U.S. patent application number 10/422295 was filed with the patent office on 2004-03-25 for products comprising corn oil and corn meal obtained from high oil corn.
This patent application is currently assigned to Renessen LLC. Invention is credited to Anderson, Beth, Anderson, Stephan C., Aufdembrink, Brent, Beaver, Michael J., Fox, Eugene J., Ingvalson, Joel, Jakel, Neal T., Kotowski, Douglas C., Tupy, Michael J., Ulrich, James F..
Application Number | 20040058052 10/422295 |
Document ID | / |
Family ID | 25455332 |
Filed Date | 2004-03-25 |
United States Patent
Application |
20040058052 |
Kind Code |
A1 |
Ulrich, James F. ; et
al. |
March 25, 2004 |
Products comprising corn oil and corn meal obtained from high oil
corn
Abstract
Corn oil and corn meal obtained from high oil corn are included
in useful products. The corn oil is extracted from the high oil
corn to form the corn meal. The corn oil generally comprises levels
of nutrients not found in commercially available corn oils, since
most or all of the corn grain, rather than just the germ, is
exposed to the extraction process. The corn grain generally
includes the steps of flaking corn grain having a total oil content
of at least about 6 wt. % and extracting a corn oil from the flaked
corn grain. The corn oil is useful for making nutritionally
enhanced edible oil or cooking oil, lubricants, biodiesel, fuel,
cosmetics and oil-based or oil-containing chemical products. The
extracted corn meal is useful for making enhanced animal feed
rations, snack food, blended food products, cosmetics, and
fermentation broth additive.
Inventors: |
Ulrich, James F.; (Highwood,
IL) ; Jakel, Neal T.; (Lake Zurich, IL) ;
Kotowski, Douglas C.; (Plymouth, MN) ; Ingvalson,
Joel; (Minneapolis, MN) ; Aufdembrink, Brent;
(Medina, MN) ; Tupy, Michael J.; (Crystal, MN)
; Fox, Eugene J.; (Dayton, OH) ; Beaver, Michael
J.; (Victoria, MN) ; Anderson, Stephan C.;
(Minneapolis, MN) ; Anderson, Beth; (Minneapolis,
MN) |
Correspondence
Address: |
LEYDIG VOIT & MAYER, LTD
TWO PRUDENTIAL PLAZA, SUITE 4900
180 NORTH STETSON AVENUE
CHICAGO
IL
60601-6780
US
|
Assignee: |
Renessen LLC
Bannockburn
IL
Cargill, Incorporated
Wayzata
MN
|
Family ID: |
25455332 |
Appl. No.: |
10/422295 |
Filed: |
April 24, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10422295 |
Apr 24, 2003 |
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09927836 |
Aug 10, 2001 |
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6648930 |
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09927836 |
Aug 10, 2001 |
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09637843 |
Aug 10, 2000 |
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09637843 |
Aug 10, 2000 |
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09249280 |
Feb 11, 1999 |
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6313328 |
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Current U.S.
Class: |
426/629 ;
554/8 |
Current CPC
Class: |
A23K 50/10 20160501;
A23K 10/20 20160501; A23K 10/30 20160501; Y02E 50/13 20130101; C08B
30/10 20130101; C10L 1/026 20130101; C08L 99/00 20130101; A23D 9/00
20130101; A23K 10/26 20160501; A23K 50/80 20160501; B02B 1/00
20130101; Y02E 50/10 20130101; A23K 50/00 20160501; Y02E 50/17
20130101; A23K 20/163 20160501; A23K 50/75 20160501; A23K 40/25
20160501; A23K 50/40 20160501; C11B 1/10 20130101; A23L 33/115
20160801; C11B 1/06 20130101; A23K 20/147 20160501; C11B 1/04
20130101; Y02A 40/818 20180101; C11B 3/001 20130101; A23K 10/24
20160501; C12P 7/06 20130101; A23J 1/144 20130101; A23K 40/20
20160501; A23D 9/007 20130101; A23L 7/107 20160801; A23L 7/198
20160801 |
Class at
Publication: |
426/629 ;
554/008 |
International
Class: |
C11B 001/00; A23L
001/36 |
Claims
We claim:
1. A corn meal remaining after the extraction of oil from whole
high oil corn.
2. The corn meal of claim 1, wherein the whole high oil corn has an
oil content of about 6 wt. % or greater.
3. The corn meal of claim 1, wherein the oil content is from about
7 wt. % to about 30 wt. %.
4. The corn meal according to claim 2, wherein the whole corn is
tempered prior to extraction of the oil.
5. The corn meal according to claim 4, wherein the tempered corn is
cracked prior to extraction of the oil.
6. The corn meal according to claim 5, wherein the cracked corn is
flaked prior to extraction of the oil.
7. The corn meal according to claim 5, wherein the tempered corn is
cracked prior to extraction of the oil.
8. The corn meal according to claim 7, wherein the cracked corn is
conditioned prior to extraction of the oil.
9. The corn meal according to claim 8, wherein the cracked corn is
flaked prior to extraction of the oil.
10. A method for processing whole high oil corn comprising: 1)
conditioning the tempered and cracked whole high oil corn; 2)
flaking the cracked whole high oil corn; and 3) extracting the
flaked corn to produce corn meal and corn oil.
11. The method of claim 10, further comprising the step of
tempering the whole high oil corn.
12. The method of claim 11, wherein the step of conditioning is
before the step of tempering the whole high oil corn.
13. The method of claim 10, further comprising the step of cracking
the whole high oil corn.
14. The method of claim 11, further comprising the step of cracking
the whole high oil corn.
15. The method of claim 13, wherein the step of cracking is before
the step of conditioning the whole high oil corn.
16. The method of claim 14, wherein the step of cracking is after
the step of tempering and before the step of conditioning the whole
high oil corn.
17. The method of claim 10, wherein the oil content of the whole
corn is about 6 wt. % or greater.
18. The method of claim 10, wherein the oil content of the whole
corn is from about 7 wt. % to about 30 wt. %.
19. The method of claim 10, wherein the step of extracting is
accomplished by extracting corn oil from grain flaked corn using a
continuous solvent extraction process.
20. The method of claim 19, wherein the flaked corn remains in
contact with the solvent for a time sufficient to extract the
desired amount of oil.
21. The method of claim 19, wherein the flaked corn remains in
contact with the solvent for at least 10 minutes.
22. The method of claim 10, wherein the thickness of the flakes is
from about 0.1 mm to about 1.0 mm.
23. The method of claim 19, wherein the solvent comprises
hexane.
24. A method of producing ethanol comprising: 1) combining the corn
meal of claim 1 with water and alpha-amylase enzyme; 2) incubating
the combination and including at least one additive to the
combination; and 3) mixing the combination with a micro-organism
capable of fermenting a carbon source to produce ethanol.
25. The method of claim 24 wherein the additive is selected from
the group consisting of glucoamylase and protease.
26. A biodiesel comprising corn oil produced by the extraction of
the oil from whole high oil corn.
27. A method of recovering lighter particles generated during the
processing of high oil corn comprising separating lighter particles
from heavier particles by passing a stream of gas over the high oil
corn particles such that lighter particles are carried away in the
gas stream.
28. The method of claim 27, wherein the gas is selected from the
group consisting of air, nitrogen and argon.
29. A method of recovering lighter particles generated during the
processing of high oil corn comprising separating lighter particles
from heavier particles by passing a liquid spray over the high oil
corn particles such that lighter particles are carried away.
30. The method of claim 29 wherein the liquid spray is water.
31. The method of claim 30, wherein said liquid spray further
comprises at least one component selected from the group consisting
of vitamins, minerals, enzymes and combinations thereof.
32. The method of claim 31, wherein said liquid spray further
comprises a caustic liquid.
33. A biodegradable product made from solvent extracted corn meal
from high oil corn.
34. The biodegradable product of claim 33 wherein the solvent
extracted corn meal is treated with an organic solvent.
35. The biodegradable product of claim 33, wherein the extracted
corn meal is further treated with a cross-linking agent.
36. The biodegradable product of claim 35, wherein the
cross-linking agent is selected from the group consisting of an
aldehyde, an acid anhydride, an epoxide or combinations
thereof.
37. A feed comprising corn meal produced by the solvent extraction
of oil from whole high oil corn.
38. The feed of claim 37, wherein the feed is animal feed or
aquaculture feed.
39. The feed of claim 38, wherein the animal feed is chicken
feed.
40. The feed of claim 39, wherein the feed is aquaculture feed.
41. Corn oil remaining after extraction of flaked corn from whole
oil corn.
42. The corn oil of claim 41, wherein the whole high oil corn has
an oil content of about 6 wt. % or greater.
43. The corn oil of claim 42, wherein the oil content is from about
7 wt. % to about 30 wt. %.
44. The corn oil according to claim 42, wherein the whole corn is
tempered prior to extraction of the flaked corn.
45. The corn oil according to claim 44, wherein the tempered corn
is cracked prior to extraction of the flaked corn.
46. The corn oil according to claim 45, wherein the cracked corn is
flaked prior to extraction of the flaked corn.
47. The corn oil according to claim 45, wherein the tempered corn
is cracked prior to extraction of the flaked corn.
48. The corn oil according to claim 47, wherein the cracked corn is
conditioned prior to extraction of the flaked corn.
Description
[0001] The present application is a continuation-in-part of
copending U.S. patent application Ser. No. 09/637,843, filed Aug.
10, 2000, which was a continuation-in-part of application Ser. No.
09/249,280, filed Feb. 11, 1999, the entire disclosures of which
are hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to products that are derived
from oil and meal extracted from corn having an oil content of
about 6 wt. % or more.
BACKGROUND OF THE INVENTION
[0003] Corn, Zea mays L., is grown for many reasons including its
use in food and industrial applications. Corn oil and corn meal are
two of many useful products derived from corn.
[0004] Commercial processing plants utilizing conventional methods
for extracting corn oil from conventional corn separate the corn
seed into its component parts, e.g., endosperm, germ, tipcap, and
pericarp, and then extract corn oil from the corn germ fraction.
Corn germ produced by wet or dry milling is processed either by
pressing the germ to remove the oil or by flaking the germ and
extracting the oil with a solvent. In both processes, because the
germ was separated from the remainder of the kernel, many or all of
the valuable components of the endosperm fraction are absent from
the oil.
[0005] A corn-based feed product known as hominy feed is obtained
from the dry milling process and is a mixture of corn bran, corn
germ, and endosperm, and has a minimum of about 4 wt. % oil.
Several steps including cracking, grinding, sieving, and blending
are required to manufacture hominy feed and the resulting particle
size of hominy feed is small relative to meal made by the
extraction method described herein.
[0006] Industry and health advocates are continually in search of
more nutritious products derived from corn, since products derived
from conventional corn lack some desired nutritional components.
Thus, there exists a need for improved products derived from corn
oil and corn meal.
BRIEF SUMMARY OF THE INVENTION
[0007] Finished products containing corn oil and/or corn meal
obtained from conventional corn include, for example, cooking oil,
animal feed, paper and paper products, numerous food products such
as salad dressings, extruded and/or puffed snack foods, products
containing corn sweeteners, cereals, chips, puddings, candies, and
breads.
[0008] One aspect of the invention provides a nutritious animal
feed comprising the corn meal remaining after extraction of oil
from high oil corn having an oil content of about 6 wt. % or
greater. The animal feed can comprise other nutritious products
such as vitamins, minerals, high oil seed-derived meal, meat and
bone meal, salt, amino acids, feather meal, and many others used in
the art of feed supplementation. The animal feed composition can be
tailored for particular uses such as for poultry feed, swine feed,
cattle feed, equine feed, aquaculture feed, pet food and can be
tailored to animal growth phases. Particular embodiments of the
animal feed include growing broiler feed, swine finishing feed, and
poultry layer finishing feed. Feed products can be made with the
extracted corn meal that will have a higher relative percentage of
protein and lower relative percentage of oil than similar products
made with conventional corn.
[0009] Some embodiments of the invention include those wherein: 1)
the corn meal has a fiber content of about 3%, a starch content of
about 65%, and a protein content of about 12%, at a moisture
content of about 10%; 2) the high oil corn grain has a total oil
content of at least about 6 wt. %, at least about 7 wt. %, at least
about 8 wt. %; at least about 10 wt. %, at least about 12 wt. %, at
least about 14 wt. %, or from about 7 wt. % to about 30 wt. %; 3)
the corn grain being flaked is whole corn grain or cracked corn
grain; 4) the corn grain has been subjected to an oil extraction
process such as solvent extraction, hydraulic pressing, or expeller
pressing, aqueous and enzyme extraction; 5) the high oil corn grain
has a total protein content of at least about 7 wt. %, at least
about 9 wt. %, at least about 11 wt. %, or from about 7 wt. % to
about 20 wt. %; 6) the high oil corn grain has a total lysine
content of at least about 0.15 wt. %, at least about 0.5 wt. %, or
from about 0.25 wt. % to about 2.0 wt. %; and/or 7) the high oil
corn grain has a total tryptophan content of at least about 0.03
wt. %, at least about 0.20 wt. %, or from about 0.03 wt. % to about
2.0 wt. %.
