Phosphorus Concentrations and Flow in Maize Wet‐Milling Streams

Marketing of coproducts such as corn gluten meal (CGM) and corn gluten feed (CGF) is important to the maize wet‐milling industry. High phosphorus concentrations could lead to limited markets for CGF due to its potential to increase phosphorus in animal wastes. The objective was to measure the concentration and flow of phosphorus in the wet‐milling process and identify streams that could be altered. Samples were taken from 21 process streams of three facilities and the phosphorus content of each was determined. Flow of phosphorus was simulated using a computer model for a 2,700 tonne/day (105,000 bu/day) wet‐milling plant. Phosphorus concentrations of streams varied from <10 mg/kg to >14,000 mg/kg. Phosphorus content of many streams differed significantly among facilities. Flow of phosphorus (kg/day) varied dramatically among streams. However light steepwater, light gluten, and process water streams (5,960, 3,080, and 970 kg/day, respectively) accounted for much of the phosphorus flow. Modification of these streams could reduce phosphorus content of coproducts. The high phosphorus content of either CGF or CGM could be reduced markedly if phosphorus was reduced in the appropriate streams.     

Comparison Between Alkali and Conventional Corn Wet-Milling: 100-g Procedures

A corn wet-milling process in which alkali was used was studied as an alternative to the conventional corn wet-milling procedure. In the alkali wet-milling process, corn was soaked in 2% NaOH at 85°C for 5 min and then debranned mechanically to obtain pericarp as a coproduct. Debranned corn was cracked in a roller mill, and the cracked corn was steeped with agitation for 1 hr in 0.5% NaOH at 45°C. The cracked and steeped corn was then processed to separate germ, fiber, and gluten by steps similar to those in conventional wet-milling. Alkali wet-milling yielded soakwater solids, pericarp, germ, starch, gluten, and fine fiber. The protein content of the starch and the starch content of the fiber from the alkali process were lower than those from the conventional process.     

Comparison of Alkali and Conventional Corn Wet-Milling: 1-kg Procedures

An alkali corn wet-milling process was developed to evaluate the process as a method to produce high purity corn starch and coproducts with added value. Using a single hybrid (R1064 × LH59), the effects of alkali concentration (0.18–0.82% NaOH), time (29–61 min), and temperature (36–75°C) were investigated. Starch yield was not affected by steep time or temperature. Starch yield was optimal at 65.2% using 0.5% alkali. Increasing the concentration of alkali to 0.82% or decreasing it to 0.18% caused a decrease in starch yield of 8–10 percentage points. Other wet-milling products (fiber, germ, and gluten) also were affected. Steep conditions of 0.5% NaOH, 60 min, and 45°C gave optimal starch yield. Comparisons between alkali and sulfur dioxide wet-milling processes, using 1-kg sample size, were performed on 10 commercial yellow dent corn hybrids. The alkali process averaged 1.7 percentage points more starch than the sulfur dioxide process. Each hybrid had a higher starch yield when wet-milled with the alkali method. Alkali wet-milling produced pure corn starch with <0.30% protein (db).     

Economics of Germ Preseparation for Dry-Grind Ethanol Facilities

A detailed economic analysis of a 914 tonnes/day (36,000 bu/day) “Quick Germ” ethanol process was performed. The Quick Germ ethanol process is a combination of a dry-grind and a wet-milling ethanol process. The Quick Germ ethanol process increases the coproduct value in the dry-grind ethanol process by recovering germ before fermentation. Germ is recovered using the conventional wet-milling degermination process. Economic assessment of the Quick Germ process proved profitable. The savings achieved by recovering germ as a coproduct and by increasing the fermentor capacity due to removal of nonfermentables from the corn mash will reduce the manufacturing cost of ethanol by 2.69 ¢/L (10.19 ¢/gal or $0.265/bu) when compared to the conventional dry-grind ethanol process.     

Fiber Separated from Distillers Dried Grains with Solubles as a Feedstock for Ethanol Production

In the dry-grind process, corn starch is converted into sugars that are fermented into ethanol. The remaining corn components (protein, fiber, fat, and ash) form a coproduct, distillers dried grains with solubles (DDGS). In a previous study, the combination of sieving and elutriation (air classification), known as the elusieve process, was effective in separating fiber from DDGS. In this study, elusieve fiber was evaluated for ethanol production and results were compared with those reported in other studies for fiber from different corn processing techniques. Fiber samples were pretreated using acid hydrolysis followed by enzymatic treatment. The hydrolyzate was fermented using Escherichia coli FBR5 strain. Efficiency of ethanol production from elusieve fiber was 89–91%, similar to that for pericarp fiber from wet-milling and quick fiber processes (86–90%). Ethanol yields from elusieve fiber were 0.23–0.25 L/kg (0.027–0.030 gal/lb); similar to ethanol yields from wet-milling pericarp fiber and quick fiber. Fermentations were completed within 50 hr. Elusieve fiber conversion could result in 1.2–2.7% increase in ethanol production from dry-grind plants. It could be economically feasible to use elusieve fiber along with other feedstock in a plant producing ethanol from cellulosic feedstocks. Due to the small scale of operation and the stage of technology development for cellulosic conversion to ethanol, implementation of elusieve fiber conversion to ethanol within a dry-grind plant may not be currently economically feasible.     

