fuel ethanol industry in the past several years, significant quantities (≈13.0 million tons in 2007) of distillers grains are now being produced. To effectively utilize these coproduct streams in the domestic market, DDGS must be transported greater distances and must be stored until final use. DDGS flow is often problematic as it can become restricted by caking and bridging that occur during shipping and storage. This flowability problem can present itself during dynamic and static flow conditions. This issue most likely results from physical or chemical interactions between particles (including particle size and shape), storage moisture, temperature, and relative humidity variations, as well as storage time. The objective of this study was to examine the effect of five moisture content levels (10, 15, 20, 25, and 30% db) on the resulting physical and chemical properties of DDGS with four soluble levels (10, 15, 20, and 25% db). To produce these materials, condensed distillers solubles (CDS) were combined with DDG, and appropriate quantities of water were added to adjust moisture contents. Carr indices were used to quantify the flowability of the DDGS samples. The results showed that both soluble level and moisture content had noticeable effects on physical and flow properties (e.g., aerated bulk density, packed bulk density, and compressibility). According to dispersibility, flowability index, and floodability index, flowability generally declined significantly (P < 0.05) with an increase in moisture content for most of the soluble levels under consideration. The color values and protein content of the DDGS were significantly affected (P < 0.05) as soluble level increased as well.     

Isolation and Characterization of Zein from Corn Distillers' Grains and Related Fractions

Corn distillers' grains with solubles (CDGS), the major coproduct of fermentation of corn to produce ethanol, were extracted with 0.1M NaOH, 0.1% dithiothreitol (DTT), and 0.5% SDS yielding 35% of the total nitrogen and ≈25% of the protein nitrogen. Gel electrophoresis revealed that the extractable proteins contained zein plus other proteins similar to the extractable proteins from corn flour. Although difficult to extract, the proteins isolated from the fermentation coproducts appeared undegraded and apparently survived gelatinization, fermentation, distillation, and drying during the production of ethanol. Extraction of CDGS with 60% ethanol at 60°C yielded 1.5–3.9% of crude zein. When the ethanol contained DTT, yields of crude zein were increased to 3.2–6.6%. Protein contents of the crude zeins were only 37–57%, indicating that lipids and pigments were coextracted with the ethanol. Gel electrophoresis showed that the protein fractions extracted by ethanol contained primarily α-zein whereas the proteins extracted by ethanol + DTT contained α- + β-zein. Further confirmation of the presence of zein in the crude prolamin preparations was obtained by amino acid analyses. The amino acid compositions of the crude zeins paralleled those of commercial zein and α-zein.