[0010] A preferred embodiment provides a method of obtaining corn
oil and solvent extracted corn meal (SEC) from high oil corn. The
method provides steps of: 1) tempering the corn; 2) cracking the
tempered corn; 3) conditioning the cracked corn; 4) flaking the
conditioned corn; 5) extracting the flaked corn; and 6) removing
the solvent from both the corn oil and solvent extracted corn meal.
The method provides a greater overall content of corn oil and
concentrates the proteins in the meal. Moreover, solvent
extractable pigments can be removed from the SEC.
[0011] Another aspect of the invention provides a corn oil-based
product comprising corn oil obtained by extraction of at least the
endosperm and germ of high oil corn. The corn oil-based product can
comprise other components such as vinegar, spices, vitamins, salt,
hydrogen (for forming hydrogenated products), and water. The corn
oil used in the products of the invention will generally contain a
higher proportion of .beta.-carotene, xanthophylls or tocotrienol
than similar products made with corn oil extracted from
conventional corn employing conventional methods. The corn oil,
used in the products of the invention, is generally produced by
exposing the entire corn grain, the cracked corn grain or the
flaked corn grain to extraction without separation of the germ from
the endosperm. Therefore, the solvent-extractable nutrients present
in the endosperm are extracted into the corn oil that has been
extracted from the germ and endosperm. Products that can be made
with the oil prepared as described herein include, but are not
limited to, salad dressings, cooking oils, margarines, spray-coated
food or feed products, breads, crackers, snack foods, lubricants,
and fuels.
[0012] Other embodiments of the invention include those wherein: 1)
high oil corn grain is cracked, conditioned, flaked and extracted
with a solvent; 2) the high oil corn grain has a total oil content
of at least about 6 wt. %, at least about 7 wt. %, at least about 8
wt. %; at least about 10 wt. %, at least about 12 wt. %, at least
about 14 wt. %, or from about 7 wt. % to about 30 wt. %; 3) the
corn oil is extracted by pressing cracked corn; 4) the corn oil is
extracted by subjecting flaked corn grain to a solvent-based
extraction process; 5) the solvents used to extract miscible or
soluble substances from the flaked grain include all forms of
commercially available hexanes, isopropyl alcohol, ethanol,
supercritical carbon dioxide or mixtures thereof; 6) the extracted
corn oil is provided as miscella; 7) the corn oil is refined by
additional processing; and 8) the corn oil is extracted by
subjecting flaked corn grain to hydraulic pressing and/or expeller
pressing, aqueous and/or enzyme extraction processes.
[0013] A third aspect of the invention provides a method of using
extracted corn meal in an animal feed ration comprising the step
of: 1) providing an extracted corn meal prepared by at least
flaking high oil corn to form flaked corn and extracting the flaked
corn to remove a portion of the corn oil therefrom; and 2)
including the extracted corn meal in an animal feed ration.
[0014] A fourth aspect of the invention provides a method of using
an extracted corn oil in a food product comprising the steps of: 1)
providing an extracted corn oil obtained by at least flaking high
oil corn to form flaked corn and extracting the flaked corn to
remove a portion of the corn oil therefrom and form the extracted
corn oil; and 2) including the extracted corn oil in a food
product.
[0015] A fifth aspect of the invention provides a method of using
extracted corn oil as a feedstock in an oil refining process. The
method comprises the steps of: 1) providing an extracted crude corn
oil obtained by at least flaking high oil corn to form flaked corn
and extracting the flaked corn to remove a portion of the corn oil
therefrom and form the extracted crude corn oil; and 2) including
the extracted crude corn oil in a raw material stream of an oil
refining process.
[0016] A sixth aspect of the invention provides various methods of
forming extracted blended meals. A first embodiment of this aspect
of the invention provides a method of forming an extracted blended
meal comprising an extracted meal obtained from high oil corn and
one or more other oilseed meals, the method comprising the step of:
1) combining high oil corn grain and one or more other oilseed
grains to form a grain mixture; and 2) subjecting the grain mixture
to flaking and an extraction process to remove oil therefrom and
form the extracted blended meal. A second embodiment provides a
method comprising the steps of: 1) combining a cracked and
conditioned high oil corn with another cracked and conditioned
oilseed to form a conditioned mixture; 2) flaking the conditioned
mixture to form a flaked mixture; and 3) subjecting the flaked
mixture to an extraction process to remove oil therefrom and form
the extracted blended meal. A third embodiment provides a method
comprising the steps of: 1) combining a cracked, conditioned and
flaked high oil corn with a cracked, conditioned and flaked other
oilseed to form a flaked mixture; and 2) subjecting the flaked
mixture to an extraction process to remove oil therefrom and form
the extracted blended meal. A fourth embodiment provides a method
comprising the step of combining an extracted corn meal with one or
more extracted other oilseed meals to form a blended meal, wherein
the extracted corn meal has been obtained by at least flaking and
extracting high oil corn to form the extracted corn meal. A fifth
embodiment provides a blended extracted meal product prepared
according to any one of the above-described methods.
[0017] A seventh aspect of the invention provides a method of using
extracted corn oil as an ingredient in cosmetic applications. The
method comprises the steps of: 1) providing an extracted crude corn
oil obtained by at least flaking high oil corn to form flaked corn
and extracting the flaked corn to remove a portion of the corn oil
therefrom and form the extracted crude corn oil; and 2) including
the extracted crude corn oil in a cosmetic product. These types of
cosmetics include but are not limited to lipstick and eye
liner.
[0018] Another aspect of the invention provides the use of a corn
meal in an animal feed or human food, wherein the corn meal is
obtained after extraction of corn oil from whole kernels of high
oil corn.
[0019] Yet another aspect of the invention provides the use of a
corn oil in an animal feed or human food, wherein the corn oil is
obtained by extraction from whole kernels of high oil corn.
[0020] Other aspects of the invention provide corn oil-containing
and/or corn meal-containing products made by the processes
described herein.
[0021] Unless otherwise defined, all technical and scientific terms
and abbreviations used herein have the same meaning as commonly
understood by one of ordinary skill in the art to which this
invention pertains. Although methods and materials similar or
equivalent to those described herein can be used in the practice of
the present invention, suitable methods and materials are described
below without intending that any such methods and materials limit
the invention described herein. All patents publications and
official analytical methods referred to herein are incorporated by
reference in their entirety. Additional features and advantages of
the invention will be apparent from the following description of
illustrative embodiments of the invention and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 illustrates the total amount of ethanol produced and
dextrose consumed by yeast grown on yellow dent corn (YD), yellow
dent meal (YDM), high oil corn (HOC), and high oil corn meal
(HOCM).
[0023] FIG. 2 illustrates the pH values of yeast cultures
containing yellow dent corn (YD), yellow dent meal (YDM), high oil
corn (HOC), and high oil corn meal (HOCM).
DETAILED DESCRIPTION OF THE INVENTION
[0024] It has been discovered that corn oil can be rapidly and
efficiently extracted on a commercial-scale from corn grain having
increased oil content by optionally cracking and then conditioning,
and flaking the corn grain and extracting a corn oil. Useful corn
grain for the novel flaking oil processing method has a total oil
content greater than about 6 wt. %. Increases in the oil content of
corn grain may increase flaking efficiency during processing.
Suitable flaking equipment and methods include conventional flaking
equipment and methods used for flaking soybean and other similar
oilseed types. Suitable extracting equipment and methods may
include conventional methods used for extracting oil from soybean
flakes and other similar oilseed types.
[0025] High oil corn seed or "grain" harvested from any of several
different types of corn plants is useful in the invention. These
types of corn plants are, for example, hybrids, inbreds, transgenic
plants, genetically modified plants or a specific population of
plants. Enhanced extracted meals can be made by subjecting enhanced
high oil corn to the extraction process described herein. Useful
corn grain types include, for example, flint corn, popcorn, flour
corn, dent corn, white corn, and sweet corn. The high oil corn
grain can be in any form including whole corn, cracked corn, or
other processed corn or parts thereof that are amenable to flaking
but different from the standard methods of germ separation employed
in dry and wet milling for subsequent recovery of oil from the
germ.
[0026] As used herein, the terms "whole kernel" or "whole corn"
mean a kernel that has not been separated into its constituent
parts, e.g. the hull, endosperm, tipcap, pericarp, and germ have
not been purposefully separated from each other. The whole corn may
or may not have been ground, crushed, cracked, flaked, or abraded.
Purposeful separation of one corn constituent from another does not
include random separation that may occur during storage, handling,
transport, crushing, flaking, cracking, grinding or abrading. A
purposeful separation of the constituent part is one wherein at
least 50% of one constituent, e.g., germ, has been separated from
the remaining constituents.
[0027] As used herein, the term "high oil corn" refers to corn
grain comprising at least about 6 wt. % or greater, preferably at
least about 7 wt. % or greater, and preferably at least about 8 wt.
% or greater oil. A high oil corn has an elevated level of oil as
compared to conventional yellow dent corn, which has an oil content
of about 3 wt. % to about 5 wt. %. Additionally, the total oil
content of corn grain suitable for the invention can be, for
example, grain having an oil content at least about 9 wt. %, at
least about 11 wt. %, at least about 12 wt. %, at least about 15
wt. %, at least about 18 wt. %, at least about 20 wt. %, from about
8 wt. % to about 20 wt. % oil, from about 10 wt. % to about 30 wt.
% oil, or from about 14 wt. % to about 30 wt. %, and values within
those ranges. Although the oil content can be determined at any
moisture content, it is acceptable to normalize the oil content to
a moisture content of about 15.5%.
[0028] High oil corn useful in making the oil and meal described
herein are available from Cargill, Incorporated (Minneapolis,
Minn.) or Pfister Hybrid Corn Co. (El Paso, Ill.). Other suitable
high oil corn includes the corn populations known as Illinois High
Oil (IHO) and Alexander High Oil (Alexo), samples of which are
available from the University of Illinois Maize Genetics
Cooperative--Stock Center (Urbana, Ill.).
[0029] Corn grain having an elevated total oil content is
identified by any of a number of methods known to those of ordinary
skill in the art. The oil content of grain, including the fat
content of a meal extracted from the grain, can be determined using
American Oil and Chemical Society Official Method, 5.sup.th
edition, March 1998, ("AOCS method Ba 3-38"). AOCS method Ba 3-38
quantifies substances that are extracted by petroleum ether under
conditions of the test. The oil content or concentration is the
weight percentage of the oil with respect to the total weight of
the seed sample. Oil content may be normalized and reported at any
desired moisture basis.
[0030] Other suitable methods for identifying high oil corn grain
are described herein. According to one method, corn ears are
selected using a near infrared (NIR) oil detector to select corn
ears having corn kernels with elevated oil levels. Likewise, an NIR
detector can also be used to select individual corn kernels having
elevated levels of corn oil. However, selecting individual ears
and/or kernels having elevated oil content may not be cost
effective in identifying high oil kernels suitable for processing
using methods described herein. Generally, corn seed producing corn
plants that yield grain having elevated total oil concentrations is
planted and harvested using known farming methods. Methods for
developing corn inbreds, hybrids, transgenic species and
populations that generate corn plants producing grain having
elevated oil concentrations are known and described in Lambert
(Specialty Corn, CRC Press Inc., Boca Raton, Fla., pp. 123-145
(1994).
[0031] One of the suitable high oil corns used as a raw material
for preparing the corn oil and corn meal used in the invention has
a nutrient profile as shown in Table 1. Amounts are expressed on an
"as is" or "as fed" moisture level. Protein, oil, and starch levels
can vary in a number of possible combinations in the high oil corn
used as a raw material for meal and oil used in the invention.
Acceptable amounts of moisture, oil, protein, starch, lysine, and
tryptophan are illustrated in Table 1. However, additional
combinations, such as 12 wt. % protein and 12 wt. % oil, not shown
as indicated amounts in the table are within the scope and range of
corn grain to be used to produce oil and meal used in the
invention.
1TABLE 1 Amount 1 Amount 2 Amount 3 General Amount Component (wt.
%) (wt. %) (wt. %) (wt. %) Moisture 14 14 14 5-45 Oil 8 12 20 6-30
Protein 9 9 17 5-20 Starch 61 54 41 35-80 Lysine 0.35 0.50 1.0
0.15-2.0 Tryptophan 0.088 0.11 0.15 0.03-2.0
[0032] Another suitable high oil corn used as a raw material for
preparing the corn oil and corn meal used in the invention has a
nutrient profile as shown in Table 2. Amounts are expressed on an
"as is" or "as fed" moisture level. The amounts shown in Table 2
are exemplary for a corn grain having 12 wt. % oil and 9 wt. %
protein.
