U.S. patent application number 15/151599 was filed with the patent office on 2016-09-01 for microbial-based process for high quality protein concentrate.
This patent application is currently assigned to DAST, LLC dba PRAIRIE AQUATECH. The applicant listed for this patent is DAST, LLC dba PRAIRIE AQUATECH. Invention is credited to Michael L Brown, WILLIAM GIBBONS.
Application Number | 20160249638 15/151599 |
Document ID | / |
Family ID | 48524185 |
Filed Date | 2016-09-01 |
United States Patent
Application |
20160249638 |
Kind Code |
A1 |
GIBBONS; WILLIAM ; et
al. |
September 1, 2016 |
Microbial-Based Process for High Quality Protein Concentrate
Abstract
The present invention describes a bio-based process to produce
high quality protein concentrate (HQPC) by converting plant derived
celluloses into bioavailable protein via aerobic incubation,
including the use of such HQPC so produced as a nutrient, including
use as a fish meal replacement in aquaculture diets.
Inventors: |
GIBBONS; WILLIAM;
(BROOKINGS, SD) ; Brown; Michael L; (BROOKINGS,
SD) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
DAST, LLC dba PRAIRIE AQUATECH |
BROOKINGS |
SD |
US |
|
|
Assignee: |
DAST, LLC dba PRAIRIE
AQUATECH
Brookings
SD
|
Family ID: |
48524185 |
Appl. No.: |
15/151599 |
Filed: |
May 11, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13691843 |
Dec 2, 2012 |
9370200 |
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15151599 |
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61566487 |
Dec 2, 2011 |
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61566557 |
Dec 2, 2011 |
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Current U.S.
Class: |
426/53 |
Current CPC
Class: |
A23J 1/125 20130101;
A23J 1/14 20130101; A23K 50/80 20160501; Y02A 40/818 20180101; A23J
1/148 20130101; A23K 10/38 20160501; A23K 20/147 20160501; A23K
40/25 20160501; A23K 10/14 20160501; A23K 40/20 20160501 |
International
Class: |
A23J 1/12 20060101
A23J001/12; A23K 50/80 20060101 A23K050/80; A23K 10/38 20060101
A23K010/38; A23K 20/147 20060101 A23K020/147; A23J 1/14 20060101
A23J001/14; A23K 10/14 20060101 A23K010/14 |
Goverment Interests
[0002] This work was made with Governmental support from the
National Science Foundation under contract DBI-1005068. The
Government has certain rights in this invention.
Claims
1-20. (canceled)
21. A composition comprising a non-animal based protein
concentrate, wherein the composition contains at least 55% protein
content by weight, exopolysaccharides and contains oligosaccharides
in an amount of between about 0.00 g/100 g to about 0.24 g/100 g on
a dry matter basis.
22. The composition of claim 21, wherein the non-animal based
protein concentrate is isolated from plant material from the group
consisting of soybeans, peanuts, Rapeseeds, canola, sesame seeds,
cottonseeds, palm kernels, barley, grape seeds, olives, safflowers,
sunflowers, copra, corn, coconuts, linseed, hazelnuts, wheat, rice,
potatoes, cassavas, legumes, camelina seeds, mustard seeds, germ
meal, corn gluten meal, distillery/brewery by-products, and
combinations thereof.
23. The composition of claim 22, produced by a process comprising:
a) cooking plant material at above room temperature to form a mash;
b) optionally adding one or more enzymes to the mash; c)
inoculating the mash with at the least one microbe, which at least
one microbe converts sugars in the mash into proteins and
exopolysaccharides; d) separating solids from liquids in the
inoculated mash via hydrodynamic force; and f) drying said
separated solids.
24. The composition of claim 23, wherein the at least one microbe
is selected from the group consisting of Aureobasidium pullulans,
Sclerotium glucanicum, Sphingomonas paucimobilis, Ralstonia
eutropha, Rhodospirillum rubrum, Kluyveromyces spp, Pichia spp,
Trichoderma reesei, Pleurotus ostreatus, Rhizopus spp, and
combinations thereof.
25. The composition of claim 23, wherein the plant material is from
soybeans in the form of soy flakes or soy meal.
26. The composition of claim 23, wherein the composition is
formulated as a feed, and wherein the feed comprises the dried
solids treated with phytase.
27. The composition of claim 23, wherein the plant material is from
distiller's dried grain with solubles (DDGS).
28. A feed or foodstuff comprising the composition of claim 21.
29. The feed or foodstuff of claim 28, wherein said feed comprises
up to about 35% to about 45% of said composition by weight.
30. The feed or foodstuff of claim 28, wherein said composition is
a complete replacement for animal-protein in a feed or a
foodstuff.
31. The feed of claim 30, wherein said feed is formulated for fish,
crustaceans, cattle, poultry, swine, goats, sheep, cats, dogs,
horses and combinations thereof.
32. The feed of claim 28, wherein the foodstuff is formulated for
humans.
33. The composition of claim 25, wherein the soybean is non-GM.
34. The feed of claim 28, wherein said feed or foodstuff comprises
a composition containing up to 80% by weight of said non-animal
based protein concentrate and up to 20% by weight of a mixture
containing one or more compounds selected from the group consisting
of lysine, methionine, lipids, biotin, choline, niacin, ascorbic
acid, inositol, pantothenic acid, folic acid, pyridoxine,
riboflavin, thiamin, vitamin A, vitamin B12, vitamin D, vitamin E,
vitamin K, calcium, phosphorus, potassium, sodium, magnesium,
manganese, aluminum, iodine, cobalt, zinc, iron, selenium, and
combinations thereof.
35. A method of producing a non-animal based protein concentrate
comprising: a. optionally milling plant material; b. cooking said
plant material at above room temperature to form a mash and
transferring the mash to a biorector; b. optionally adding one or
more enzymes to the mash in the bioreactor; c. inoculating the mash
with at least one microbe, which microbe converts released sugars
into proteins and exopolysaccharides; d. separating solids from
liquids in the mash via hydrodynamic force; and e. drying said
separated solids and evaporating the separated liquids.
36. The method of claim 35, wherein the one or more enzymes are
selected from the group consisting of phytase, endo-xylanase and
.beta.-xylosidase, glycoside hydrolase, .beta.-glucosidases,
hemicellulase activities, and combinations thereof.
37. The method of claim 35, further comprising: mixing the extruded
materials with water to achieve a solid loading rate of at least
about 5% in the bioreactor; and optionally, autoclaving and cooling
the cooked plant material.
38. The method of claim 35, further comprising: reducing the
temperature of the enzyme treated mash to between about 30.degree.
C. to about 37.degree. C., optionally aerating the inoculated mash
at about 0.05 L/L/min to about 0.5 L/L/min; and incubating the mash
until utilization of sugars by the at least one microbe ceases.
39. The method of claim 35, further comprising combining the solids
from the evaporated liquid with the dried solids.
40. The method of claim 35, wherein the plant material is
non-GM.
41. A composition produced by the method of claim 35.
42. A composition containing up to 80% by weight of said non-animal
based protein concentrate comprising at least 55% protein content
by weight, exopolysaccharides and oligosaccharides in an amount of
between about 0.00 g/100 g to about 0.24 g/100 g on a dry matter
basis and up to 20% by weight of a mixture containing one or more
compounds selected from the group consisting of amino acids,
lipids, vitamins, minerals, enzymes, antioxidants, and combinations
thereof.