Recovery of Lysine from Corn Steepwater

One approach to increasing the utilization of agricultural products is fractionation of low-value materials to yield high-value products. In this study, lysine recovery from corn steepwater, an internal processing stream generated in the wet-milling of corn, was investigated. A weakly acidic cation exchange resin was employed to selectively recover lysine from corn steepwater at pH 7.0. In column studies, the product from the ion exchange operation had a lysine content of 4–6% (db). The only other amino acid in the product was arginine. The presence of sodium, potassium, and magnesium ions at significant concentrations in the steepwater limited the lysine content of the product because of competitive adsorption on the resin. The lysine-enriched product reported here is 4–10 times higher in lysine content than other corn milling coproducts and could potentially be useful as a lysine supplement in animal feeds.     

Critical nutrient concentrations and DRIS analysis of leaf and grain from high‐yielding corn

Abstract

A field experiment was conducted to optimize fertilizer inputs for maximizing the yield of irrigated com (Zea mays L.). This report is a summary of the nutrient composition of leaf and grain samples from the highest yielding treatment in the experiment. The experiment had 15 treatments replicated three times in a randomized complete block design. The N rate treatments were 45,100, 200, 300, and 400 kg N/ha with and without 50 kg P/ha, 67 kg K/ha, and 22 kg S/ha. The plant populations were 74,000 plants/ha (30,000 plants/A) and 100,000 plants/ha. The highest corn yield was 15.6 Mg/ha (250 bu/A with 15.5% moisture) which was produced with 300 kg N/ha combined with complete N, P, K, and S fertilization. It is assumed that samples of corn leaf and grain from a plot yielding that high would have nutrient concentrations in the sufficiency range. Many of the nutrient concentrations from these arbitrarily designated sufficiency ranges are close to the critical ranges and concentrations reported in the literature. It can be concluded that established critical concentrations and ranges could be useful for diagnosing high‐yielding corn. Furthermore, the negative DRIS indices for N, P, K, S, and Cu indicate that these nutrients are most likely to be limiting based on the published norms.     

Phytosterol and tocopherol components in extracts of corn distiller's dried grain

As the ethanol industry continues to grow, it will become very important to develop value-added markets for its coproducts in order for the industry to remain profitable. Corn distiller's dried grain (DDG) is a major coproduct of ethanol fermentation from corn processed by dry-milling and is primarily sold as livestock feed. The objective of this research was to determine if valuable phytochemicals found in corn oil and corn fiber oil, such as phytosterols and their saturated equivalents, phytostanols, ferulate phytosterol esters (FPE), tocopherols, and tocotrienols, are retained in DDG. Hexane and supercritical carbon dioxide (CO2) extracts of DDG were similar in their concentrations of total phytosterols (15.8-17.3 mg/g of extract), FPE (3.75-3.99 mg/g of extract), and tocols (1.7-1.8 mg/g of extract). Ethanol extracts were slightly lower in concentration of phytosterols (8.9-11.4 mg/g of extract), FPE (1.62-1.98 mg/g of extract), and tocols (0.73-0.76 mg/g of extract).     

Analysis and properties of arabinoxylans from discrete corn wet-milling fiber fractions

Three fibrous corn wet-milling fractions, coarse fiber, fine fiber, and spent flake, were isolated. More highly valued uses are sought for these milling products, which are generally directed into the corn gluten feed product stream. Coarse fiber was further dissected into pericarp and aleurone layers. An alkaline hydrogen peroxide process was used to efficiently extract corn fiber gum (CFG) from each of the materials. CFG is a hemicellulose B arabinoxylan which also contains low levels of D,L-galactose and D-glucuronic acid. CFG yield information was obtained from each source, as well as structural information in terms of degrees of branching of the beta-D-xylopyranose backbone with alpha-L-arabinofuranosyl moieties. There were significant differences in degree of branching among the CFGs from the various fractions. A novel capillary electrophoresis procedure was developed to measure these differences. Solution viscosity differences among the CFGs were also observed.     