2 TABLE 2 Amount General Component (wt. %) Amount (wt. %) Moisture
14 5-45 Oil 12 6-30 Protein 9 5-20 Starch 65 35-80 Fiber 3 1-5 Ash
1.18 0.59-4.72 Lysine 0.33 0.2-2.0 Tryptophan 0.09 0.03-2.0
Methionine 0.25 0.13-1.00 Total Sulfur Amino Acids 0.46 0.23-1.84
Valine 0.45 0.23-1.80 Isoleucine 0.34 0.17-1.36 Arginine 0.45
0.23-1.80 Threonine 0.34 0.17-1.36 Leucine 1.03 0.52-4.12 Histidine
0.27 0.14-1.08 Phenylalanine 0.44 0.22-1.76 Alanine 0.70 0.35-2.80
Aspartic 0.74 0.37-2.96 Cystine 0.22 0.11-0.88 Glutamic 1.9
0.95-7.6 Glycine 0.46 0.23-1.84 Proline 0.86 0.43-3.44 Tyrosine
0.06 0.03-0.54 Serine 0.46 0.23-1.84
[0033] Table 3 shows amino acid levels (based on a corn grain
moisture content of about 10%) of two high oil corn grain samples
and normal yellow corn grain. The oil and protein levels of high
oil corn sample 1 (HOC 1) were 13.3 wt. % and 10.7 wt. %
respectively, expressed on a dry matter basis. The oil and protein
levels of high oil corn sample 2 (HOC 2) were 13.0 wt. % and 11.2
wt. % respectively, expressed on a dry matter basis. For
comparison, normal yellow corn grain has about 4.2 wt. % oil and
about 9.2 wt. % protein on a dry matter basis.
3TABLE 3 Amino Acid HOC 1 (%) HOC 2 (%) Yellow Corn (%) Aspartic
Acid 0.71 0.68 0.48 Threonine 0.33 0.30 0.19 Serine 0.37 0.27 0.19
Glutamic Acid 1.84 1.79 1.16 Proline 0.83 0.78 0.52 Glycine 0.40
0.42 0.24 Alanine 0.77 0.74 0.47 Valine 0.51 0.52 0.33 Cystine 0.21
0.23 0.16 Methionine 0.46 0.47 0.39 Isoleucine 0.30 0.30 0.20
Leucine 1.19 1.08 0.74 Tyrosine 0.11 0.11 0.06 Phenylalanine 0.52
0.48 0.32 Tryptophan 0.06 0.07 0.05 Lysine 0.34 0.38 0.21 Histidine
0.29 0.29 0.18 Arginine 0.45 0.48 0.28
[0034] High oil corn is generally subjected to an extraction
process as described herein to provide the enhanced corn oil and
corn meal to be included in the finished products of the invention.
As used herein, the term "finished product" or "product" refers to
an article or manufacture made by combining the corn oil and/or
corn meal of the invention with a variety of other ingredients. The
specific ingredients included in a product will be determined
according to the ultimate use of the product. Exemplary products
include animal feed, raw material for chemical modification,
biodegradable plastic, blended food product, edible oil, cooking
oil, lubricant, biodiesel, snack food, cosmetics, and fermentation
process raw material. Products incorporating the meal described
herein also include complete or partially complete swine, poultry,
and cattle feeds, pet foods, and human food products such as
extruded snack foods, breads, as a food binding agent, aquaculture
feeds, fermentable mixtures, food supplements, sport drinks,
nutritional food bars, multi-vitamin supplements, diet drinks, and
cereal foods.
[0035] For example, starting with a single corn type (e.g., 12 wt.
% oil and 9 wt. % protein), more than one corn meal type can be
made to meet certain nutritional requirements. The significance of
this flexibility relates to the nutrient density within feed
products and to dietary requirements of animals. One significant
advantage of the use of this type of high oil corn and extraction
process is that an extracted corn meal can be made to have a
specific oil level depending on the extent of oil extraction. Once
the oil is removed from the flakes, the remaining corn meal has a
nutrient density for protein, amino acids, and other nutrients not
removed by the process, greater or different than normal corn grain
and greater than that of the starting corn, e.g., 12 wt. % oil, 9
wt. % protein.
[0036] According to one extraction process used in preparing the
corn oil and corn meal as described herein, whole grain high oil
corn is optionally tempered, optionally cracked, and then
conditioned and flaked. After flaking, the flaked corn is extracted
as described herein.
[0037] Whole grain corn is optionally tempered before the
extraction process. As used herein, the term "tempering" is used
interchangeably with the terms "heat soaking" or "steaming" and is
a means to uniformly distribute the added moisture through the
entire corn kernel. Any tempering method known in the art is
acceptable. In general, the corn is steeped in an appropriate
amount of water for any suitable length of time, such as at least
20 minutes, preferably at least 4 hours, preferably at least 6
hours, more preferably at least 12 hours, or most preferably at
least 24 hours. After the corn has steeped for the desired length
of time, its moisture content is retested. The corn may be stored
for short periods of time, but is preferably processed within 24
hours and most preferably processed immediately.
[0038] Whole grain corn is also optionally cracked. In a preferred
embodiment, the whole high oil corn is cracked after tempering yet
before conditioning. The high oil corn may be cracked by passing
the whole grain corn between two rollers with corrugated teeth
spinning toward each other spaced by a defined gap, and/or passing
through a grind mill where a rotating toothed disk spins at an
adjustable distance from a stationary disk, and/or the use of a
hammermill where two rotating metal "hammer" like devices spinning
next to one another. Methods for cracking corn or high oil seeds
are described in Watson, S. A. & P. E. Ramstad, ed. (1987,
Corn: Chemistry and Technology, Chapter 11, American Association of
Cereal Chemist, Inc., St. Paul, Minn.), the disclosure of which is
hereby incorporated by reference in its entirety. A "cracked" corn
is a corn that has undergone the above-described cracking
process.
[0039] Regardless of whether or not the corn is cracked, it is
conditioned using methods known to those of ordinary skill in the
art and/or methods described herein. As used herein, the term
"conditioning" refers to a process by which the corn kernel is
softened or plasticized to render it more pliable and amenable to
the flaking and extraction processes. Conditioning may include the
addition of steam (saturated and/or non-saturated steam) and/or
water to the high oil corn. This is done by the use of a rotary
conditioner. During the steam addition process, both the
temperature and the moisture levels are elevated. The temperature
ranges between about 140.degree. F. and about 210.degree. F. and
the moisture is increased by about 1% to about 15%.
[0040] The high oil corn grain is then flaked to any useful size.
As used herein, the term "flaking" refers to a process by which
corn grain is passed one or more times through flaking rollers to
produce flakes. The flaked corn may have a final flake thickness of
about 5/1000 to 100/1000 of an inch (.about.0.12 mm to 2.0 mm) or
preferably about 0.01 inches (0.25 mm), although other thicknesses
may also be used. Useful flake thickness may depend on external
limiting parameters such as the oil content of the corn, the
moisture content, the corn type, e.g., dent or flint, and the oil
extractor type. Suitable methods for flaking high oil corn are
detailed herein and in D. R. Erickson, Practical Handbook of
Soybean Processing Utilization (1995, AOCS Press), the entire
disclosure of which is hereby incorporated by reference. Suitable
flaking methods also include those known to those of ordinary skill
in the art of oilseed processing.
[0041] After the corn is tempered, cracked and/or conditioned and
flaked, the flaked corn is subjected to an extraction process to
extract oil to form an extracted corn meal (ECM). Corn oil is
extracted from flaked grain by one or more extraction steps using
any extraction method. Generally, substantially, or about all of
the oil is extracted in a single extraction process. Useful
extraction methods include solvent extraction, continuous solvent
extraction, hydraulic pressing, expeller pressing, aqueous and/or
enzyme extraction. Useful solvents for solvent extraction include,
for example, all forms of commercially available pentane, hexanes,
isopropyl alcohol, ethanol, supercritical carbon dioxide,
combinations thereof, and other similar solvents. For example, corn
oil can be extracted from flaked grain using a hexane-based solvent
extractor. Solvent extractors can include both percolation and
immersion type extractors. In a preferred embodiment, a continuous
solvent extraction process allows the flaked corn to remain in
contact with the solvent for at least 10 minutes, preferably at
least 30 minutes, more preferably at least 60 minutes, and most
preferably at least 90 minutes.
[0042] Materials removed from solvent-based extractors include wet
flakes and miscella. A miscella is a mixture of extracted oil and
solvent. The wet flakes are the materials that remain after some or
all of the solvent-soluble material has been extracted. Wet flakes
also contain a quantity of solvent. Solvent is reclaimed from both
the miscella and wet flakes using methods such as rising film
evaporation, or drying, and raising the temperature using equipment
such as flash tanks and/or de-solventiser/toasters. For example,
heat is applied to the wet flakes or miscella under atmospheric
pressure, under elevated pressure, or under vacuum to evaporate the
solvent. The evaporated solvent is then condensed in a separate
recovery system, and optionally dewatered and recycled to the
extractor.
[0043] Desolventized miscella is commonly termed crude oil, which
can be stored and/or undergo further processing. Crude oil can be
refined to produce a final oil product. Methods for refining crude
oil to obtain a final oil are known to those of ordinary skill in
the art. Hui (1996) provides a thorough review of oils and oilseeds
(Bailey's Industrial Oil and Fat Products, Fifth Ed., Vol. 2, Wiley
and Sons, Inc., New York, 1996). Chapter three of Hui (pp.
125-158), the disclosure of which is hereby incorporated by
reference, specifically describes corn oil composition and
processing methods. Crude oil isolated using the flaking methods
described herein is of a high quality but can be further purified
as needed using conventional oil refining methods.
[0044] In a preferred embodiment, the present invention relates to
a method of recovering lighter particles, such as fines, during the
processing of high oil corn. As used herein, the term "fines" means
any particle of the corn process that passes through a #18 sieve
having a 1.00 mm opening as defined in ASTM E-11 specifications.
The recovery of the particles may occur before, after, or during
any step in the process, such as during the moisture removal step,
during the cracking step or before or after the flaking process. In
general, fines are recovered by passing a current of gas (e.g.,
air, nitrogen, argon) over the corn at a suitable velocity and
direction such that smaller and lighter particles are carried away
in the stream, leaving behind larger and heavier particles.
Alternatively, lighter particles can be separated from heavier
particles using a liquid spray (e.g., water, process water). The
liquid is applied broadly enough so as to physically eliminate the
lighter, airborne particles. The liquid spray can include
components that add value to the end product, such as vitamins,
minerals, enzymes, and combinations thereof. In addition, the
liquid spray can further comprise a caustic liquid. Regardless of
the separation method, these fine particles can be captured or
recovered by any method known in the art such as using a baghouse.
Preferably, the recovered lighter particles can be reintroduced
into starch-containing product streams for the recovery of starch.
Additionally the fines may be sold as an animal feed.
[0045] Corn endosperm includes some valuable components such as
carotenoids, lutein, and zeaxanthin. Carotenoids in grains are
classified into two general groups, the carotenes and the
xanthophylls. The carotenes are important because they are vitamin
A precursors. Blessin et al. (Cereal Chemistry, 40, 582-586(1963))
found that over 90% of the carotenoids, of which beta-carotene is
predominant, are located in the endosperm of yellow dent corn and
less than 5% are located in the germ. Vitamin A is derived
primarily from beta-carotene.
[0046] Another group of valuable components found in the endosperm
includes the tocotrienols. Grams et al. (1970) discovered that in
corn, tocotrienols were found only in the endosperm, whereas the
germ contained most of the tocopherols. Tocotrienols can be
extracted from plant material using various solvents. Processes for
recovering tocotrienols from plant material are described by Lane
et al. in U.S. Pat. No. 5,908,940, the entire disclosure of which
is incorporated by reference.
[0047] Accordingly, the process described herein provides a
nutritionally enhanced corn oil enriched with lutein, zeaxanthin,
and/or beta-carotene and optionally one or more other nutritional
components.
[0048] Oil-based products made with corn oil obtained by the
extraction method described herein can contain higher levels of
important nutrients than similar products made with corn oil
produced by conventional methods. The corn oil obtained by the
extraction methods described herein will include the corn oil from
the germ and endosperm, and one or more other components extracted
from the rest of the kernel. The one or more other components can
be oil from the endosperm, tocotrienols, tocopherols, carotenoids,
carotenes, xanthophylls, and sterols.
[0049] Tocopherols (vitamin E) and vitamin A are antioxidants and
fat-soluble vitamins. When included in the diet, both have
demonstrated health benefits. Blending of oil of the present
invention with other oils or substances to achieve an appropriate
level of beta-carotene, vitamin E, and tocotrienols is deemed
within the scope of the present invention. In some embodiments,
extracted corn oil prepared as described herein comprises about 0.1
wt. % to about 0.5 wt. % of tocopherol.
[0050] Oil produced in accordance with the present invention also
may include approximately a 200% to 300% increase in tocotrienol
content over conventionally-produced crude corn oil. Using the
method of optionally tempering, cracking and/or conditioning and/or
flaking and extraction of high oil corn, the corn oil was extracted
and was then analyzed for tocotrienol content. The actual minimum
and maximum values for tocotrienol content will depend upon the
particular high oil corn used.
[0051] The oxidative stability index (OSI), measured in hours, is a
measure of an oil's relative stability toward oxidation. Generally,
the greater the OSI, the less susceptible the oil is toward
oxidation and the longer it takes to oxidize the oil under test or
use conditions. In addition, the greater the content of unsaturated
fatty acids present in the oil, the lower the OSI. Exemplary oils
prepared according to the extraction method described herein
generally possess OSI values ranging from about 10-22 hours.
[0052] Extraction of carotenes and xanthophylls and other pigments
is described in detail by Blessin (Cereal Chemistry, 39, 236-242
(1962); the entire disclosure of which is incorporated by
reference). Combinations of solvents, primarily ethanol and
hexanes, can be used to extract carotenes and xanthophylls from
corn. Ethanol, hexanes, other solvents combinations, and ratios
thereof may be used to produce oil of the present invention on a
commercial scale.