43. A microbially converted composition comprising soy protein,
wherein the composition contains at least 60% protein content,
exopolysaccharides, and a microbe selected from the group
consisting of Aureobasidium pullulans, Sclerotium glucanicum,
Sphingomonas paucimobilis, Ralstonia eutropha, Rhodospirillum
rubrum, Kluyveromyces spp, Pichia spp, Trichoderma reesei,
Pleurotus ostreatus, Rhizopus spp and combinations thereof.
44. The composition of claim 42, wherein the oligosaccharide is
stachyose or raffinose.
45. The composition of claim 43, wherein the microbe is
Aureobasidium pullulans.
46. The composition of claim 43, wherein the composition improves a
performance characteristic of a feed containing said composition
compared to equivalent feed comprising an untreated soy-based
protein concentrate, wherein said performance characteristic is
weight gain, specific growth rate, protein efficiency ratio, feed
conversion ratio, total consumption, Fulton's condition factor, or
a combination thereof.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. Ser. No.
13/691,843, filed Dec. 12, 2012 under 35 U.S.C. .sctn.120, and
claims benefit under 35 U.S.C. .sctn.119(e) to U.S. Provisional
Application No. 61/556,487, filed on Dec. 2, 2011, and U.S.
Provisional Application No. 61/566,557, filed on Dec. 2, 2011, each
of which is incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The invention generally relates to incubation processes, and
specifically microbial-based aerobic incubation processes to
produce high quality protein concentrates, including products made
therefrom and use of such products in the formulation of nutrient
feeds.
[0005] 2. Background Information
[0006] In 2008, approximately 28% of the world's wild, marine fish
stocks were overexploited and 52% were fully exploited, even as the
demand for per capita consumption of fish and shellfish products
have increased with the increasing human population. With dwindling
wild fish stocks, in an effort to meet this increased demand,
commercial aquaculture production has increased dramatically.
However, one of the primary constituents of dietary formulations
for aquaculture, fish meal protein, is also derived from wild
capture fisheries. It is estimated that at least 6.7 mmt of fish
meal will be required to support commercial aquaculture production
by 2012. This is clearly an unsustainable trend.
[0007] Lower cost, more sustainable plant-derived sources of
protein have been used to partially replace fish meal in
aquaculture diets. Defatted soybean meal (SBM, 42-48% protein) has
commonly been used to replace up to 20% of total protein in grower
diets for several species, while soy protein concentrate (SPC, 65%
protein) has been tested successfully at higher total protein
replacement levels, largely governed by the trophic status of the
species. These soybean products provide high protein and relative
good amino acid profiles, but are still deficient in some critical
amino acids (e.g., taurine) required by carnivorous marine fishes.
SPC can be used at higher levels than soybean meal, primarily
because the solvent extraction process used to produce SPC removes
anti-nutritional factors (e.g., oligosaccharides) and thereby
increases protein bioavailability. In addition, a thermal step has
been used to inactivate heat-labile antigenic factors. The primary
limitations of the current solvent extraction process are its cost,
the lack of use for the oligosaccharides removed in the process,
and quality issues that frequently limit inclusion to 50% of total
protein in the diet. Further, processing of soy material into
soybean meal or soy protein concentrates can be environmentally
problematic (e.g., problems with disposal of chemical waste
associated with hexane-extraction).
[0008] Corn co-products, including dried distiller's grains with
solubles (DDGS), have also been evaluated in aquaculture diets at
fish meal replacement levels of up to 20%. DDGS has lower protein
(28-32%) and more fiber than soy products, but is typically priced
at .about.50% of the value of defatted soybean meal. Some ethanol
plants have incorporated a dry fractionation process to remove part
of the fiber and oil prior to the conversion process, resulting in
a dry-frac DDGS of up to 42% protein. While this product has been
used to replace 20-40% of fish meal in aquaculture feeds, there
remains the need for a higher protein, more digestible DDGS aqua
feed product. Such a product would be especially attractive if the
protein component had higher levels of critical amino acids such as
taurine, lysine, methionine, and cysteine.
[0009] Therefore, a plant-derived protein source which is
cost-effective and "green," and that is of a high-enough quality to
fully or substantially replace more of the fish meal in an
aquaculture diet is needed.
SUMMARY OF THE INVENTION
[0010] The present disclosure relates to an organic,
microbially-based system to convert plant material into a highly
digestible, concentrated protein source that also contains a
microbial gum (exopolysaccharide) binder, including such a
concentrated source which is suitable for use as a feed for animals
used for human consumption.
[0011] In embodiments, a composition containing a non-animal based
protein concentrate is disclosed, where the composition contains at
least 55% protein content and no detectable stachyose on a dry
matter basis. In one aspect, the composition contains Aureobasidium
pullulans deposited strain NRRL No. 50792, NRRL No. 50793, NRRL No.
50794, NRRL No. 50795, or a combination thereof.
[0012] In one aspect, the non-animal based protein concentrate is
isolated from cereal grain and oilseed plant material including,
but not limited to, soybeans, peanuts, Rapeseeds, canola, sesame
seeds, barley, cottonseeds, palm kernels, grape seeds, olives,
safflowers, sunflowers, copra, corn, coconuts, linseed, hazelnuts,
wheat, rice, potatoes, cassavas, legumes, camelina seeds, mustard
seeds, germ meal, corn gluten meal, distillery/brewery by-products,
portions and combinations thereof.
[0013] In another aspect, the protein content of the composition is
in the range of from about 56% to about 90% on a dry matter basis
produced by a process including extruding plant material at above
room temperature to form a mash; adding one or more
cellulose-deconstructing enzymes to release sugars into the mash;
inoculating the enzyme-treated mash with at least one microbe,
which microbe converts released sugars into proteins and
exopolysaccharides; precipitating the resulting proteins, microbes,
and exopolysaccharides with ethanol or a flocculent; recovering the
precipitated material via hydrodynamic force; and drying said
precipitated material.
[0014] In a related aspect, the at least one microbe includes, but
is not limited to, Aureobasidium pullulans, Sclerotium glucanicum,
Sphingomonas paucimobilis, Ralstonia eutropha, Rhodospirillum
rubrum, Kluyveromyces spp, Pichia spp, Trichoderma reesei,
Pleurotus ostreatus, Rhizopus spp, and combinations thereof.
[0015] In one aspect, the plant material is from soybeans in the
form of soy flakes or soy meal. In another aspect, the plant
material is from oil seeds or their de-oiled meals. In another
aspect, the plant material is from distiller's dried grain with
solubles (DDGS).
[0016] In one aspect, the protein concentrate includes at least 0.1
g hydroxylysine/100 g of concentrate.
[0017] In one embodiment, an animal feed comprising a non-animal
based protein concentrate is disclosed, where the composition
includes at least about 1.25 g of lipid/100 g composition, where
the composition contains no detectable stachyose or raffinose and
at least 55% protein content on a dry matter basis, and where the
composition includes at least 35% of said animal feed by
weight.