Chemical composition, in vitro fermentation characteristics, and in vivo digestibility responses by dogs to select corn fibers

The objective was to examine the chemical composition, in vitro fermentation characteristics, and in vivo digestibility responses of fiber-rich corn coproducts resulting from corn wet milling. Native corn fibers, native corn fibers with fines, hydrolyzed corn fibers, and hydrolyzed extracted corn fibers were analyzed chemically and their capacity to produce short-chain fatty acids determined. Ash content was low (<1.2%), crude protein content varied little, but fat and fiber concentrations varied widely. Most fiber was in the insoluble form, with glucose being predominant followed by xylose. Total short-chain fatty acid production ranged from 211.6 to 699.52 micromol/g of dry matter, whereas branched-chain fatty acid production was low. Four corn fibers (native and processed) were included in a canine diet matrix at the 7% inclusion level. Nutrient digestibility, food intake, and fecal characteristics were not affected by corn fiber inclusion in canine diets, suggesting that they should be considered as potential dietary fiber sources in dog foods.     

Laboratory Wet Milling of Corn: Milling Fraction Correlations and Variations Among Crop Years

Several coproducts result from fractionating corn in the wet‐milling process. Because small changes in product composition and milling characteristics can have a major impact on coproduct yields and values, testing is done to anticipate final product yields. Using small sample size and controlled conditions, a laboratory wet‐milling method proved to be a useful tool for wet milling and genetics industries. A wet‐milling process (100‐g batches) was used for data collection. Data collected during 11 years (1994–2004) were observed for samples used as benchmarks to verify process precision and accuracy and determine correlations among wet‐milling yields. More than 400 milling tests were performed on benchmark samples. Data from benchmark samples also were pooled. Coefficients of variation were low (<6%) for mean yields; year‐to‐year standard deviations of benchmark sample yield means were homogenous and implied precision of the procedure. Some differences were detected in mean yields among years (P ≤ 0.05) for benchmark data due to combined effects of hybrid and environment. A negative correlation (r = –0.58) was observed between starch and gluten yield for pooled benchmark data. Four years (2002–2005) of milling data from commercially available hybrids were analyzed using the milling procedure. For pooled commercial data, the correlation between starch and fiber yield was (r = –0.80); correlation between starch and gluten was (r = –0.76).     

Comparison of Yield and Composition of Oil Extracted from Corn Fiber and Corn Bran

We recently reported that corn fiber oil contains high levels of three potential cholesterol-lowering phytosterol components: ferulate-phytosterol esters (FPE) (3–6 wt%), free phytosterols (1–2 wt%), and phytosterol-fatty acyl esters (7–9 wt%). A previous study also indicated that corn bran oil contained less phytosterol components than corn fiber oil. The current study was undertaken to attempt to confirm this preliminary observation using more defined conditions. Accordingly, oil was extracted from corn fiber and corn bran prepared under controlled laboratory conditions, using the same sample of corn hybrid kernels for each, and using recognized bench-scale wet-milling, and dry-milling procedures, respectively. After extraction, the chemical composition of the phytosterol components in the oil were measured. This study confirmed our previous observation—that FPE levels were higher in corn fiber oil than in corn bran oil. During industrial wet-milling, almost all of the FPE are recovered in the fiber fraction (which contains both fine and coarse fiber). During laboratory-scale wet-milling, ≈60–70% of the FPE are recovered in the coarse fiber (pericarp) and 30–40% are recovered in the fine fiber. During laboratory-scale dry-milling, <20% of the FPE are recovered in the bran (pericarp), and the rest in the grits. The recoveries of the other two phytosterol components (free phytosterols and phytosterol-fatty acyl esters) revealed a more complex distribution, with significant levels found in several of the dry- and wet-milled products.     

Influence of Stenocarpella maydis Infected Corn on the Composition of Corn Kernel and Its Conversion into Ethanol

Widespread epidemics of Stenocarpella ear rot (formerly Diplodia ear rot) have occurred throughout the central U.S. Corn Belt in recent years, but the influence of S. maydis infected grain on corn ethanol production is unknown. In this study, S. maydis infected ears of variety Heritage 4646 were hand‐harvested in 2010 from a production field in central Illinois and segregated into one of five levels of ear rot severity based upon visual symptoms. The concentration of ergosterol, a sterol produced by fungi but not plants, was observed to increase with the severity of ear rot (127–306.5 μg/g), and none was detected in the control corn. Corn test weight declined with progression of the disease and was 42.6% lower for the most severely rotted grain from ears infected early in their development. Accompanying changes in composition were also apparent. Crude fat and oil contents decreased (from 4.7 to 1.5%) and fiber increased (from 6.6 to 9.6%), but starch content remained largely invariant. Oil composition also varied among the infected samples. Control and infected corn samples were subjected to ethanol fermentation with a laboratory‐scale corn dry‐grind ethanol process. Ethanol yields for control and infected samples were similar on an equivalent weight basis (2.77–2.85 gal/bu). In comparison with the control, S. maydis infection altered the distillers dried grains with solubles (DDGS) properties, wherein the crude protein was significantly higher and oil significantly reduced, and ash, fiber, and yield per ton were not significantly different. Based upon these results, we conclude that Stenocarpella ear rot has the potential to affect DDGS composition but not ethanol yield on an equivalent weight basis.     