[0053] Exemplary embodiments of the crude oil obtained according to
the extraction method described herein generally possess the
partial composition profile featured in Table 4.
4TABLE 4 Exemplary Extracted Extracted High Component High Oil Corn
Oil Corn (Range) FFA (%) 1.45 0.7-3.00 C16:0 11.4 10-14 C18:0 2.1
1.5-3.5 C18:1, cis 33 26-50 C18:1, trans C18:2, cis 50 42-60 C18:2,
trans C18:3 0.8 0.6-1.6 Phosphorus (ppm) 190 100-400 Total
Tocopherols (ppm) 0.13 0.1-.50
[0054] Fatty acids generally found in the corn oil generally
include palmitic, stearic, oleic, linoleic and linolenic acids.
[0055] The crude oil prepared according to the methods described
herein can be subsequently partially or completely hydrogenated.
Suitable methods for partially or completely hydrogenating oil are
described in D. R. Erickson, Practical Handbook of Soybean
Processing Utilization (1995, AOCS Press), the entire disclosure of
which is hereby incorporated by reference.
[0056] When making oil-based products according to the invention,
those products can include conventional corn oil, soy oil, canola
oil, olive oil, palm oil, sunflower oil, safflower oil,
antioxidant, flavoring, hydrogenated oil, partially hydrogenated
oil and/or animal fat. By mixing the corn oil herein with one or
more other oils, blended oil products are made. The corn oil-based
products can also include materials such as food additives, salt,
fat, food colors, .beta.-carotene, annatto extract, curcumin or
tumeric, .beta.-apo-8'-carotenal and methyl and ethyl esters
thereof, natural or synthetic flavors, antioxidants, propyl
gallate, butylated hydroxytoluene, butylated hydroxyanisole,
natural or synthetic tocopherols, ascorbyl palmitate, ascorbyl
stearate, dilauryl thiodiproprionate, antioxidant synergists,
citric acid, sodium citrate, isopropyl citrate, phosphoric acid,
monoglyceride citrate, anti-foaming agent, dimethyl polysiloxane,
crystallization inhibitor, oxystearin, amino acids, vitamin,
minerals, carbohydrates, sugars, herbs, spices, acidity regulators,
firming agents, enzyme preparations, flour treatment agents,
viscosity control agents, enzymes, lipids, and/or vegetable or
animal protein. Additionally, these edible products can be enhanced
or enriched with protein supplements containing utilizable protein.
An exemplary food product such as a breakfast cereal could include
ingredients such as meal of the invention, wheat and oat flour,
sugar, salt, corn syrup, milled corn, dried fruit, vitamin C, B
vitamins, folic acid, baking soda, and flavorings.
[0057] Other exemplary oil-based products that can comprise the oil
prepared herein include food oil, cooking oil, edible oil and
blended oil.
[0058] Equipment used for the extraction of oil from oilseeds, such
as soybean and canola, can be used to prepare the corn oil and
extracted corn meal described herein. Useful commercial-scale
oilseed flakers can be obtained from French Oil Mill Machinery
Company, Piqua, Ohio; Roskamp Champion, Waterloo, Iowa; Buhler,
based in Switzerland with offices in Plymouth, Minn.; Bauermeister,
Inc., Germany; Consolidated Process Machinery Roskamp Company, on
the world wide web at http://www.cpmroskamp.com, and Crown Iron
Works, Minneapolis, Minn.
[0059] Commercial-scale methods and equipment are sufficient for
extracting corn oil from at least about 1 ton of corn per day. In
some embodiments, the capacity of commercial-scale operations
ranges from about 100 tons of corn per day to about 3000 tons of
corn per day, or the capacity ranges from about 700 tons of corn
per day to about 1700 tons of corn per day. Commercial-scale
operations that process greater than about 3000 tons of corn per
day are also sufficient.
[0060] Corn oil or corn meal quality is determined by evaluating
one or more quality parameters such as the oil yield, phosphorus
content, free fatty acid percentage, the neutral starch percentage,
protein content, and moisture content. Any method can be used to
calculate one or more of the quality parameters for evaluating the
oil or meal quality.
[0061] The phosphorus concentration of crude oil can be determined
using AOCS method Ca 12-55. AOCS method Ca 12-55 identifies the
phosphorus or the equivalent phosphatide zinc oxide, followed by
the spectrophotometric measurement of phosphorus as a blue
phosphomolybdic acid complex. AOCS method Ca 12-55 is applicable to
crude, degummed, and refined vegetable oils. The phosphorus
concentration is converted to phospholipid concentration, i.e., gum
concentration, by multiplying the phosphorus concentration by 30.
In some embodiments, corn oil produced according to the invention
includes about 100-400 ppm of phosphorus.
[0062] The free fatty acid percentage of oil can be determined
using AOCS method Ca 5a-40. AOCS method Ca 5a-40 identifies the
free fatty acids existing in the oils sample. AOCS method Ca 5a-40
is applicable to all crude and refined vegetable oils, marine oils,
and animal fats. The neutral oil loss during processing is
determined by adding the gum percentage and the free fatty acid
percentage together. The amount of free fatty acid obtained in the
extracted corn oil will depend upon the amount of fatty acids found
within the high oil corn from which the oil was extracted. In some
embodiments, the free fatty acid content of the extracted oil
ranges from about 0.70 wt. % to 3.00 wt. %
[0063] Oil color can be determined using AOCS method Cc 13b-45.
AOCS method Cc 13b-45 identifies the color of an oil sample by
comparing the oil sample with known color characteristics. AOCS
method Cc 13b-45 is applicable to fats and oils provided no
turbidity is present in the sample. Color values are evaluated
qualitatively by visual inspection of the oil. Generally, visual
inspection results in an oil being classified as a light oil or a
dark oil compared to a known oil color. Color values are
quantitated by determining a red color value and a yellow color
value using the AOCS method Cc 13b-45. Typically, crude corn oil
isolated using conventional dry milling methods has a red color
value ranging from about 7 to about 10 and a yellow color value
ranging from about 60 to about 70. Corn oils isolated using flaking
methods described herein have oil colors that qualitatively are
considered light and generally are lighter than crude corn oil
derived from wet or dry milling techniques. The yellow color values
may range from about 60 to about 70 and red color values may range
from about 7 to about 10, as determined by AOCS Method Cc
13b-93.
[0064] The extracted corn oil can be used as a raw material for
chemical modification, a component of biodegradable plastic, a
component of a blended food product, a component of an edible oil
or cooking oil, lubricant or a component thereof, biodiesel or a
component thereof, a component of a snack food, a fermentation
process raw material, and a component of cosmetics. Since the oil
obtained by the extraction process herein has one or more
components obtained from non-germ parts of the corn kernel, the oil
is enhanced. In some embodiments, the oil will have an oleic range
from about 20% to 80%, or preferably 25% to 50%, whereas normal
corn has about 25% to 40% oleic acid in the oil. When making
blended oils with the extracted oil, the blending can be done
before, during or after the extraction process.
[0065] Biodiesel can be produced using the extracted corn oil of
the invention. Biodiesel is a general term used for a variety of
ester-based oxygenated fuels. Biodiesel produced today is a mixture
of fatty acid methyl esters produced by methylating refined
vegetable oil. Refined oil is preferable to crude oil or spent
fryer oil due primarily to the quality of the glycerol by-product.
The main drawbacks with previous biodiesel products and related
vegetable oil lubricants are low temperature properties and
reactivity toward oxidation and polymerization. A preferred
biodiesel product comprises a low cloud point, reduced stearic and
polyunsaturated fatty acid content, and high oleic acid content.
Pour point correlates with low temperature properties and is
influenced by the saturated fatty acid content of the oil.
Polyunsaturated fatty acids are more susceptible to oxidation and
polymerization reactions.
[0066] Solvent-extracted corn (SEC) oil exhibits improved cloud
point performance over soy, while exhibiting similar chemical
stability.
5TABLE 5 % % % % % % Palmitic Stearic Oleic Linoleic Linolenic
Erucic Oil (16:0) (18:0) (18:1) (18:2) (18:3) (22:1) Rape 3 1 14 12
7 49 Canola 4 1 60 20 9 2 Soy 8-10 4 19-28 53-56 6-10 0 SEC 11 2 27
56
[0067] SEC oil corn can be further processed to form lubricants
such as by published procedures practiced currently in the industry
(see, e.g., U.S. Pat. No. 6,174,501).
[0068] Meal produced from the flaking and oil extraction process
described herein is used to produce unique feed products. The corn
meal used herein has been obtained after extraction of oil from
whole kernels of high oil corn, wherein the kernel has not been
separated into its constituent part, although the kernel may or may
not have been ground, flaked, cracked, chipped, or abraded. The
process of removing the oil from corn via extraction serves to
concentrate the remaining nutrients such as protein and essential
amino acids.
[0069] Feed products containing predominantly corn meal produced by
extraction require less supplementation with protein from other
sources such as soybeans than feed products containing
predominantly normal corn grain. The meal, by virtue of the
composition arising from the processing method, offers feed
manufacturers flexibility to produce feeds that could otherwise not
be made. Animal feed rations having unique physical properties such
as bulk density, texture, pelletability, and moisture holding
capacity and/or unique nutritional properties are created by
including the extracted corn meal of the present invention as a
component of said rations. The extracted corn meal isolated using
flaking and extraction methods as described herein can, on its own,
be a low-fat corn meal. Alternatively, it can be used in
combination with other corn meals or nutritional components to make
feed rations and food products. The extracted corn meal can also be
combined with meals made from crops such as soybeans, canola,
sunflower, oilseed rape, cotton, and,other crops. The extracted
corn meal can also be made from genetically modified corn and/or
combined with meals made from transgenic oilseed grains to form an
enhanced meal or enhanced product.
[0070] The extracted corn meal can be provided as a loose product
or a pelleted product, optionally in combination with other
components. For example, a pelleted product could include the
extracted corn meal (by itself or in combination with other
components) that has been pelleted and subsequently coated with
zein protein. The corn meal can be included in blended meal
products which can be provided in loose or pelleted form.
[0071] The feed rations prepared with the extracted corn meal will
generally meet the dietary and quality standards set forth in the
CODEX ALIMENTARIUS or by the National Research Council. The corn
meal of the invention will generally comprise the components in the
approximate amounts indicated in Table 6 below.
6 TABLE 6 Sample A Sample B Sample C Component Amount (%) Amount
(%) Amount (%) Moisture 5-45 5-25 5-45 Starch 40-70 40-80 40-70
Protein 8-20 7-20 8-20 Fat (Oil) 0.75-6 0.75-6.0 0.75-12 Crude
Fiber 2-4 2-4 Ash 1.5-3 0.5-2.0 Fructose 0.15-0.3 Glucose 0.2-0.5
Sucrose 1.5-2.5 Lysine 0.2-2.0 Tryptophan 0.03-2.0
[0072] The corn meals above may also further comprise unspecified
amounts of the components for which no amounts have been
indicated.
[0073] Varying levels of nutrients are required by different
animals depending on species, age, and breed. Feed rations
comprising different levels of nutrients are made by subjecting the
high oil corn to different degrees of extraction, i.e., more oil is
removed from the corn by subjecting it to extraction to a greater
degree. Therefore, feed rations comprising the extracted corn meal
of the invention can be made to include different amounts of fat,
protein, and carbohydrates by controlling the extent to which the
high oil corn is extracted. Table 7 details the amounts in which
the indicated ingredients are present in animal feed rations
comprising the extracted corn meal, the specific inclusion range
being indicative of exemplary rations in which extracted corn meal
is a main ingredient and the general inclusion range being
indicative of rations in which one or more other ingredients, for
example, carbohydrate-based energy sources such as sorghum, wheat,
and/or other cereal grains or their by-products, or other
non-cereal grain ingredients, may be included.
7TABLE 7 General Exemplary Ingredient Inclusion Range Inclusion
Range Corn meal described herein 2-95% 50-90% Oilseed Meal.sup.1
3-35% 10-30% Meat and Bone Meal 0-12% 0-7% Feather Meal 0-6% 0-4%
Fat 0-10% 1-6% Salt 0.1-0.5% 0.1-0.5% Lysine 0-0.4% 0-0.4%
Methionine 0-0.3% 0-0.3% Nutrient Premix 0.01-1.0% 0.01-1.0%
.sup.1Oilseed meal can consist of, but is not limited to, soy,
sunflower, canola, cottonseed, and other plant-based meals, which
themselves may or may not have been subjected to an oil extraction
process.
[0074] Meat and bone meal is obtained from suppliers such as
Darling International, Inc. (Irving, Tex.). Oilseed meal is
obtained from suppliers such as Cargill Oilseeds (Cedar Rapids,
Iowa). Feather meal is obtained from suppliers such as Agri Trading
Corp., (Hetchinson, Minn.). Amino acids are obtained from suppliers
such as DuCoa, (Highland, Ill.).