[0018] In a related aspect, the composition is a complete
replacement for animal-based fishmeal in a fish feed. In a further
related aspect, fish feed is formulated for fish including, but not
limited to, Siberian sturgeon, Sterlet sturgeon, Starry sturgeon,
White sturgeon, Arapaima, Japanese eel, American eel, Short-finned
eel, Long-finned eel, European eel, Chanos chanos, Milkfish,
Bluegill sunfish, Green sunfish, White crappie, Black crappie, Asp,
Catla, Goldfish, Crucian carp, Mud carp, Mrigal carp, Grass carp,
Common carp, Silver carp, Bighead carp, Orangefin labeo, Roho
labeo, Hoven's carp, Wuchang bream, Black carp, Golden shiner,
Nilem carp, White amur bream, Thai silver barb, Java, Roach, Tench,
Pond loach, Bocachico, Dorada, Cachama, Cachama Blanca, Paco, Black
bullhead, Channel catfish, Bagrid catfish, Blue catfish, Webs
catfish, Pangasius (Swai, Tra, Basa) catfish, Striped catfish,
Mudfish, Philippine catfish, Hong Kong catfish, North African
catfish, Bighead catfish, Sampa, South American catfish, Atipa,
Northern pike, Ayu sweetfish, Vendace, Whitefish, Pink salmon, Chum
salmon, Coho salmon, Masu salmon, Rainbow trout, Sockeye salmon,
Chinook salmon, Atlantic salmon, Sea trout, Arctic char, Brook
trout, Lake trout, Atlantic cod, Pejerrey, Lai, Common snook,
Barramundi/Asian sea bass, Nile perch, Murray cod, Golden perch,
Striped bass, White bass, European seabass, Hong Kong grouper,
Areolate grouper, Greasy grouper, Spotted coralgrouper, Silver
perch, White perch, Jade perch, Largemouth bass, Smallmouth bass,
European perch, Zander (Pike-perch), Yellow Perch, Sauger, Walleye,
Bluefish, Greater amberjack, Japanese amberjack, Snubnose pompano,
Florida pompano, Palometa pompano, Japanese jack mackerel, Cobia,
Mangrove red snapper, Yellowtail snapper, Dark seabream, White
seabream, Crimson seabream, Red seabream, Red porgy, Goldlined
seabream, Gilthead seabream, Red drum, Green terror, Blackbelt
cichlid, Jaguar guapote, Mexican mojarra, Pearlspot, Three spotted
tilapia, Blue tilapia, Longfin tilapia, Mozambique tilapia, Nile
tilapia, Tilapia, Wami tilapia, Blackchin tilapia, Redbreast
tilapia, Redbelly tilapia, Golden grey mullet, Largescale mullet,
Gold-spot mullet, Thinlip grey mullet, Leaping mullet, Tade mullet,
Flathead grey mullet, White mullet, Lebranche mullet, Pacific fat
sleeper, Marble goby, White-spotted spinefoot, Goldlined spinefoot,
Marbled spinefoot, Southern bluefin tuna, Northern bluefin tuna,
Climbing perch, Snakeskin gourami, Kissing gourami, Giant gourami,
Snakehead, Indonesian snakehead, Spotted snakehead, Striped
snakehead, Turbot, Bastard halibut (Japanese flounder), Summer
Flounder, Southern flounder, Winter flounder, Atlantic Halibut,
Greenback flounder, Common sole, and combinations thereof.
[0019] In one aspect, the fish feed effects greater performance in
one or more performance aspects including, but not limited to,
growth, weight gain, protein efficiency ratio, feed conversion
ratio, total consumption, survival, and Fulton's condition factor
compared to equivalent fish feed comprising animal-based fishmeal
or soy protein concentrate.
[0020] In another aspect, the fish feed effects the performance
aspects at a crude protein content that is less than or equal to
the protein content of equivalent fish feed comprising animal-based
fishmeal or soy protein concentrate.
[0021] In one aspect, the animal feed is supplemented with lysine,
methionine, lipids, biotin, choline, niacin, ascorbic acid,
inositol, pantothenic acid, folic acid, pyridoxine, riboflavin,
thiamin, vitamin A, vitamin B12, vitamin D, vitamin E, vitamin K,
calcium, phosphorus, potassium, sodium, magnesium, manganese,
aluminum, iodine, cobalt, zinc, iron, selenium or a combination
thereof.
[0022] In another embodiment, a method of producing a non-animal
based protein concentrate is disclosed including extruding plant
material at above room temperature to form a mash and transferring
the mash to a biorector; adding one or more
cellulose-deconstructing enzymes to release sugars into the mash in
the bioreactor; inoculating the enzyme treated mash with at least
one microbe, which microbe converts released sugars into proteins
and exopolysaccharides; precipitating the resulting proteins,
microbes, and exopolysaccharides with ethanol, a flocculent or a
combination thereof; recovering the precipitated material via
hydrodynamic force; and drying the precipitated material.
[0023] In a related aspect, extrusion is carried out at between
about 50.degree. C. to about 170.degree. C., at a compression ratio
of about 3:1, and at a screw speed sufficient to provide a shearing
effect against ridged channels on both sides of an extrusion
barrel.
[0024] In another related aspect, the method includes mixing the
extruded materials with water to achieve a solid loading rate of at
least 5% in the bioreactor; and optionally, autoclaving and cooling
the diluted extruded materials, where the one or more
cellulose-deconstructing enzymes are selected from the group
consisting of endo-xylanase and beta-xylosidase, glycoside
hydrolase, .beta.-glucosidases, hemicellulase activities, and
combinations thereof.
[0025] In one related aspect, the method includes reducing the
temperature of the enzyme treated mash to between about 30.degree.
C. to about 37.degree. C.; inoculating the cooled mash with 2%
(v/v) of a 24 hour culture of the at least one microbe, where the
at least one microbe includes, but is not limited to Aureobasidium
pullulans, Sclerotium glucanicum, Sphingomonas paucimobilis,
Ralstonia eutropha, Rhodospirillum rubrum, Kluyveromyces spp,
Pichia spp, Trichoderma reesei, Pleurotus ostreatus, Rhizopus spp,
and combinations thereof; optionally aerating the inoculated mash
at about 0.05 L/L/min; and incubating until utilization of sugars
ceases or after about 96 to 120 hours incubation in the presence of
the at least one microbe.
[0026] In one aspect, the method includes adding about 0.6 L
ethanol/L of mash; centrifuging the ethanol treated mash;
recovering the ethanol; optionally recovering fine suspended
particles, recovering centrifuged solids; and drying the recovered
centrifuge solids. In another aspect, the supernatant may be dried,
dried solids recovered, and thereafter mixed with the centrifuge
solids.
[0027] In one embodiment, a biologically pure culture of
Aureobasidium pullulans strain selected from the group consisting
of NRRL No. 50792, NRRL No. 50793, NRRL No. 50794, and NRRL No.
50795 is disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] FIG. 1 shows a flow chart for the HQSPC conversion
process.
[0029] FIG. 2 shows a flow chart for the HQSPC conversion process
for aqua feeds.
[0030] FIG. 3 shows bench scale, extended incubation trials to
evaluate HQSPC composition and yield.
[0031] FIG. 4 shows a flow chart for the HP-DDGS conversion process
for aqua feeds.
[0032] FIG. 5 shows the effect of moisture content and extrusion
speed on glucose recovery following extrusion of HP-DDGS at
100.degree. C.
DETAILED DESCRIPTION OF THE INVENTION
[0033] Before the present composition, methods, and methodologies
are described, it is to be understood that this invention is not
limited to particular compositions, methods, and experimental
conditions described, as such compositions, methods, and conditions
may vary. It is also to be understood that the terminology used
herein is for purposes of describing particular embodiments only,
and is not intended to be limiting, since the scope of the present
invention will be limited only in the appended claims.
[0034] As used in this specification and the appended claims, the
singular forms "a", "an", and "the" include plural references
unless the context clearly dictates otherwise. Thus, for example,
references to "a nucleic acid" includes one or more nucleic acids,
and/or compositions of the type described herein which will become
apparent to those persons skilled in the art upon reading this
disclosure and so forth.