Laboratory Yields and Process Stream Compositions from E‐Mill and Dry‐Grind Corn Processes Using a Granular Starch Hydrolyzing Enzyme

In dry‐grind corn processing, the whole kernel is fermented to produce ethanol and distillers dried grains with solubles (DDGS); the E‐Mill process was developed to generate coproducts in addition to DDGS. Compositions of thin stillage and wet grains obtained from the E‐Mill process will be different from the dry‐grind process. Knowledge of thin stillage compositions will provide information to improve coproducts from both processes. Laboratory dry‐grind and E‐Mill processes that used granular starch hydrolyzing enzymes (GSHE) were compared and process yields determined. Two methods, centrifugation and screening, were used to produce thin stillage and wet grains from the laboratory processes. Compositions of process streams were determined. In the dry‐grind process using GSHE, solids contents of beer, whole stillage, and wet grains were higher compared to the same fractions from the E‐Mill process using GSHE. Solids contents of mash for both processes were similar. Total solids, soluble solids, and ash contents of thin stillage were similar for the two processes. Fat content of thin stillage from E‐Mill was lower than that from the dry‐grind process; protein content of E‐Mill thin stillage was higher than that from dry‐grind thin stillage. Removal of germ and fiber before fermentation changed composition of thin stillage from the E‐Mill process. The screening method produced higher thin stillage and lower wet grains yields than using a centrifugation method. The screening method was less time consuming but resulted in limited wet grains material for additional analyses or processing. The centrifugation method of thin stillage separation removed more solids from thin stillage than the screening method.     

Factors Affecting Yield and Composition of Zein Extracted from Commercial Corn Gluten Meal

Twelve corn gluten meal samples obtained from six wet-milling plants were processed into zein. Zein was extracted using 88% aqueous isopropyl alcohol at pH 12.5, followed by chilling. Protein recovery ranged from 21.3 to 32.0%, and protein purity ranged from 82.1 to 87.6%. Protein recovery increased as the protein purity increased (r = 0.76) (P < 0.01). One of the major factors influencing extraction yield was protein composition; especially α-zein content, which ranged from 53.4 to 64% of the total protein in the corn gluten meal samples. The intensity of red color of the corn gluten meal was negatively correlated with protein recovery and zein purity (r = -0.66 and -0.72, respectively) (P < 0.02).     

Pericarp Fiber Separation from Corn Flour Using Sieving and Air Classification

In the dry‐grind process, starch in ground corn (flour) is converted to ethanol, and the remaining corn components (protein, fat, fiber, and ash) form a coproduct called distillers dried grains with solubles (DDGS). Fiber separation from corn flour would produce fiber as an additional coproduct that could be used as combustion fuel, cattle feed, and as feedstock for producing valuable products such as “cellulosic” ethanol, corn fiber gum, oligosaccharides, phytosterols, and polyols. Fiber is not fermented in the dry‐grind corn process. Its separation before fermentation would increase ethanol productivity in the fermenter. Recently, we showed that the elusieve process, a combination of sieving and elutriation (air flow), was effective in fiber separation from DDGS. In this study, we evaluated the elusieve process for separating pericarp fiber from corn flour. Corn flour remaining after fiber separation was termed “enhanced corn flour”. Of the total weight of corn flour, 3.8% was obtained as fiber and 96.2% was obtained as enhanced corn flour. Neutral detergent fiber (NDF) of corn flour, fiber, and enhanced corn flour (dry basis) were 9.0, 61.5, and 5.7%, respectively. Starch content of corn flour, fiber, and enhanced corn flour (dry basis) were 68.8, 23.5, and 71.3%, respectively. Final ethanol concentration from enhanced corn flour (14.12% v/v) was marginally higher than corn flour (13.72% v/v). No difference in ethanol yields from corn flour and enhanced corn flour was observed. The combination of sieving and air classification can be used to separate pericarp fiber from corn flour. The economics of fiber separation from corn flour using the elusieve process would be governed by the production of valuable products from fiber and the revenues generated from the valuable products.     