[0075] Feed rations are made by mixing various materials such as
grains, seed meals, vitamins, and/or purified amino acids together
to form a composite material that meets dietary requirements for
protein, energy, fat, vitamins, minerals, and other nutrients. The
mixing process can include grinding and blending the components to
produce a relatively homogeneous mixture of nutrients. Physical
properties of the feed raw materials and of the compounded feed
affect the nutritional quality, storability, and overall value of
the products. Suitable processes for manufacturing feed rations are
disclosed in Feed Manufacturing Technology IV (1994, American Feed
Industry Association) and incorporated herein in its entirety.
[0076] The extracted corn meal may be somewhat analogous to
steam-flaked corn in terms of digestibility of the starch fraction,
but may have better digestibility in ruminants by virtue of the
processing conditions. As discussed herein, specific oil levels can
be achieved in the extracted meal by altering processing
conditions. The protein, amino acid, and oil levels of the present
extracted meal cannot be achieved in steam-flaked normal corn, and
steam-flaked high oil corn may have too much oil, which could
adversely affect ruminant animal health.
[0077] Many types of animal feed rations can be developed using
extracted corn meal of the present type, and for illustration
purposes, the following diet types will be described herein: (1)
meal made from corn grain wherein the said corn grain has an oil
content of 12 wt. % and a protein content of 9 wt. %, and meal
resulting from this corn has an oil content of 1.5 wt. % for use in
a hog finishing diet; and (2) meal made from corn grain wherein the
said corn grain has an oil content of 12 wt. % and a protein
content of 9 wt. %, and meal resulting from this corn has an oil
content of 4.0 wt. % for use in a poultry broiler diet.
[0078] Extracted corn meal of the present invention has several
advantages over normal corn grain when used as an ingredient in
aquaculture feed products. In agriculture, pigments such as
carotenoids in feed are often deposited in fatty tissue when
consumed resulting in an undesirable color. For some aquaculture
species, consumer preference is for very light colored tissue. In
other species, such as salmon, consumer preference is for a pink or
red tissue. An advantage of extracted corn meal in aquaculture
diets is that some undesired pigments will be reduced by virtue of
the process to produce extracted corn meal; the solvent-soluble
pigment compounds (such as carotenoids) are removed from the meal
and concentrated in the oil. A second advantage of extracted corn
meal over corn dry-milled or wet-milled corn products is the
improved protein content and quality, since the oil has been
substantially removed from the kernel resulting in a meal product
in which the protein has been concentrated. Because the meal is
obtained from all portions of the kernel, including most or all of
the embryo, the proteins are generally of higher quality and
quantity than would be found in extracted corn grits. By including
extracted corn meal in aquaculture feeds, it will be possible to
raise animals with fewer undesirable pigment compounds in the
tissue.
[0079] Solvent extracted corn meal is also useful for
fermentation-based production of compounds, such as, for example,
ethanol, lactic acid, and vitamins. Solvent extracted corn meal
from high oil corn can be hydrolyzed to provide soluble sugars. The
meal serves as a carbon and nitrogen source for bacterial, fungal,
or yeast cultures. Biotin and other vitamins can be produced
through the cultivation of microorganisms. Organisms can include
Pseudomonas mutabilis (ATCC 31014), Corynebacterium primorioxydans
(ATCC 31015), Arthrobacter species, Gibberella species, Penicillium
species, or combinations thereof.
[0080] Nutrients used in the cultivation of these and other
microorganisms include, for example, starch, glucose, alcohols,
ketones, and as a nitrogen source, peptone, corn steep liquor,
soybean powder, ammonium chloride, ammonium sulfate, ammonium
nitrate, extracted corn meal, or urea. Various salts and trace
elements may also be included in media for the culture of
microorganisms. The pH of the culture medium is about 4 to about 9,
preferably about 6 to about 8 and most preferably about 7 for
bacterial species. The pH is about 5 to about 7 for mold or yeast.
During cultivation, temperatures are kept between 10.degree. C. to
100.degree. C, preferably between 20.degree. C. to 80.degree. C.,
more preferably between about 20.degree. C. to 40.degree. C., and
most preferably about 25.degree. C.
[0081] Biotin production is described in U.S. Pat. No. 3,859,167,
incorporated herein by reference.
Cis-tetrahydro-2-oxo-4-n-pentyl-thieno[- 3,4-d]imidazoline is added
to a culture medium containing solvent extracted corn meal and
other appropriate identified ingredients in combination with a
microbial species capable of forming biotin. In general, the
microorganism is cultivated for 1 to 10 days, preferably 1 to 8
days, and more preferably 2 to 7 days, after which time biotin is
separated and purified. In one embodiment, to purify biotin, cells
are removed from the culture medium, the filtrate is absorbed on
activated charcoal, and purified with an ion exchange column.
Alternative methods of purification are also used such as
crystallization by adjusting the pH of the biotin-contained
solution to near its isoelectric point.
[0082] Solvent extracted corn meal can also be further processed to
produce biodegradable materials. For instance, the meal of the
present invention may be incorporated as a thermoplasticising
agent. The meal of the invention may be included in the methods
described in U.S. Pat. No. 5,320,669, which is incorporated herein
by reference. The thermoplastic material is prepared using solvent
extracted corn meal, as obtained from the process described herein.
In one embodiment, the biodegradable thermoplastic composition
prepared using the meal of the present invention is treated with an
organic solvent, and optionally a cross-linking agent, to link
together the starch and protein of the extracted corn grain. The
cross-linking agent referred to herein may be any compound capable
of linking the starch and the protein, such as, for example, an
aldehyde, an acid anhydride or an epoxide. The compositions so
formed using the meal of the present invention can be used to make
extruded or molded articles that are biodegradable,
water-resistant, and/or have a high level of physical strength.
[0083] Blended products comprising the extracted corn meal and one
or more other oilseed meals are made by one or more of the
following ways: 1) combining the high oil corn and the other
oilseed prior to cracking and/or flaking and subjecting the entire
seed mixture to the flaking and extraction process described herein
to form a blended meal; 2) combining the high oil corn and the
other oilseed after cracking and conditioning, but prior to flaking
and subjecting the entire seed mixture to an extraction process as
described herein to form a blended meal; 3) combining the high oil
corn and the other oilseed after flaking and subjecting the entire
seed mixture to the extraction process described herein to form a
blended meal; 4) combining the extracted corn meal with extracted
or non-extracted other oilseed meal to form a blended meal; or 5)
combinations thereof to form a blended meal. At any time during
these processes, additional components can be added to the blended
meals to form a blended product.
[0084] The extracted corn meal can also be used in foodstuffs such
as snack food, blended food products, breads, fermentation
feedstock, breakfast cereals, thickened food products such canned
fruit fillings, puffed or extruded foods, and porridge.
[0085] When used in edible products for humans or animals, the
extracted corn meal can be combined with other components such as
other meal, other oilseed meal, grain, other corn, sorghum, wheat,
wheat milled byproducts, barley, tapioca, corn gluten meal, corn
gluten feed, bakery byproduct, full fat rice bran, and rice
hull.
[0086] The extracted corn meal can also be used as a raw material
for production of corn protein isolates, for fermentation, for
further chemical processing, in addition enzymes, such as amylases
and proteases, can be added to the meal to help facilitate the
breakdown of starch and proteins.
[0087] The extracted corn meal is optionally subjected to
conventional methods of separating the starch and protein
components. Such methods include, for example, dry milling, wet
milling, high pressure pumping or cryogenic processes. These and
other suitable processes are disclosed in Watson, S. A. & P. E.
Ramstad, ed. (1987, Corn: Chemistry and Technology, Ch. 11 and 12,
American Association of Cereal Chemist, Inc., St. Paul, Minn.), the
disclosure of which is hereby incorporated by reference. Due to the
prior removal of oil from the corn meal, the starch and protein
components of the extracted corn meal are separated from other
components more easily than they would be if the corn oil were not
extracted.
[0088] Several important quality parameters for the extracted meal
include the fat, starch, protein, and moisture content. Methods for
evaluating quality parameters of oilseed meals are disclosed in the
AOCS methods, the relevant disclosure of which is hereby
incorporated by reference. These methods can also be applied to the
extracted corn meal prepared as described herein.
[0089] The moisture content of the grain can affect the flaking
process. It may be necessary for the moisture of the corn grain to
be increased by about 1% to about 15% before flaking the seed.
Optimizing the grain moisture content to facilitate efficient
processing is within the knowledge of those of ordinary skill in
the art.
[0090] Corn meals derived using different methods or isolated at
different times are compared by normalizing the meals to a common
moisture content. The moisture content of an oilseed protein
concentrate, such as a corn meal or whole corn, is determined using
AOCS method Ba 2b-82. The crude fiber content of corn meal is
determined using AOCS method Ba 6-84. AOCS method Ba 6-84 is useful
for grains, meals, flours, feeds and all fiber bearing material
from which the fat can be extracted leaving a workable residue.
Crude protein content of corn meal is determined using AOCS method
Ba 4e-93. The starch content of corn meal is determined using AOCS
method Ba 4e-93. The starch content of corn meal is determined
using the Standard Analytical Methods of the Member Companies of
the Corn Refiners Association Incorporated, 2d Edition, Apr. 15,
1986, method A-20 ("Corn Refiner's method A-20").
[0091] It is to be understood that the analytical methods provided
herein are illustrative examples of useful methods for computing
various quality parameters for the oils and meals described herein.
Other suitable methods are known and may be used to compute the
quality parameters disclosed and claimed herein.
[0092] The following examples are included to demonstrate specific
embodiments of the invention. It should be appreciated by those of
skill in the art that the techniques disclosed in the examples
which follow represent techniques discovered by the inventors to
function well in the practice of the invention, and thus can be
considered to constitute exemplary modes for its practice. However,
those of skill in the art should, in light of the present
disclosure, appreciate that many changes can be made in the
specific embodiments which are disclosed and still obtain a like or
similar result without departing from the spirit and scope of the
invention.
EXAMPLE 1
[0093] Processing High Oil Corn Using Cracking, Conditioning and
Flaking Method
[0094] This example describes the process of obtaining corn oil and
corn meal from high oil corn. A 45-pound sample of high oil corn
was cracked using a Roskamp 6.5 Series (9' two sets) set at a roll
gap of 0.27 inches. A sample was taken for analysis and the
remaining sample split into 4 sub-samples. Each of the four
sub-samples was then conditioned independently to different
temperatures (120.degree. F., 150.degree. F., 180.degree. F.,
200.degree. F.). The samples were heated in a Crown.TM. 18 inch
De-solventiser/Toaster. After each sample reached its conditioning
temperature, the samples were passed through flaking rolls. The
flaking rolls used were a Ross 10-inch set to a gap of 0.007
inches. A sample of the flakes was taken and about a 500 gram
sample was extracted. The flaked sample was washed for four
20-minute periods with 1200 ml of hexanes each period for a total
of 4800 ml of solvent over 80 minutes. The solvent temperature was
about 120.degree. F. The miscella was collected and filtered
through #4 qualitative circles each having a diameter of 185 mm.
The filtered miscella was roto-evaporated to estimate the percent
oil recovery. The meal was air dried at room temperature. Samples
of the oil and meal were taken and analyzed for fatty acid profile,
starch, protein and fiber. During the extraction a sieve analysis
was performed and flake thickness was measured.
[0095] Other equipment used for the analysis included a Mettler
Toledo.TM. HR73 Halogen Moisture Analyzer, Ohaus Explore.TM. scale,
Buchi R-1 14 Roto-Vap.TM., Crown.TM. extractor screen 0.032 sieve
and a easy-load master Flex Model 7529-30 pump.
[0096] The color of the crude oil was visually evaluated and
determined to be a light yellow color compared to crude oil
isolated using conventional wet milling methods, which was a dark
brown color.
[0097] The desolventized corn meal was characterized using AOCS
methods Ba 3-38, Ba 2b-82, Ba 6-84, and Ba 4e-93, and Corn
Refiner's Method A-20. When normalized to 10% moisture content, the
corn meal had about 3.2% fiber content, about 65% starch content,
and about 14% protein content. Meal fat was determined to be about
1.07% using AOCS method 3-38. For comparison, corn gluten feed
created using conventional wet milling methods and normalized to a
10% moisture content can be expected to contain an oil content of
about 4%, a protein content of about 20%, and a fiber and other
carbohydrate content of about 60%. Also for comparison, corn gluten
meal created using conventional wet milling methods and normalized
to a 10% moisture content can be expected to contain an oil content
of about 3%, a protein content of about 60%, and a fiber and other
carbohydrate content of about 22%.
[0098] The nutrient profiles of two types of meal (1.5 wt. % oil
and 4.0 wt. % oil) produced according to this process are shown in
Table 8. Amounts are expressed on an "as is" or "as fed" moisture
level.