[0035] Unless defined otherwise, all technical and scientific terms
used herein have the same meaning as commonly understood by one of
ordinary skill in the art to which this invention belongs. Any
methods and materials similar or equivalent to those described
herein can be used in the practice or testing of the invention, as
it will be understood that modifications and variations are
encompassed within the spirit and scope of the instant
disclosure.
[0036] As used herein, "about," "approximately," "substantially"
and "significantly" will be understood by a person of ordinary
skill in the art and will vary in some extent depending on the
context in which they are used. If there are uses of the term which
are not clear to persons of ordinary skill in the art given the
context in which it is used, "about" and "approximately" will mean
plus or minus <10% of particular term and "substantially" and
"significantly" will mean plus or minus >10% of the particular
term.
[0037] As used herein, the term "animal" means any organism
belonging to the kingdom Animalia and includes, without limitation,
humans, birds (e.g. poultry), mammals (e.g. cattle, swine, goal,
sheep, cat, dog, mouse and horse) as well as aquaculture organisms
such as fish (e.g. trout, salmon, perch), mollusks (e.g. clams) and
crustaceans (e.g. lobster and shrimp).
[0038] Use of the term "fish" includes all vertebrate fish, which
may be bony or cartilaginous fish.
[0039] As used herein "non-animal based protein" means that the
protein concentrate comprises at least 0.81 g of crude fiber/100 g
of composition (dry matter basis), which crude fiber is chiefly
cellulose and lignin material obtained as a residue in the chemical
analysis of vegetable substances.
[0040] As used herein, "incubation process" means the provision of
proper conditions for growth and development of bacteria or cells,
where such bacteria or cells use biosynthetic pathways to
metabolize various feed stocks. In embodiments, the incubation
process may be carried out, for example, under aerobic conditions.
In other embodiments, the incubation process may include
fermentation.
[0041] As used herein, the term "incubation products" means any
residual substances directly resulting from an incubation
process/reaction. In some instances, an incubation product contains
microorganisms such that it has a nutritional content enhanced as
compared to an incubation product that is deficient in such
microorganisms. The incubation products may contain suitable
constituent(s) from an incubation broth. For example, the
incubation products may include dissolved and/or suspended
constituents from an incubation broth. The suspended constituents
may include undissolved soluble constituents (e.g., where the
solution is supersaturated with one or more components) and/or
insoluble materials present in the incubation broth. The incubation
products may include substantially all of the dry solids present at
the end of an incubation (e.g., by spray drying an incubation broth
and the biomass produced by the incubation) or may include a
portion thereof. The incubation products may include crude material
from incubation where a microorganism may be fractionated and/or
partially purified to increase the nutrient content of the
material.
[0042] As used herein, a "conversion culture" means a culture of
microorganisms which are contained in a medium that comprises
material sufficient for the growth of the microorganisms, e.g.,
water and nutrients. The term "nutrient" means any substance with
nutritional value. It can be part of an animal feed or food
supplement for an animal. Exemplary nutrients include but are not
limited to proteins, peptides, fats, fatty acids, lipids, water and
fat soluble vitamins, essential amino acids, carbohydrates,
sterols, enzymes and trace minerals, such as, phosphorus, iron,
copper, zinc, manganese, magnesium, cobalt, iodine, selenium,
molybdenum, nickel, fluorine, vanadium, tin, and silicon.
[0043] Conversion is the process of culturing microorganisms in a
conversion culture under conditions suitable to convert
protein/carbohydrate/polysaccharide materials, for example, soybean
material into a high-quality protein concentrate. Adequate
conversion means utilization of 90% or more of specified
carbohydrates to produce microbial cell mass and/or
exopolysaccharide. In embodiments, conversion may be aerobic or
anaerobic.
[0044] As used herein a "flocculent" or "clearing agent" is a
chemical that promotes colloids to come out of suspension through
aggregation, and includes, but is not limited to, a multivalent ion
and polymer. In embodiments, such a flocculent/clearing agent may
include bioflocculents such as exopolysaccharides.
[0045] A large number of plant protein sources may be used in
connection with the present disclosure as feed stocks for
conversion. The main reason for using plant proteins in the feed
industry is to replace more expensive protein sources, like animal
protein sources. Another important factor is the danger of
transmitting diseases through feeding animal proteins to animals of
the same or related species. Examples for plant protein sources
include, but are not limited to, protein from the plant family
Fabaceae as exemplified by soybean and peanut, from the plant
family Brassiciaceae as exemplified by canola, cottonseed, the
plant family Asteraceae including, but not limited to sunflower,
and the plant family Arecaceae including copra. These protein
sources, also commonly defined as oilseed proteins may be fed
whole, but they are more commonly fed as a by-product after oils
have been removed. Other plant protein sources include plant
protein sources from the family Poaceae, also known as Gramineae,
like cereals and grains especially corn, wheat and rice or other
staple crops such as potato, cassava, and legumes (peas and beans),
some milling by-products including germ meal or corn gluten meal,
or distillery/brewery by-products. In embodiments, feed stocks for
proteins include, but are not limited to, plant materials from
soybeans, peanuts, Rapeseeds, barley, canola, sesame seeds,
cottonseeds, palm kernels, grape seeds, olives, safflowers,
sunflowers, copra, corn, coconuts, linseed, hazelnuts, wheat, rice,
potatoes, cassavas, legumes, camelina seeds, mustard seeds, germ
meal, corn gluten meal, distillery/brewery by-products, and
combinations thereof.
[0046] In the fish farming industry the major fishmeal replacers
with plant origin reportedly used, include, but are not limited to,
soybean meal (SBM), maize gluten meal, Rapeseed/canola (Brassica
sp.) meal, lupin (Lupinus sp. like the proteins in kernel meals of
de-hulled white (Lupinus albus), sweet (L. angustifolius) and
yellow (L. luteus) lupins, Sunflower (Helianthus annuus) seed meal,
crystalline amino acids; as well as pea meal (Pisum sativum),
Cottonseed (Gossypium sp.) meal, Peanut (groundnut; Arachis
hypogaea) meal and oilcake, soybean protein concentrate, corn (Zea
mays) gluten meal and wheat (Triticum aestivum) gluten, Potato
(Solanum tuberosum L.) protein concentrate as well as other plant
feedstuffs like Moringa (Moringa oleifera Lam.) leaves, all in
various concentrations and combinations.
[0047] The protein sources may be in the form of non-treated plant
materials and treated and/or extracted plant proteins. As an
example, heat treated soy products have high protein
digestibility.
[0048] A protein material includes any type of protein or peptide.
In embodiments, soybean material or the like may be used such as
whole soybeans. Whole soybeans may be standard, commoditized
soybeans; soybeans that have been genetically modified (GM) in some
manner; or non-GM identity preserved soybeans. Exemplary GM
soybeans include, for example, soybeans engineered to produce
carbohydrates other than stachyose and raffinose. Exemplary non-GM
soybeans include, for example, Schillinger varieties that are line
bred for low oil, low carbohydrates, and low trypsin
inhibition.
[0049] Other types of soybean material include soy protein flour,
soy protein concentrate, soybean meal and soy protein isolate, or
mixtures thereof. The traditional processing of whole soybean into
other forms of soy protein such as soy protein flours, soy protein
concentrates, soybean meal and soy protein isolates, includes
cracking the cleaned, raw whole soybean into several pieces,
typically six (6) to eight (8), to produce soy chips and hulls,
which are then removed. Soy chips are then conditioned at about
60.degree. C. and flaked to about 0.25 millimeter thickness. The
resulting flakes are then extracted with an inert solvent, such as
a hydrocarbon solvent, typically hexane, in one of several types of
countercurrent extraction systems to remove the soybean oil. For
soy protein flours, soy protein concentrates, and soy protein
isolates, it is important that the flakes be desolventized in a
manner which minimizes the amount of cooking or toasting of the soy
protein to preserve a high content of water-soluble soy protein.