Effect of sulfur additions on soil and the nutrition of wheat

Abstract

A field experiment was conducted for two years to determine the effects of four sulfur (S) sources applied at various rates on the elemental composition of Coker 747³ wheat and on the soil S concentration. The concentration of S in plants increased by all sources of applied S. Increased S in the soil from S application decreased P concentrations in plants regardless of the S source used. Sulfur additions did not significantly affect the concentrations of Cu, Ca, Mg, or N in plants. The concentrations of Mn, Zn, and Fe in plants either increased or decreased depending on S source used. Analysis of the silt loam soil to a depth of 90 cm revealed that applied S moved readily from the surface to the lower depths and that the elemental form of S moved less rapidly than the more soluble forms of applied S.     

Near-Infrared Reflectance Correlated to 100-g Wet-Milling Analysis in Maize

An understanding of the genetic control of starch, protein, and oil concentrations in the corn (Zea mays L.) kernel is essential for improvement of grain quality. Because large numbers of progenies are needed for genetic studies, a rapid, accurate, analytical procedure is necessary. As part of a study to identify chromosomal regions associated with starch and protein, a rapid near-infrared reflectance (NIR) method and a more labor-intensive 100-g wet-milling procedure were compared for consistency in ranking families and identifying quantitative trait loci (QTL) using a set of 200 F₂S₁ families from the cross of the 70th generations of the Illinois High Protein (IHP) × Illinois Low Protein (ILP) corn strains. NIR starch and wet-milling starch values were highly correlated (r = 0.80), as were NIR protein and gluten measured by wet-milling (r = 0.72). Chromosomal regions associated with NIR starch and wet-milling starch were generally the same. Fiber concentration was significantly negatively correlated with starch and positively correlated with protein. Chromosome regions with significant associations with starch also had significant associations with fiber. The NIR method is satisfactory for measuring starch and protein in material with a wide range of variability in the early stages of a corn-breeding program.     

Comparison of Enzymatic (E‐Mill) and Conventional Dry‐Grind Corn Processes Using a Granular Starch Hydrolyzing Enzyme

A new low temperature liquefaction and saccharification enzyme STARGEN 001 (Genencor International, Palo Alto, CA) with high granular starch hydrolyzing activity was used in enzymatic dry‐grind corn process to improve recovery of germ and pericarp fiber before fermentation. Enzymatic dry‐grind corn process was compared with conventional dry‐grind corn process using STARGEN 001 with same process parameters of dry solid content, pH, temperature, enzyme and yeast usage, and time. Sugar, ethanol, glycerol and organic acid profiles, fermentation rate, ethanol and coproducts yields were investigated. Final ethanol concentration of enzymatic dry‐grind corn process was 15.5 ± 0.2% (v/v), which was 9.2% higher than conventional process. Fermentation rate was also higher for enzymatic dry‐grind corn process. Ethanol yields of enzymatic and conventional dry‐grind corn processes were 0.395 ± 0.006 and 0.417 ± 0.002 L/kg (2.65 ± 0.04 and 2.80 ± 0.01 gal/bu), respectively. Three additional coproducts, germ 8.0 ± 0.4% (db), pericarp fiber 7.7 ± 0.4% (db), and endosperm fiber 5.2 ± 0.6% (db) were produced in addition to DDGS with enzymatic dry‐grind corn process. DDGS generated from enzymatic dry‐grind corn process was 66% less than conventional process.     

Growth and composition of corn,alfalfa, and orchardgrass grown on soils contaminated with airborne dust containing Ca and Mg

Abstract

A greenhouse experiment was conducted with soils allegedly contaminated with airbourne dust containing Mg and Ca oxides and carbonates to study the growth and composition of corn, orchardgrass, and alfalfa plants. Soils were obtained from sites varying in distance from the alleged source of airbourne dust.

Soil pH values ranged from 6.2 to 8.7. Plant yields decreased only when the soil pH increased above 7.7. There was no apparent relationship between the observed yield decrease and the N, P, K, and B concentrations in the plants. Although the Mn and Zn concentrations generally decreased with increasing soil pH, the decrease was not great enough to account for the yield depressions. The obviously minor symptoms occurring on the plants growing on the most affected soils could not be associated with a deficiency or excess of any other element.

The Ca/Mg ratio in the alfalfa plants decreased as soil pH increased over the range from 6.2 to 8.7. However, the Ca/Mg ratios in the corn and orchardgrass plants decreased only when the soil pH values increased above 7.7. The apparent imbalance of Ca and Mg in the tissues may account for the yield depressions.