8 TABLE 8 Meal Sample 1 Meal Sample 2 Component Amount (%) Amount
(%) Moisture 12 12 Oil 1.5 4 Protein 10.5 10.2 Starch 58.0 56.3
Neutral Detergent Fiber 11.3 11 Acid Detergent Fiber 2.8 2.8 Ash
1.4 1.3 Lysine 0.39 0.37 Tryptophan 0.105 0.102 Methionine 0.29
0.28 Cystine 0.25 0.24 Total Sulfur Amino Acids 0.54 0.52 Valine
0.53 0.51 Isoleucine 0.40 0.39 Arginine 0.53 0.51 Threonine 0.40
0.39 Leucine 1.20 1.17 Histidine 0.32 0.31 Phenylalanine 0.51 0.5
Alanine 0.82 0.79 Serine 0.54 0.52 True metabolizable energy 3023
3133 (TMEn; kcal/kg) Swine metabolizable energy 3191 3301 (ME;
kcal/kg)
[0099] When compared to meals made from conventional corn, the
extracted corn meal described herein provides a greater amount of
key nutritional components such as vitamins, folic acid,
pantothenic acid, lysine, tryptophan, and/or niacin. For example,
Meal Samples 1 and 2 of extracted corn meal that are prepared above
include the nutritional components in the amounts shown in Table 9.
Amounts for the same components, to the extent they are found in
yellow corn that has not been processed as described herein, are
included for comparison.
9TABLE 9 Component Yellow Corn Meal Sample 1 Meal Sample 2 Vitamin
B6 0.400 0.820 0.660 (mg/100 g) Vitamin B12 0.500 0.500 0.500
(mg/100 g) Folic Acid -- 25.0 25.0 (.mu.g/100 g) Pantothenic Acid
-- 0.660 0.890 (mg/100 g) Niacin 2.05 2.30 1.15 (mg/100 g)
[0100] The extracted corn meal prepared as described herein
advantageously can be made to contain specific levels of oil and,
in particular, specific ratios of oil to protein, of oil to
carbohydrate or of oil to protein to carbohydrate. For example,
normal corn with 8 wt. % protein and 4 wt. % oil has a protein:oil
ratio of 2.0, and high oil corn with 9 wt. % protein and 12 wt. %
oil has a protein:oil ratio of 0.75. Meal produced by extraction to
have 10.5 wt. % protein and 1.5 wt. % oil has a protein:oil ratio
of 7.0. This higher ratio makes this meal type and products made
from it desirable for certain applications, one example being a
swine-finishing ration.
[0101] The present invention provides an extracted corn oil with
greater amounts of lutein, zeaxanthin and beta-carotene than
commercially available crude oil obtained from commodity normal
yellow #2 dent corn. Conventional crude oil can be obtained from
suppliers such as Cargill, Incorporated (Minneapolis, Minn.). For
example, a corn oil prepared as described above comprised the
ingredients shown in Table 10 in the amounts indicated as compared
to commercially available crude oil.
10TABLE 10 Lutein Zeaxanthin Beta-Carotene Sample (mg/g) (mg/g)
(IU/100 g) Commercial Crude Corn Oil 0.005 0.005 15.5 Oil Sample 1
0.04 0.012 72.3 Oil Sample 2 0.330 0.112 302
EXAMPLE 2
[0102] Use of Meal Derived From Corn Processed Through Flaking and
Extraction as a Component of Hog Finishing Feed Ration
[0103] This example details a comparison of two different feed
rations: a first feed ration containing normal corn that has not
been solvent extracted and a second feed ration containing
extracted corn meal. The feed ration containing extracted corn meal
is used when lean pork meat is a desired end product. A hog
finishing feed ration comprising an extracted corn meal containing
less than or about 1.5 wt. % oil is prepared by providing the
following ingredients in the amounts indicated in Table 11. The
feed ration is generally produced by blending, mixing, and
pelletting the ingredients to produce a feed product; however, one
or more of these steps can be omitted in the process of preparing
the feed ration. Table 11 shows a comparison of swine feed rations
made using normal corn (not high oil corn) and extracted corn meal
obtained from high oil corn comprising 12 wt. % oil, 9 wt. %
protein, wherein the extracted corn meal has about 1.5 wt. % or
less of oil (fat). Amounts are expressed on an "as is" or "as fed"
moisture level.
11 TABLE 11 Swine Finishing Feed Normal Corn Extracted Corn (%)
Meal (%) Ingredients Corn 79.98 -- Extracted corn meal -- 83.55
(about 1.5% oil) Soybean meal 12.45 6.60 Meat & bone meal 6.59
7.22 Feather meal -- -- Fat 0.10 1.50 Salt 0.40 0.70 Lysine 0.08
0.15 Methionine -- -- Premix 0.15 0.15 Nutrient Crude protein, %
15.44 15.78 ME, kcal/kg 3200 3200 Crude fiber, % 1.96 2.12 Calcium,
% 0.85 0.85 Phosphorus, % 0.58 0.58 Amino Acids, % Arginine 0.96
0.93 Cyctine 0.28 0.29 Histidine 0.40 0.42 Isoleucine 0.57 0.58
Leucine 1.39 1.49 Lysine 0.81 0.81 Methionine 0.26 0.34
Phenylalanine 0.70 0.72 Threonine 0.56 0.58 Tryptophan 0.14 0.14
Tyrosine 0.47 0.48 Valine 0.72 0.75
[0104] In Table 11, absolute values for ingredient percentages are
given, however, in practice, the ingredients may include using the
inclusion rates shown in other tables herein.
[0105] Some advantages of the new feed ration are that a user of
the meal would not need to grind the corn, thus saving an energy
intensive step, less soybean or other oilseed meal is required to
meet desired protein levels, and the meal may have better
digestibility than corn grain.
EXAMPLE 3
[0106] Use of Meal Derived from Corn Processed Through Flaking and
Extraction as a Component of Poultry Finishing Feed Ration
[0107] The feed ration of this example is used to fulfill the
high-energy requirements of growing birds such as broilers. A
poultry broiler finishing feed ration comprising an extracted corn
meal containing less than or about 4 wt. % oil (fat) is prepared by
providing the following ingredients in the amounts indicated in
Table 12. The feed ration is generally produced by blending,
mixing, and pelletting the ingredients to produce a feed product;
however, one or more of these steps can be omitted in the process
of preparing the feed ration.
[0108] Table 12 shows the comparison of poultry feed rations made
using normal corn (not high oil corn) and extracted corn meal
obtained from high oil corn comprising 12 wt. % oil, 9 wt. %
protein, wherein the extracted corn meal has about 4 wt. % or less
of oil (fat). Amounts are expressed on an "as is" or "as fed"
moisture level and absolute values for ingredient percentages are
given, however, in practice, the ingredients may be included using
the inclusion rates shown in other tables herein.
12 TABLE 12 Growing Broiler Extracted Normal Corn (%) Corn Meal (%)
Ingredients Normal corn 66.85 -- Extracted corn meal -- 70.86
(about 4% oil) Soybean meal 20.96 16.42 Meat & bone meal 5.00
5.00 Feather meal 2.00 2.00 Fat 3.29 3.76 Salt 0.37 0.37 Added
Lysine 0.13 0.19 Added Methionine 0.15 0.09 Premix 0.10 0.10
Nutrient Crude protein, % 19.48 19.52 ME, kcal/kg 3100 3100 Crude
fiber, % 1.97 2.12 Calcium, % 0.94 0.94 Phosphorus, % 0.63 0.62
Amino Acids, % Arginine 1.27 1.23 Cyctine 0.38 0.39 Histidine 0.47
0.48 Isoleucine 0.78 0.79 Leucine 1.68 1.74 Lysine 1.06 1.06
Methionine 0.44 0.44 Phenylalanine 0.92 0.92 Threonine 0.74 0.75
Tryptophan 0.19 0.20 Tyrosine 0.61 0.62 Valine 0.95 0.96
EXAMPLE 4
[0109] Use of Oil Derived from Corn Processed Through Flaking and
Extraction as a Component of Food Products, or as a Starting
Material for Purification of Kernel Components
[0110] In this example, oil with approximately a 200% to 300%
increase in tocotrienol content over conventionally produced crude
corn oil is described. Using the method of flaking and extraction
of Example 1, corn oil was extracted from high oil corn grain
having an oil content of about 12 wt. %. The corn oil was then
analyzed for tocotrienol content. The table below includes data
concerning the alpha- and gamma-tocotrienol content of conventional
corn oils produced by conventional processing of conventional corn
and the extracted corn oil prepared according to the method of
Example 1. Conventional Crude oil refers to an unrefined corn oil
sample. The sample is representative of corn oil of the type that
is most commonly produced presently. As noted below, the
tocotrienol content of extracted whole kernel oil (EWKO) samples
from two different high oil corn samples that were extracted with
solvent at temperatures ranging from 120 to 200.degree. F. was
found to be approximately two to three times higher than in the
conventional crude oil sample. As shown in Table 13, the
tocotrienol content of the EWKO samples ranged from about 26 ppm to
about 33 ppm of .alpha.-tocotrienol and from about 48 ppm to about
84 ppm of .gamma.-tocotrienol. Generally, increasing the extraction
temperature results in an increase in the tocotrienol content of
the extracted corn oil. The actual minimum and maximum values for
tocotrienol content will depend upon the particular high oil corn
used.
13TABLE 13 .alpha.-tocotrienol .gamma.-tocotrienol Sample (ppm)
(ppm) Conventional Crude Oil (Control) 11.88 29.94 EWKO 1
(120-200.degree. F.) 29.36-33.19 48.11-59.36 EWKO 2 (120.degree.
F.) 26.05-28.43 79.55-84.21
[0111] Accordingly, the process of Example 1 is used to make an
extracted corn oil comprising elevated levels of tocotrienols.
EXAMPLE 5
[0112] Use of Meal Derived from Corn Processed Through Flaking and
Extraction as a Component of a Blended Animal Feed Product
Comprised of Corn Meal and an Oilseed Meal
[0113] This example illustrates a novel feed ingredient comprised
of a blend of a corn meal produced by the flaking and oil
extraction method and another plant-based meal such as an oilseed
meal. This blended material could be in the form of simply a loose
aggregate mixture of both meal types or a pelletted product.
Because the method for producing the corn and oilseed meals would
be similar, i.e., cracking, conditioning, flaking and solvent
extraction, it is possible to produce both meals in proximity and
blend them prior to shipment to a customer. An advantage of this
approach is that varying protein and energy levels can be created
in a single meal. Additional ingredients are optionally added
either at the meal blending stage or at a later time. For example,
an energy-intensive step in feed manufacturing involves grinding
corn grain and blending it with other ingredients at a feed mill.
The present blended meal generally requires less energy to produce
a finished feed product than does a conventional blended meal.
[0114] Table 14 shows nutrient profiles of soybean meal (SBM),
extracted corn meal (ECM), a blend of 20% SBM and 80% ECM
(S20-C80), a blend of 10% SBM and 90% ECM (Si10-C90), and nutrient
requirements for poultry and swine diets. The poultry and swine
nutrient requirements shown are in accordance with National
Research Council (NRC) guidelines. The ECM was prepared according
to Example 1.
14TABLE 14 Nutrient Nutrient 20% SBM & Needs for 10% SBM &
Needs for Parameter SBM ECM 80% ECM Poultry Diets 90% ECM Swine
Diets Crude Protein (CP) 47.5 10.2 17.66 18 13.93 13.2 Swine ME,
kcal/kg 3380 3301 3316.8 3308.90 3265 Poultry ME, kcal/kg 2440 3133
2994.4 3200 3063.70 Crude Fat, % 3 4 3.8 3.90 Neutral Detergent
Fiber, % 8.9 11.3 10.82 11.06 Acid Detergent Fiber, % 5.4 2.8 3.32
3.06 Arginine 3.48 0.45 1.06 1.00 0.75 0.19 Histidine 1.28 0.27
0.47 0.27 0.37 0.19 Isoleucine 2.16 0.34 0.70 0.62 0.52 0.33
Leucine 3.66 1.03 1.56 0.93 1.29 0.54 Lysine 3.02 0.33 0.87 0.85
0.60 0.60 Methionine 0.67 0.25 0.33 0.32 0.29 0.16 Cystine 0.74
0.21 0.32 0.28 0.26 0.35 Phenylalanine 2.39 0.44 0.83 0.56 0.64
0.34 Tyrosine 1.82 0.29 0.60 0.48 0.44 0.55 Threonine 1.85 0.34
0.64 0.68 0.49 0.41 Tryptophan 0.65 0.09 0.20 0.16 0.15 0.11 Valine
2.27 0.45 0.81 0.70 0.63 0.40 Total Essential Amino 23.99 4.49 8.39
6.85 6.44 4.17 Acids (EAA) EAA/CP 0.505 0.440 0.45 0.381 0.45
0.316
EXAMPLE 6
[0115] Processing High Oil Corn Using Flaking Method
[0116] Shelled kernels of individual ears of yellow dent corn were
screened for a total oil content greater than about 7 wt. % oil
using a Pertenrm bulk near infrared (NIR) seed tester (model
9100-H.F) Perten Instruments (Reno, Nev.). Kernels from the ears
having at least a 7 wt. % oil content were screened further for
individual kernels having an oil content of at least 13 wt. % oil
in a Brimrose.TM. seedmeister single kernel NIR tester (Brimrose
Corp., Baltimore, Md.). The kernels were stored at a moisture
content of about 13.5%. At the time of processing, the moisture
content of the seed was about 10%.
[0117] A bench scale flaking apparatus containing a two-inch
stainless steel rod and plate was used to flake the whole corn
grain. The whole corn grain sample was passed through the rollers
four times to obtain a final flake thickness of about 0.01 inches.