This is typically accomplished by using vapour desolventizers or
flash desolventizers. The flakes resulting from this process are
generally referred to as "edible defatted flakes" or "white
soy(bean) flakes."
[0050] White soy bean flakes, which are the starting material for
soy protein flour, soy protein concentrate, and soy protein
isolate, have a protein content of approximately 50%. White soybean
flakes are then milled, usually in an open-loop grinding system, by
a hammer mill, classifier mill, roller mill or impact pin mill
first into grits, and with additional grinding, into soy flours
with desired particle sizes. Screening is typically used to size
the product to uniform particle size ranges, and can be
accomplished with shaker screens or cylindrical centrifugal
screeners. Other oil seeds may be processed in a similar
manner.
[0051] In embodiments, distiller's dried grain solubles (DDGS) may
be used. DDGS are currently manufactured by the corn ethanol
industry. Traditional DDGS comes from dry grind facilities, in
which the entire corn kernel is ground and processed. DDGS in these
facilities typically contains 28-32% protein.
[0052] The protein sources may be in the form of non-treated plant
materials and treated and/or extracted plant proteins. As an
example, heat treated soy products have high protein digestibility.
Still, the upper inclusion level for full fat or defatted soy meal
inclusion in diets for carnivorous fish is between an inclusion
level of 20 to 30%, even if heat labile antinutrients are
eliminated. In fish, soybean protein has shown that feeding fish
with protein concentration inclusion levels over 30% causes
intestinal damage and in general reduces growth performance in
different fish species. In fact, most fish farmers are reluctant to
use more than 10% plant proteins in the total diet due to these
effects.
[0053] The present invention solves this problem and allows for
plant protein inclusion levels of up to 40 or even 50%, depending
on, amongst other factors, the animal species being fed, the origin
of the plant protein source, the ratio of different plant protein
sources, the protein concentration and the amount, origin,
molecular structure and concentration of the glucan and/or mannan.
In embodiments, the plant protein inclusion levels are up to 40%,
preferably up to 20 or 30%. Typically the plant protein present in
the diet is between 5 and 40%, preferably between 10 or 15 and 30%.
These percentages define the percentage amount of a total plant
protein source in the animal feed or diet, this includes fat, ashes
etc. In embodiments, pure protein levels are up to 50%, typically
up to 45%, in embodiments 5-95%.
[0054] The proportion of plant protein to other protein in the
total feed or diet may be 5:95 to 95:5, 15:85 to 50:50, or 25:75 to
45:55.
Microorganisms
[0055] The disclosed microorganisms must be capable of converting
carbohydrates and other nutrients into a high-quality protein
concentrate in a conversion culture. In embodiments, the
microorganism is a yeast-like fungus. An example of a yeast-like
fungus is Aurobasidium pullulans. Other example microorganisms
include yeast such as Kluyveromyces and Pichia spp, Lactic acid
bacteria, Trichoderma reesei, Pleurotus ostreatus, Rhizopus spp,
and many types of lignocellulose degrading microbes. Generally,
exemplary microbes include those microbes that can metabolize
stachyose, raffinose, xylose and other sugars. However, it is
within the abilities of a skilled artisan to pick, without undue
experimentation, other appropriate microorganisms based on the
disclosed methods.
[0056] In embodiments, the microbial organisms that may be used in
the present process include, but are not limited to, Aureobasidium
pullulans, Sclerotium glucanicum, Sphingomonas paucimobilis,
Ralstonia eutropha, Rhodospirillum rubrum, Kluyveromyces and Pichia
spp, Trichoderma reesei, Pleurotus ostreatus, Rhizopus spp, and
combinations thereof. In embodiments, the microbe is Aureobasidium
pullulans.
[0057] In embodiments, the A. pullulans is adapted to various
environments/stressors encountered during conversion. In
embodiments, an A. pullulans strain denoted by NRRL deposit No.
50793, which was deposited with the Agricultural Research Culture
Collection (NRRL), Peoria, Ill., under the terms of the Budapest
Treaty on Nov. 30, 2012, exhibits lower gum production and is
adapted to DDGC. In embodiments, an A. pullulans strain denoted by
NRRL deposit No. 50792, which was deposited with the Agricultural
Research Culture Collection (NRRL), Peoria, Ill., under the terms
of the Budapest Treaty on Nov. 30, 2012, is adapted to high levels
of the antibiotic tetracycline (e.g., from about 75 .mu.g/ml
tetracycline to about 200 .mu.g/ml tetracycline). In embodiments,
an A. pullulans strain denoted by NRRL deposit No. 50794, which was
deposited with the Agricultural Research Culture Collection (NRRL),
Peoria, under the terms of the Budapest Treaty on Nov. 30, 2012, is
adapted to high levels of the antibiotic LACTROL.RTM. (e.g., from
about 2 .mu.g/ml virginiamycin to about 6 .mu.g/ml virginiamycin).
In embodiments, an A. pullulans strain denoted by NRRL deposit No.
50795, which was deposited with the Agricultural Research Culture
Collection (NRRL), Peoria, Ill., under the terms of the Budapest
Treaty on Nov. 30, 2012, is acclimated to condensed corn
solubles.
Conversion Culture
[0058] In exemplary embodiments, after pretreatment, the protein
material (such as extruded soy white flakes) may be blended with
water at a solid loading rate of at least 5%, with pH adjusted to
4.5-5.5. Then appropriate dosages of hydrolytic enzymes may be
added and the slurry incubated with agitation at 150-250 rpm at
50.degree. C. for 3-24 h. After cooling to 35.degree. C., an
inoculum of A. pullulans may be added and the culture may be
incubated for an additional 72-120 h, or until the carbohydrates
are consumed. During incubation, sterile air may be sparged into
the reactor at a rate of 0.5-1 L/L/h. In embodiments, the
conversion culture undergoes conversion by incubation with the
soybean material for less than about 96 hours. In embodiments, the
conversion culture will be incubated for between about 96 hours and
about 120 hours. In embodiments, the conversion culture may be
incubated for more than about 120 hours. The conversion culture may
be incubated at about 35.degree. C.
[0059] In embodiments, the pH of the conversion culture, while
undergoing conversion, may be about 4.5 to about 5.5. In
embodiments, the pH of the conversion culture may be less than 4.5
(e.g., at pH 3). In embodiments, the conversion culture may be
actively aerated such as is disclosed in Deshpande et al.,
Aureobasidium pullulans in applied microbiology: A status report,
Enzyme and Microbial Technology (1992), 14(7):514.
[0060] The high-quality protein concentrate (HQPC), as well as
pullulan and siderophores, may be recovered from the conversion
culture following the conversion process by optionally alcohol
precipitation and centrifugation. An example alcohol is ethanol,
although the skilled artisan understands that other alcohols should
work. In embodiments, salts may also be used to precipitate.
Exemplary salts may be salts of potassium, sodium and magnesium
chloride. In embodiments, a polymer or mutilvalent ions may be used
alone or in combination with the alcohol.
[0061] In embodiments, final protein concentrations solids recovery
may be modulated by varying incubation times. For example, about
75% protein may be achieved with a 14 day incubation, where the
solids recovery is about 16-20%. In embodiments, incubation for
2-2.5 days increase solids recovery to about 60-64%, and protein
level of 58-60% in the HQPC. In embodiments, 4-5 day incubation may
maximize both protein content (e.g., but not limited to greater
than about 70%) and solids recovery (e.g., but not limited to
greater than about 60%). These numbers may greater or lower,
depending on the feed stock. In embodiments, the protein
concentrates (i.e., HQSPC or HP-DDGS) may have a specific
lipid:protein ratio, e.g., at about 0.010:1 to about 0.03:1, about
0.020:1 to about 0.025:1 or about 0.021:1 to about 0.023:1.
[0062] In embodiments, feed stocks may be extruded in a single
screw extruder (e.g., BRABENDER PLASTI-CORDER EXTRUDER Model
PL2000, Hackensack, N.J.) with a barrel length to screw diameter of
1:20 and a compression ratio of 3:1, although other geometries and
ratios may be used. Feed stocks may be adjusted to about 10% to
about 15% moisture, to about 15%, or to about 25% moisture. The
temperature of feed, barrel, and outlet sections of extruder may be
held at between about 40.degree. C. to about 50.degree. C. or to
about 50.degree. C. to about 100.degree. C., about 100.degree. C.
to about 150.degree. C., about 150.degree. C. to about 170.degree.
C., and screw speed may be set at about 50 rpm to about 75 rpm or
about 75 rpm to about 100 rpm or about 100 rpm to about 200 rpm to
about 250 rpm. In embodiments, the screw speed is sufficient to
provide a shearing effect against the ridged channels on both sides
of a barrel. In embodiments, screw speed is selected to maximize
sugar release.
[0063] In embodiments, extruded feed stock materials (e.g., plant
proteins or DDGS) may be mixed with water to achieve a solid
loading rate of at least 5% in a reactor (e.g., a 5 L NEW BRUNSWICK
BIOFLO 3 BIOREACTOR; 3-4 L working volume). The slurry may be
autoclaved, cooled, and then saccharified by subjection to
enzymatic hydrolysis using a cocktail of enzymes including, but not
limited to, endo-xylanase and beta-xylosidase, Glycoside Hydrolase,
.beta.-glucosidases, hemicellulase activities. In one aspect, the
cocktail of enzymes includes NOVOZYME.RTM. enzymes. Dosages to be
may include 6% CELLICCTEK.RTM. (per gm glucan), 0.3%
CELLICHTEK.RTM. (per gm total solids), and 0.15% NOVOZYME 960.RTM.
(per gm total solids). Saccharification may be conducted for about
12 h to about 24 h at 40.degree. to about 50.degree. C. and about
150 rpm to about 200 rpm to solubilize the fibers and
oligosaccharides into simple sugars. The temperature may then be
reduced to between about 30.degree. C. to about 37.degree. C., in
embodiments to about 35.degree. C., and the slurry may be
inoculated with 2% (v/v) of a 24 h culture of the microbe. The
slurry may be aerated at 0.5 L/L/min and incubation may be
continued until sugar utilization ceases or about 96 h to about 120
h. In fed-batch conversions more extruded feed stock may be added
during either saccharification and/or the microbial conversion
phase.
[0064] In embodiments, the feed stock and/or extrudate may be
treated with one or more antibiotics (e.g., but not limited to,
tetracycline, penicillin, erythromycin, tylosin, virginiamycin, and
combinations thereof) before inoculation with the converting
microbe to avoid, for example, contamination by unwanted bacteria
strains.
[0065] During incubation, samples may be removed at 6-12 h
intervals. Samples for HPLC analysis may be boiled, centrifuged,
filtered (e.g., through 0.22-.mu.m filters), placed into
autosampler vials, and frozen until analysis. In embodiments,
samples may be assayed for carbohydrates and organic solvents using
a WATERS HPLC system, although other HPLC systems may be used.
Samples may be subjected to plate or hemocytometer counts to assess
microbial populations. Samples may also be assayed for levels of
cellulose, hemicellulose, and pectin using National Renewable
Energy Laboratory procedures.
Dietary Formulations
[0066] In exemplary embodiments, the high-quality protein
concentrate recovered from the conversion culture that has
undergone conversion is used in dietary formulations. In
embodiments, the recovered high-quality protein concentrate (HQPC)
will be the primary protein source in the dietary formulation.
Protein source percentages in dietary formulations are not meant to
be limiting and may include 24 to 80% protein. In embodiments, the
high-quality protein concentrate (HQPC) will be more than about
50%, more than about 60%, or more than about 70% of the total
dietary formulation protein source. Recovered HQPC may replace
protein sources such as fish meal, soybean meal, wheat and corn
flours and glutens and concentrates, and animal byproduct such as
blood, poultry, and feather meals. Dietary formulations using
recovered HQPC may also include supplements such as mineral and
vitamin premixes to satisfy remaining nutrient requirements as
appropriate.
[0067] In certain embodiments, performance of the HQPC, such as
high-quality soy protein concentrate (HQSPC) or high-quality DDGS
(HP-DDGS), may be measured by comparing the growth, feed
conversion, protein efficiency, and survival of animal on a
high-quality protein concentrate dietary formulation to animals fed
control dietary formulations, such as fish-meal. In embodiments,
test formulations contain consistent protein, lipid, and energy
contents. For example, when the animal is a fish, viscera (fat
deposition) and organ (liver and spleen) characteristics, dress-out
percentage, and fillet proximate analysis, as well as intestinal
histology (enteritis) may be measured to assess dietary
response.
[0068] As is understood, individual dietary formulations containing
the recovered HQPC may be optimized for different kinds of animals.
In embodiments, the animals are fish grown in commercial
aquaculture. Methods for optimization of dietary formulations are
well-known and easily ascertainable by the skilled artisan without
undue experimentation.
[0069] Complete grower diets may be formulated using HQPC in
accordance with known nutrient requirements for various animal
species. In embodiments, the formulation may be used for yellow
perch (e.g., 42% protein, 8% lipid). In embodiments, the
formulation may be used for rainbow trout (35% protein, 16% lipid).
In embodiments, the formulation may be used for any one of the
animals recited supra.
[0070] Basal mineral and vitamin premixes for plant-based diets may
be used to ensure that micro-nutrient requirements will be met. Any
supplements (as deemed necessary by analysis) may be evaluated by
comparing to an identical formulation without supplementation;
thus, the feeding trial may be done in a factorial design to
account for supplementation effects. In embodiments, feeding trials
may include a fish meal-based control diet and ESPC- and LSPC-based
reference diets [traditional SPC (TSPC) is produced from solvent
washing soy flake to remove soluble carbohydrate; texturized SPC
(ESPC) is produced by extruding TSPC under moist, high temperature;
and low-antigen SPC (LSPC) is produced from TSPC by altering the
solvent wash and temperature during processing]. Pellets for
feeding trials may be produced using the lab-scale single screw
extruder (e.g., BRABENDERPLASTI-CORDER EXTRUDER Model PL2000).
Feeding Trials
[0071] In embodiments, a replication of four experimental units per
treatment (i.e., each experimental and control diet blend) may be
used (e.g., about 60 to 120 days each). Trials may be carried out
in 110-L circular tanks (20 fish/tank) connected in parallel to a
closed-loop recirculation system driven by a centrifugal pump and
consisting of a solids sump, and bioreactor, filters (100 .mu.m
bag, carbon and ultra-violet). Heat pumps may be used as required
to maintain optimal temperatures for species-specific growth. Water
quality (e.g., dissolved oxygen, pH, temperature, ammonia and
nitrite) may be monitored in all systems.