A miscella was extracted from the flaked corn grain using hot
(60.degree. C. to 65.degree. C.) n-hexane and a Kimble.TM. model
585050 Soxhlet extractor. The resulting miscella and corn meal were
desolventized. The miscella was desolventized by heating the
miscella to 70EC under a vacuum of 25 inches of mercury. The corn
meal was desolventized according to AOCS method Ba 2a-38.
[0118] The total recovered oil was determined to be 14.74 wt. % of
the whole corn grain sample. The phosphorus content of the
desolventized crude oil was determined to be 365 ppm using AOCS
method Ca 12-55. The phospholipid concentration was determined to
be 1.095% (0.0365% * 30). The free fatty acid content was
determined to be 0.2% using AOCS method Ca 5a-40. The neutral oil
loss during processing was determined to be 1.3% (1.095%+0.2%).
Using the same methods, crude oil extracted from normal, i.e., 3-4
wt. % total oil content, corn grain using conventional wet milling
methods can be expected to have a phosphorus content from about 600
ppm to about 800 ppm, a free fatty acid concentration from about
0.5% to about 1.0% and a neutral oil loss during processing ranging
from about 3% to about 4%.
[0119] The color of the crude oil was visually evaluated and
determined to be a light yellow color compared to a crude oil
isolated using conventional wet milling methods, which was a dark
brown color.
[0120] The desolventized corn meal was characterized using AOCS
methods Ba 3-38, Ba 2b-82, Ba 6-84, and Ba 4e-93, and Corn
Refiner's Method A-20. When normalized to a 10% moisture content,
the corn meal had a 3.2% fiber content, a 65% starch content, and a
14% protein content. Meal fat was determined to be 1.07% using AOCS
method 3-38. For comparison, corn gluten feed created using
conventional wet milling methods and normalized to a 10% moisture
content can be expected to contain an oil content of about 4%, a
protein content of about 20%, and a fiber and other carbohydrate
content of about 60%. Also for comparison, corn gluten meal created
using conventional wet milling methods and normalized to a 10%
moisture content can be expected to contain an oil content of about
3%, a protein content of about 60%, and a fiber and other
carbohydrate content of about 22%.
EXAMPLE 7
[0121] Process of Refining High Oil Corn
[0122] This example describes a continuous solvent extraction
process in the context of the present invention. The extraction
process consisted fundamentally of four parts: pre-extraction,
extraction, meal desolventization, and oil desolventization. These
various stages are described in further detail below.
[0123] (A) Pre-Extraction
[0124] 5.4 tons of whole kernel high oil corn (approximately 12 wt.
% oil) was tempered and then gate fed from a porta-bin to a bucket
elevator to a cracking mill. From the cracking mill, cracks (i.e.,
particles of whole corn) were conveyed to a conditioner, which
discharged to an insulated conveyance system. This system consisted
of a second bucket elevator, air mechanical conveyor, heated steam
jacketed conveyor, and chutes connected in series. From the
conveyance system, corn cracks were fed to a flaking roll.
[0125] Prior to transport to the cracking mill, whole corn was
tempered to nominally 14.5% moisture by adding water to "as is"
moisture corn in a 350 liter Toronto Coppersmithing.TM. Toreo Model
R-12 ribbon blender. Water was sprayed into the vessel at a rate of
2 liters/hr. After the appropriate amount of water was added, the
corn was stirred for another hour. The corn was then allowed to
soak for 24 hours before being tested for moisture. The tempered
corn was then stored for 11 days to 15 days.
[0126] After storage, the tempered corn was cracked at ambient
temperature using a Roskamp.TM. (Waterloo, Iowa) model number 6.5
series double stand cracking roll having rolls with 9" diameters
and 12" lengths. Both top and bottom rolls were set such that one
roll rotated faster than the other. The fast rolls rotated at 1065
revolutions per minute (rpm) with 6 spiral RBV cut corrugations per
inch. The slow rolls were cut identically but rotated at 708 rpm.
Crack moistures were 13.3% to 15.7%. Cracks of the following
average particle size distribution ranges were generated: 15.9%
retained by US #4 mesh screens, 39.9% retained by US #6 mesh
screens, 27.8% retained by US #8 mesh screens, 6.8% retained by US
#10 mesh screens, 4.3% retained by US #18 mesh screens, and 5.3%
passed through US #18 mesh screens.
[0127] The cracked corn was then conditioned in a two-deck nominal
100-kilogram capacity conditioner (Simon-Rosedowns, currently owned
by De Smet; Prins Boudewijnlaan 265; B-2650 EDEGEM; Antwerp) with
sweep arm agitation (36 inches in diameter, 20 inches high per
deck). The bottom deck was run full. Residence time in the sparged
steam section was 55 minutes. The top deck crack depth was varied
to achieve a residence time in the indirect heating section
averaging 39 minutes and for a total residence time was 94 minutes.
Sparge steam addition was a rate from 0 to 5 kg/hr. Conditioning
exit moistures were in the range of 12.1% to 14.5%. Exit
temperatures were in the range from 75.degree. C. to 85.degree.
C.
[0128] Flakes were then generated from the cracked corn using a
Roskamp (Waterloo, Iowa) model number 2862 flaking mill. The mill
was 62 inch long and 28 inch wide rolls. The main drive was
designed to turn the fast roll nominally at 300 rpm, and inter-roll
drive (IRD) ratio was 8%. Roll pressure was held constant at 500
psig. Flaking exit moistures were in the range of 9.1 % to 11.7%.
Exit temperatures were in the range from 60.degree. C. to
83.degree. C. Flake thickness ranged from 0.3 mm to 0.7 mm with the
roll gap optimally set at 0.2 mm (0.008 inches).
[0129] (B) Extraction
[0130] A continuous 150 kg/hr Crown.TM. (Roseville, Minn.) model II
pilot extractor was used to process the flaked corn. This pilot
scale extractor utilized mixed hexanes as a solvent with 5
counter-current miscella wash zones and a tail wash section.
Six-miscella recirculation pumps were utilized with fresh hexanes
at 50.degree. C. to 60.degree. C. fed in the upper portion of the
extractor. The dimensions of the extractor were 29 feet long, 7.8
inches wide, and 4.5 inches deep. Twenty-three of the 29-foot
extractor feet was wetted, of which 19.5 feet was subjected to
washing. The average feed rate was approximately 75 kg/hr. The
residence time was approximately 60 min. The solvent-to-meal ratios
were adjusted between 0.75:1 and 1.33:1. Full miscella was sent to
the oil desolventization system at 27.degree. C. to 34.degree.
C.
[0131] (C) Meal Desolventization
[0132] Ambient and indirect heat desolventization occurred first in
a Schnecken.TM. (Crown Iron Works, Roseville, Minn.) steam jacketed
conveyor (SJC). The SJC consisted of a hollow flight screw inside
of a steam jacket (12 feet long, 10 inches in diameter). The open
flight screw created a tumbling action as it conveyed the extracted
material through the conveyor, thus ensuring that all material was
exposed to the heated wall. A pneumatic controller regulated the
amount of steam supplied to the jacket. The temperature at the
outlet of the conveyor was monitored and used as the basis for the
control of steam supplied to the jacket. Vapors from the conveyor
were collected in the low vacuum condenser by the slight negative
pressure developed by the system fan. A double-deck nominal 100
kg-capacity desolventizer and toaster (DT) with sweep arm agitation
was utilized (36 inches in diameter, 20 inches high per deck).
Steam sparge was piped through the top sweep arm only. Meal exit
moistures ranged from 9.4% to 17.7%, and exit temperatures ranged
from 57.degree. C. to 104.degree. C. Hexanes recovered from the SJC
and extractor were condensed, dewatered, and recycled to the
extractor.
[0133] (D) Oil Desolventization
[0134] Oil desolventization was executed using a rising film
evaporator (RFE). This unit consisted of sixteen 1.5 cm diameter
tubes inside a large jacket. The jacket was filled with steam,
heating the tubes. The extract-laden liquid (normally oil in
hexanes called miscella) was pumped into the bottom of the tubes.
As it traveled up the inside of the tubes, steam heat caused the
liquid to boil. The vapors held the liquid against the wall of the
tube in a thin, rising film. At the top, the liquid and vapor were
allowed to separate. The oil flowed into an overflow pipe to the
oil stripper (OS), while the vapors were carried over to a
condenser. The tubes were under vacuum so that the liquid boiled at
a low temperature.
[0135] The oil stripper was a disc and donut style distillation
column. The liquid was spread out in a thin film over a disc and
dripped down onto a donut back onto a disc allowing the oil to
cascade down the column. At the same time, steam was injected into
the bottom of the stripper, which passed over the liquid film
thereby removing the solvent remaining in the liquid. A steam
jacket to keep the liquid and steam hot surrounded the disc and
donut column. The oil stripper was also operated under vacuum.
Hexanes recovered from the rising film evaporator and the OS were
condensed, dewatered, and recycled to the extractor.
[0136] (E) Analysis of Oil Obtained from High Oil Corn
[0137] The oil was recovered and analyzed for vitamins, fatty
acids, and micronutrients. As a control, 800 lbs. of yellow #2 corn
was extracted in an identical manner, and the recovered oil was
analyzed for the same components. Vitamin A and .beta.-carotene
were analyzed by a contract lab using a proprietary procedure.
Alternative published procedures include Bates, et al., Proc. Fla.
State Hort Soc., 88, 266-271 (1975). Free fatty acids were analyzed
by gas chromatography (GC) using a CP88 cyanopropyl column (100
m.times.0.265 mm, 0.5 mm film thickness) and a flame ionization
detector as described in American Oil Chemist Society (AOCS)
methods Ce 1c-82, Ce 2-65, Cd 3a-94 and Cd 1c-85.
[0138] Tocopherols and tocotrienols were analyzed by high
performance liquid chromatography (HPLC, Waters model number 2590)
using a normal phase silica column with hexane-isopropanol as the
mobile phase and detected using fluorescence detection (Waters
model number 2690), according to the procedure described in AOCS Ce
8-89. Lutein was analyzed by HPLC using a C30 reverse phase column
with water-acetonitrile mobile phase and detected with a UV
detector.
[0139] Table 15, set forth below, presents a comparison of the oil
composition obtained from high oil corn and yellow #2 corn. For
comparison, the composition of oil from yellow #2 corn extracted in
a corn wet milling process is also given.
15TABLE 15 High Oil Y#2, Corn Component Corn Yellow #2 wet Milling
Palmitic Acid % 11.4 10.7 10.7 Stearic Acid % 2.2 1.9 2.0 Oleic
Acid % 35.6 25.5 27.5 Linoleic Acid % 48 58.4 57.1 Linolenic Acid %
0.7 1.2 1.1 .alpha.-Tocotrienol (ppm) 184 48 12 .alpha.-Tocopherol
(ppm) 237 231 136 Vitamin B1, mg/100 g 0.390 NA 0.260 Vitamin B2,
mg/100 g 0.090 NA 0.080 Vitamin B6, mg/100 g 0.82 NA 0.4 Vitamin
B12, mg/100 g 0.5 NA 0.5
EXAMPLE 8
[0140] Recovering Lighter Particles During Moisture Removal
Step
[0141] This example sets forth one method of recovering lighter
particles, such as fines, generated during the moisture removal
step from the processing of high oil corn.
[0142] High oil corn is cracked and flaked as described in Example
7. The whole flaked corn from the flaking process is heated to
remove moisture using standard processing equipment such as Kice
SSI zig-zag classifier model A2612, (Kice Inc., Wichita, Kans.).
During the moisture removal step, a controlled air stream is
regulated such that the smaller and lighter particles are carried
away, hence separating them from the heavier flakes. One such
example of the controlled air stream is provided by a CrownTm
multi-stage aspirating system operated at 2600 cubic feet-per
minute. The lighter particles are recovered by standard process
equipment such as a baghouse. The recovered lighter particles are
introduced into starch-containing product streams for the recovery
of starch.
EXAMPLE 9
[0143] Method of Recovering Lighter Particles During Cracking-Step
with Air
[0144] This example sets forth one method of recovering lighter
particles such as fines, generated during the cracking step from
the processing of high oil corn.
[0145] Whole kernels from a high oil corn are cracked using a
standard cracking mill roller such as Roskamp 6.5 Series,
(Waterloo, Iowa). During this cracking step, a controlled air
stream is directed to pass across the cracking mill roller, and the
velocity of the air stream is regulated such that the smaller and
lighter particles are carried away in the air stream, hence
separating them from the heavier particles. One such example of the
controlled air stream is provided by a Crown.TM. multi-stage
aspirating system operated at 2600 cubic feet per minute. The
lighter particles are recovered by standard process equipment such
as a baghouse. The recovered lighter particles are introduced into
starch-containing product streams for the recovery of starch.
EXAMPLE 10
[0146] Method of Recovering Lighter Particles with Liquid Spray
[0147] This example sets forth a method for the recovery of fines
generated before and after the flaking process by means of a liquid
spray.
[0148] High oil corn is processed as described in Example 7. The
cracked corn prior to flaking and the corn flakes after the flaking
process are sprayed or misted with a source of liquid providing
broad enough coverage to physically eliminate the lighter, airborne
particles. Water is used as the liquid. Alternatively, the liquid
spray can be a substance that adds value to the resulting meal as
well as recovers the value from the fines. The liquid spray is
typically pure water, process water or water that has been
supplemented with nutritional additives such as vitamins, enzymes
or minerals. The liquid stream containing the particulates is
carried away from the heavier particles in each case and is
collected. The particulates are separated from the liquid using
standard process equipment including a hydrocyclone or centrifuge.