[0072] In embodiments, experimental diets may be delivered
according to fish size and split into two to five daily feedings.
Growth performance may be determined by total mass measurements
taken at one to four weeks (depending upon fish size and trial
duration); rations may be adjusted in accordance with gains to
allow satiation feeding and to reduce waste streams. Consumption
may be assessed biweekly from collections of uneaten feed from
individual tanks. Uneaten feed may be dried to a constant
temperature, cooled, and weighed to estimate feed conversion
efficiency. Protein and energy digestibilities may determined from
fecal material manually stripped during the midpoint of each
experiment or via necropsy from the lower intestinal tract at the
conclusion of a feeding trial. Survival, weight gain, growth rate,
health indices, feed conversion, protein and energy
digestibilities, and protein efficiency may be compared among
treatment groups. Proximate analysis of necropsied fishes may be
carried out to compare composition of fillets among dietary
treatments. Analysis of amino and fatty acids may be done as needed
for fillet constituents, according to the feeding trial objective.
Feeding trial responses of dietary treatments may be compared to a
control (e.g., fish meal) diet response to ascertain whether
performance of HQPC diets meet or exceed control responses.
[0073] Statistical analyses of diets and feeding trial responses
may be completed with an a priori a=0.05. Analysis of performance
parameters among treatments may be performed with appropriate
analysis of variance or covariance (Proc Mixed) and post hoc
multiple comparisons, as needed. Analysis of fish performance and
tissue responses may be assessed by nonlinear models.
[0074] In embodiments, the present disclosure proposes to convert
fibers and other carbohydrates in soy flakes/meal or DDGS into
additional protein using, for example, a GRAS-status microbe. A
microbial exopolysaccharide (i.e., gum) may also be produced that
may facilitate extruded feed pellet formation, negating the need
for binders. This microbial gum may also provide immunostimulant
activity to activate innate defense mechanisms that protect fish
from common pathogens resulting from stressors. Immunoprophylactic
substances, such as .beta.-glucans, bacterial products, and plant
constituents, are increasingly used in commercial feeds to reduce
economic losses due to infectious diseases and minimize antibiotic
use. The microbes of the present disclosure also produce
extracellular peptidases, which should increase corn protein
digestibility and absorption during metabolism, providing higher
feed efficiency and yields. As disclosed herein, this microbial
incubation process provides a valuable, sustainable aquaculture
feed that is less expensive per unit of protein than SBM, SPC, and
fish meal.
[0075] As disclosed, the instant microbes may metabolize the
individual carbohydrates in soy flakes/meal or DDGS, producing both
cell mass (protein) and a microbial gum. Various strains of these
microbes also enhance fiber deconstruction. The microbes of the
present invention may also convert soy and corn proteins into more
digestible peptides and amino acids. In embodiments, the following
actions in may be performed: 1) determining the efficiency of using
select microbes of the present disclosure to convert pretreated soy
protein, oil seed proteins, DDGS and the like, yielding a high
quality protein concentrate (HQPC) with a protein concentration of
at least 45%, and 2) assessing the effectiveness of HQPC in
replacing fish meal. In embodiments, optimizing soy, oil seed, and
DDGS pretreatment and conversion conditions may be carried out to
improve the performance and robustness of the microbes, test the
resultant grower feeds for a range of commercially important
fishes, validate process costs and energy requirements, and
complete steps for scale-up and commercialization. In embodiments,
the HQPC of the present disclosure may be able to replace at least
50% of fish meal, while providing increased growth rates and
conversion efficiencies. Production costs should be less than
commercial soy protein concentrate (SPC) and substantially less
than fish meal (including harvest).
[0076] FIGS. 1 and 2 show the approach of the present disclosure in
the pretreatment of plant based product, converting sugars into
cell mass (protein) and gum, recovering HQSPC and generating aqua
feeds, and testing the resulting aqua feeds in fish feeding
trials.
[0077] After extrusion pretreatment, cellulose-deconstructing
enzymes may be evaluated to generate sugars, which microbes of the
present disclosure may convert to protein and gum. In embodiments,
sequential omission of these enzymes and evaluation of co-culturing
with cellulolytic microbes may be used. Ethanol may be evaluated to
precipitate the gum and improve centrifugal recovery of the HQPC.
After drying, the HQPC may be incorporated into practical diet
formulations. In embodiments, test grower diets may be formulated
(with mineral and vitamin premixes) and comparisons to a fish-meal
control and commercial SPC (SPC is distinctly different from
soybean meal, as it contains traces of oligopolysaccharides and
antigenic substances glycinin and b-conglycinin) diets in feeding
trials with a commercially important fish, e.g., yellow perch or
rainbow trout, may be performed. Performance (e.g., growth, feed
conversion, protein efficiency), viscera characteristics, and
intestinal histology may be examined to assess fish responses.
[0078] In other embodiments, optimizing the HQPC production process
by determining optimum pretreatment and conversion conditions while
minimizing process inputs, improving the performance and robustness
of the microbe, testing the resultant grower feeds for a range of
commercially important fishes, validating process costs and energy
requirements, and completing initial steps for scale-up and
commercialization may be carried out.
[0079] In the past few years, a handful of facilities have
installed a dry mill capability that removes corn hulls and germ
prior to the ethanol production process. This dry fractionation
process yields a DDGS with up to 42% protein (hereafter referred to
as dryfrac DDGS). In embodiments, conventional and dryfrac DDGS
under conditions previously determined to rapidly generate a
sufficient amount of high protein DDGS (HP-DDGS) for use in perch
feeding trials may be compared. In embodiments, careful monitoring
of the performance of this conversion (via chemical composition
changes) is carried out and parameters with the greatest impact on
HP-DDGS quality identified. In some embodiments, low oil DDGS may
be used as a substrate for conversion, where such low oil DDGS has
a higher protein level than conventional DDGS. In a related aspect,
low oil DDGS increase growth rates of A. pullulans compared to
conventional DDGS.
[0080] Several groups are evaluating partial replacement of
fish-meal with plant derived proteins, such as soybean meal and
DDGS. However, the lower protein content, inadequate amino acid
balance, and presence of anti-nutritional factors have limited the
replacement levels to 20-40%. Preliminary growth trials indicate
that no current DDGS or SPC-based diets provide performance similar
to fish-meal control diets. Several deficiencies have been
identified among commercially produced DDGS and SPCs, principally
in protein and amino acid composition, which impart variability in
growth performance and fish composition. However, HP-DDGS and HQSPC
diets as disclosed herein containing nutritional supplements
(formulated to meet or exceed all requirements) have provided
growth results that are similar to or exceed fish-meal controls.
Thus, the processes as disclosed herein and products developed
therefrom provide a higher quality HQSPC or HP-DDGS (relative to
nutritional requirements) and support growth performance equivalent
to or better than diets containing fish meal.