Optionally, the recovered fines may be dried before further use.
The recovered lighter particles are then introduced into
starch-containing product streams for the recovery of starch.
EXAMPLE 11
[0149] Molded Food Product
[0150] This example sets forth a description of using the extracted
corn meal of the present invention to produce biodegradable
materials with improved tensile strength.
[0151] Corn meal of the present invention is suspended in hexanes
in a sealed container, at a 2:3 corn meal:solvent weight ratio. The
mixture is allowed to stand at room temperature without mixing for
about 18 hours. The organic solvent is removed from the extracted
corn meal, and the extracted corn meal residue is washed during
filtering with an aliquot of hexanes in a 1:1 residue:solvent
weight ratio. The residue is dried in a convection oven at
50.degree. C. for 16 hours. The dried residue is sprayed with water
with mixing until the moisture content of the residue is 10.7% to
11.3%. The solvent-treated extracted corn meal composition is
molded into an ASTM standard dogbone article using a compression
molding press (Wabash Metal Products, Inc. Wabash, Ind.) at 5000
psi, 140.degree. C. to 160.degree. C. for 10 minutes. The untreated
corn meal composition is likewise combined with water to a 10.7% to
11.3% water content and molded into an ASTM standard dogbone
article. The articles produced with the solvent-treated extracted
corn meal will exhibit significantly improved tensile properties as
compared to non-solvent treated extracted corn meal.
[0152] Alternatively, corn meal of the present invention is
separately suspended in aqueous ethanol (95%) at 1:3 weight-ratio
of meal to oil, and boiled for 2 hours with reflux and mechanical
stirring. The meal is filtered and the residues are washed with
ethanol (1:1 residue:ethanol). The residues are dried, remoistened,
and molded according to the procedure above. Tensile properties and
water-absorption of the meal treated with ethanol at boiling
temperature for a short 2 hour period would be similar to the meals
treated at room temperature for an extended 18 hour period.
EXAMPLE 12
[0153] Production of Ethanol
[0154] (A) Starch Hydrolysis
[0155] Solvent extracted corn meal of the present invention
prepared as described herein is a rich source of starch for
fermentation. One method to provide soluble sugars suitable for
fermentation is to hydrolyze starch molecules, which are included
in the solvent extracted corn meal. About 300 g of corn meal
prepared according to the present invention was passed through a 1
mm screen and combined with 700 ml of 99.degree. C. to 100.degree.
C. water and 0.5 ml .alpha.-amylase in a sealed container. The pH
was adjusted to 5.9 with base. The mixture was stirred for 45
minutes and additional a-amylase enzyme was added. After an
additional 45 minutes of incubation, the pH of the mixture is
adjusted to 4.5 with acid. Half a milliliter (0.5 ml) glucoamylase
(Optimax 7525) and 0.5 g protease (Fungal Protease 5000) were added
and incubated with both enzymes at 62.degree. C. for 22-24 hours.
Throughout the procedure, the degree of starch hydrolysis was
monitored by HPLC (Waters 2690 Separations module) using an organic
acid column (Aminex HPX-87H Ion Exclusion Column, 300 mm.times.7.8
mm, Bio Rad).
[0156] Total nitrogen content for each sample was determined by
Leco 2000 CN. Free amino nitrogen (FAN) was determined by the AOAC
method (15.sup.th ED. 1990. pg. 735). For comparison, cracked corn
grain was prepared and fermented in a manner similar to the
extracted corn meal. The amount of dextrose liberated from starch
by the milling process and the amount of available nitrogen in the
corn samples are outlined in Table 16. YDM displayed the highest
dextrose content and HOC the lowest.
[0157] Both high oil corn (HOC) and high oil corn meal (HOCM)
displayed higher total nitrogen in comparison to yellow dent (YD)
and yellow dent meal (YDM). Additionally, HOC and HOCM contained
more free amino nitrogen than YD and YDM, respectively. Overall,
the milling procedure was fairly consistent for all samples, with
weight losses due to evaporation maintained between 4-5%.
16 TABLE 16 Dextrose Total nitrogen Corn sample (g/L)* FAN (ppm)
(ppm) YD 242.40 261.15 3437.6 YDM 311.28 195.84 4009.6 HOC 228.02
302.95 4916.0 HOCM 240.68 232.65 5032.0 *indicates values obtained
after treatment with amylases and protease
[0158] (B) Fermentation
[0159] Forty-five grams (45 g) of enzyme-treated corn grits and
solvent extracted corn meal (targeting approximately 20%
carbohydrate) were added to 125 ml flasks. Yeast extract was added
at 1 g/L to ensure that nitrogen was not limiting. Cultures were
inoculated with 10% inoculum from overnight yeast cultures (a
typical Altech ethanol yeast of Saccharomyces cerevisiae) and
incubations proceeded for 42 hours at 30.degree. C. on a rotary
shaker at 125 rpm. Ethanol production was monitored by HPLC.
[0160] Previous studies indicated that yeast grown on YD corn with
sugar concentrations near or above 25% did not provide maximal
ethanol yields after 42 h. Consequently, media for fermentations
were normalized on a weight basis, targeting an initial fermentable
sugar concentration of approximately 20%. Starting dextrose
concentrations for cultures containing YD, YDM, HOC, and HOCM were
212.21, 236.19, 187.85, and 222.77 g/L, respectively (FIG. 1).
Cultures grown on HOC completely utilized the available dextrose,
while the other cultures consumed dextrose to less than 1 g/L final
concentration. The fastest rate of dextrose consumption was also
seen in cultures grown with milled HOC. YD, YDM, and HOCM cultures
displayed similar dextrose utilization curves. HOC and HOCM
cultures reached over 80 g/L ethanol, but stopped production after
19 hours, possibly due to the limitation of a necessary nutrient.
None of the cultures reached the maximum theoretical ethanol yield
of 50%, however YD cultures did achieve 45% yield followed by YDM
at 43%, HOC at 41% and HOCM at 38% (Table 17). The maximum ethanol
yields are relatively close and perhaps minor growth condition
adjustments account for the differences.
[0161] Examination of ethanol productivity revealed that yeast
grown on HOC demonstrated the highest, producing over 5 g/L/h after
7 hours (Table 17). Productivity in these cultures dropped after 19
hours, however by this time all of the dextrose was exhausted. The
remaining cultures reached maximum productivity values over 4.5
g/L/h after 19 hours. The ethanol productivity values for the four
cultures were quite similar.
17TABLE 17 Ethanol Yield Ethanol Productivity Fermentation (g
EtOH/g sugar) (g/L/h) media with: 7 h 19 h 26 h 42 h 7 h 19 h 26 h
42 h YD 0.10 0.40 0.45 0.41 3.51 4.92 3.97 2.26 YDM 0.12 0.38 0.43
0.40 3.65 4.6 3.81 2.21 HOC 0.19 0.41 0.39 0.39 5.14 4.11 2.91 1.76
HOCM 0.11 0.38 0.36 0.36 3.78 4.6 3.22 2.01
[0162] To ensure that the generation of acidic conditions during
fermentation did not influence yeast growth and subsequent ethanol
production, the pH of the culture media was monitored (FIG. 2). All
cultures dropped in pH, following a similar trend over time and
final pH values fell between 3.75 and 3.9. There were no apparent
fluctuations in pH to account for differences in ethanol
production.
EXAMPLE 13
[0163] Aquaculture Feed Comprised of Corn Meal Derived from High
Oil Corn
[0164] This example sets forth the use of extracted corn meal in an
aquaculture feed product.
[0165] Two feeding programs are used for two species of fish:
tillapia and catfish. One feeding program utilizes a feed including
corn grits produced from dry-milled yellow corn grain. The other
feeding program utilizes a feed including ECM derived from high oil
corn. Feeds are produced with the following ingredients (Table
18):
18 TABLE 18 Ingredient Percent Herring Fishmeal 8 Soybean Meal 50
Corn 34.3 Wheat Middlings 5 Dicalcium Phosphate 1 Vitamin Mix 1.5
Trace Mineral Mix 0.2 Crude Protein (N .times. 6.25) 32
[0166] In the feed ration described in Table 18, extracted corn
meal (ECM) can be substituted for some or all of the corn, some or
all of the wheat middlings, and/or some of the soybean meal at
various levels to produce a desired nutrient profile that can vary
depending on the fish species to be fed.
[0167] One group of tillapia is fed feed containing extracted corn
meal. A second group of tillapia is fed feed containing corn grits.
Similarly, one group of catfish is fed feed containing extracted
corn meal, and one group of catfish is fed feed-containing corn
grits.
[0168] The experimental design included four ponds per treatment of
one hundred fish per pond, for a total of sixteen ponds and 1,600
fish. Fish within species and ponds are of similar size and weight.
Within each species and treatment, fish are fed amounts of feed
necessary to support growth rates typical in commercial aquaculture
production. Fish are raised from fingerling size to a suitable size
reflective of typical market weights, for example, to about one and
a half pounds.
[0169] Fish are caught and processed in a manner to produce fillets
that are compared visually. The effect of extracted corn meal on
meat quality is evaluated by measuring the color of the tissue
using a color reference guide. A trained and experienced sensory
panel is used to evaluate the consumer preference factors such as
color and appearance.
[0170] The process to produce extracted corn meal separates some of
the solvent soluble pigments from the meal portion. Therefore, fish
fed with extracted corn meal receive less of these pigments in
their diet than fish fed a diet containing corn. Pigments such as
carotenoids can be deposited in tissue when consumed in the diet.
Therefore, fish fed diets containing extracted corn meal will have
lighter colored tissue than fish fed diets containing corn. Growth
of fish raised on diets containing extracted corn meal would be
similar to fish raised on diets containing corn, but adjustments to
the proportions of ration ingredients may need to be made to
account for differences in starch digestibility, amino acid
availability, and fatty acid content.
EXAMPLE 14
[0171] Biodiesel Comprised of Corn Oil Derived from High Oil
Corn
[0172] This example sets forth the use of oil from high oilcorn as
a source of an improved biodiesel fuel.
[0173] In a continuous process, approximately 62 kg/hr (137 lbs/hr)
of oil extracted from high oil corn and refined according to known
industry processes, is mixed with 18 kg/hr (40 lbs/hr) of methanol
in a stirred tank reaction unit. Simultaneously 0.08 kg/hr (0.1775
lbs/hr) of sodium hydroxide is added to the same stirred tank
reaction unit, which operated at 20 psig and approximately
80.degree. C. These conditions provide essentially 100% conversion
of added triglycerides to fatty acids and methyl esters.
[0174] The two phases of the reaction mixture are allowed to stand
and separate to provide methyl esters in the upper phase, and a
mixture of glycerol and approximately 10-15 wt. % residual methyl
esters, methanol, and base in the lower phase. Approximately 6.4
kg/hr (14 lbs/hr) of the glycerol phase is neutralized, present
methanol flashed off, and the remainder is sent to a continuously
stirred reaction unit, operated at 80.degree. C. and 320 psig. The
reaction unit also contains approximately 4 wt. % Amberlyst-15
catalyst with a residence time of 2 hours and approximately 7.9
kg/hr (17.5 lbs/hr) iso-butylene is fed to the reaction unit. The
biodiesel fuel is produced at approximately 66 kg/hr (145 lbs/hr)
and has a kinematic viscosity and cloud-point that is greater than
biodiesel without glycerol ethers present.
[0175] All references, including publications, patent applications,
and patents, cited herein are hereby incorporated by reference to
the same extent as if each reference were individually and
specifically indicated to be incorporated by reference and were set
forth in its entirety herein.
[0176] The use of the terms "a" and "an" and "the" and similar
referents in the context of describing the invention (especially in
the context of the following claims) are to be construed to cover
both the singular and the plural, unless otherwise indicated herein
or clearly contradicted by context. Recitation of ranges of values
herein are merely intended to serve as a shorthand method of
referring individually to each separate value falling within the
range, unless otherwise indicated herein, and each separate value
is incorporated into the specification as if it were individually
recited herein. All methods described herein can be performed in
any suitable order unless otherwise indicated herein or otherwise
clearly contradicted by context. The use of any and all examples,
or exemplary language (e.g., "such as") provided herein, is
intended merely to better illuminate the invention and does not
pose a limitation on the scope of the invention unless otherwise
claimed. No language in the specification should be construed as
indicating any non-claimed element as essential to the practice of
the invention.
[0177] Preferred embodiments of this invention are described
herein, including the best mode known to the inventors for carrying
out the invention. Of course, variations of those preferred
embodiments will become apparent to those of ordinary skill in the
art upon reading the foregoing description. The inventors expect
skilled artisans to employ such variations as appropriate, and the
inventors intend for the invention to be practiced otherwise than
as specifically described herein. Accordingly, this invention
includes all modifications and equivalents of the subject matter
recited in the claims appended hereto as permitted by applicable
law. Moreover, any combination of the above-described elements in
all variations thereof is encompassed by the invention unless
otherwise indicated herein or otherwise clearly contradicted by
context.
* * * * *
References