[0081] Fish that can be fed the fish feed composition of the
present disclosure include, but are not limited to, Siberian
sturgeon, Sterlet sturgeon, Starry sturgeon, White sturgeon,
Arapaima, Japanese eel, American eel, Short-finned eel, Long-finned
eel, European eel, Chanos chanos, Milkfish, Bluegill sunfish, Green
sunfish, White crappie, Black crappie, Asp, Catla, Goldfish,
Crucian carp, Mud carp, Mrigal carp, Grass carp, Common carp,
Silver carp, Bighead carp, Orangefin labeo, Roho labeo, Hoven's
carp, Wuchang bream, Black carp, Golden shiner, Nilem carp, White
amur bream, Thai silver barb, Java, Roach, Tench, Pond loach,
Bocachico, Dorada, Cachama, Cachama Blanca, Paco, Black bullhead,
Channel catfish, Bagrid catfish, Blue catfish, Wels catfish,
Pangasius (Swai, Tra, Basa) catfish, Striped catfish, Mudfish,
Philippine catfish, Hong Kong catfish, North African catfish,
Bighead catfish, Sampa, South American catfish, Atipa, Northern
pike, Ayu sweetfish, Vendace, Whitefish, Pink salmon, Chum salmon,
Coho salmon, Masu salmon, Rainbow trout, Sockeye salmon, Chinook
salmon, Atlantic salmon, Sea trout, Arctic char, Brook trout, Lake
trout, Atlantic cod, Pejerrey, Lai, Common snook, Barramundi/Asian
sea bass, Nile perch, Murray cod, Golden perch, Striped bass, White
bass, European seabass, Hong Kong grouper, Areolate grouper, Greasy
grouper, Spotted coralgrouper, Silver perch, White perch, Jade
perch, Largemouth bass, Smallmouth bass, European perch, Zander
(Pike-perch), Yellow Perch, Sauger, Walleye, Bluefish, Greater
amberjack, Japanese amberjack, Snubnose pompano, Florida pompano,
Palometa pompano, Japanese jack mackerel, Cobia, Mangrove red
snapper, Yellowtail snapper, Dark seabream, White seabream, Crimson
seabream, Red seabream, Red porgy, Goldlined seabream, Gilthead
seabream, Red drum, Green terror, Blackbelt cichlid, Jaguar
guapote, Mexican mojarra, Pearlspot, Three spotted tilapia, Blue
tilapia, Longfin tilapia, Mozambique tilapia, Nile tilapia,
Tilapia, Wami tilapia, Blackchin tilapia, Redbreast tilapia,
Redbelly tilapia, Golden grey mullet, Largescale mullet, Gold-spot
mullet, Thinlip grey mullet, Leaping mullet, Tade mullet, Flathead
grey mullet, White mullet, Lebranche mullet, Pacific fat sleeper,
Marble goby, White-spotted spinefoot, Goldlined spinefoot, Marbled
spinefoot, Southern bluefin tuna, Northern bluefin tuna, Climbing
perch, Snakeskin gourami, Kissing gourami, Giant gourami,
Snakehead, Indonesian snakehead, Spotted snakehead, Striped
snakehead, Turbot, Bastard halibut (Japanese flounder), Summer
Flounder, Southern flounder, Winter flounder, Atlantic Halibut,
Greenback flounder, Common sole, and combinations thereof
[0082] It will be appreciated by the skilled person that the fish
feed composition of the present disclosure may be used as a
convenient carrier for pharmaceutically active substances such as
for example antimicrobial agents and immunologically active
substances including vaccines against bacterial or viral
infections, and any combination thereof.
[0083] The fish feed composition according to present disclosure
may be provided as a liquid, pourable emulsion, or in the form of a
paste, or in a dry form, for example as a granulate or pellet, a
powder, or as flakes. When the fish feed composition is provided as
an emulsion, a lipid-in-water emulsion, it is may be in a
relatively concentrated form. Such a concentrated emulsion form may
also be referred to as a pre-emulsion as it may be diluted in one
or more steps in an aqueous medium to provide the final enrichment
medium for the organisms.
[0084] In embodiments, cellulosic-containing starting material for
the microbial-based process as disclosed is corn. Corn is about
two-thirds starch, which is converted during a fermentation and
distilling process into ethanol and carbon dioxide. The remaining
nutrients or fermentation products may result in condensed
distiller's solubles or distiller's grains such as DDGS, which can
be used in feed products. In general, the process involves an
initial preparation step of dry milling or grinding of the corn.
The processed corn is then subject to hydrolysis and enzymes added
to break down the principal starch component in a saccharification
step. The following step of fermentation is allowed to proceed upon
addition of a microorganism (e.g., yeast) provided in accordance
with an embodiment of the disclosure to produce gaseous products
such as carbon dioxide. The fermentation is conducted for the
production of ethanol which can be distilled from the fermentation
broth. The remainder of the fermentation medium can be then dried
to produce fermentation products including DDGS. This step usually
includes a solid/liquid separation process by centrifugation
wherein a solid phase component can be collected. Other methods
including filtration and spray dry techniques can be employed to
effect such separation. The liquid phase components can be
subjected further afterwards to an evaporation step that can
concentrate soluble coproducts, such as sugars, glycerol and amino
acids, into a material called syrup or condensed corn solubles
(CCS). The CCS can then be recombined with the solid phase
component to be dried as incubation products (DDGS). It shall be
understood that the subject compositions and can be applied to new
or already existing ethanol plants based on dry milling to provide
an integrated ethanol production process that also generates
fermentation products with increased value.
[0085] In embodiments, incubation products produced according to
the present disclosure have a higher commercial value than the
conventional fermentation products. For example, the incubation
products may include enhanced dried solids with improved amino acid
and micronutrient content. A "golden colored" product can be thus
provided which generally indicates higher amino acid digestibility
compared to darker colored HQSP. For example, a light-colored HQSP
may be produced with an increased lysine concentration in
accordance with embodiments herein compared to relatively darker
colored products with generally less nutritional value. The color
of the products may be an important factor or indicator in the
assessing the quality and nutrient digestibility of the
fermentation products or HQSP. Color is used as an indicator of
exposure to excess heat during drying causing caramelization and
Millard reactions of the free amino groups and sugars, reducing the
quality of some amino acids.
[0086] The basic steps in a dry mill or grind ethanol manufacturing
process may be described as follows: milling or grinding of corn or
other grain product, saccharification, fermentation, and
distillation. For example, selected whole corn kernels may be
milled or ground with typically either hammer mills or roller
mills. The particle size can influence cooking hydration and
subsequent enzymatic conversion. The milled or ground corn can be
then mixed with water to make a mash that is cooked and cooled. It
may be useful to include enzymes during the initial steps of this
conversion to decrease the viscosity of the gelatinized starch. The
mixture may be then transferred to saccharification reactors,
maintained at selected temperatures such as 140.degree. F., where
the starch is converted by addition of saccharifying enzymes to
fermentable sugars such as glucose or maltose. The converted mash
can be cooled to desired temperatures such as 84.degree. F., and
fed to fermentation reactors where fermentable sugars are converted
to carbon dioxide by the use of selected strains of microbes
provided in accordance with the disclosure that results in more
nutritional fermentation products compared to more traditional
ingredients such as Saccharomyces yeasts. The resulting product can
be flashed to separate out carbon dioxide and the resulting liquid
can be fed to a recovery system consisting of distillation columns
and a stripping column. The ethanol stream can be directed to a
molecular sieve where remaining water is removed using adsorption
technology. Purified ethanol, denatured with a small amount of
gasoline, can produce fuel grade ethanol. Another product can be
produced by further purifying the initial distillate ethanol to
remove impurities, resulting in about 99.95% ethanol for non-fuel
uses.
[0087] The whole stillage can be withdrawn from the bottom of the
distillation unit and centrifuged to produce distiller's wet grains
(DWG) and thin stillage (liquids). The DWG can leave the centrifuge
at 55-65% moisture, and can either be sold wet as a cattle feed or
dried as enhanced fermentation products provided in accordance with
the disclosure. These products include an enhanced end product that
may be referred to herein as distiller's dried grains (DDG). Using
an evaporator, the thin stillage (liquid) can be concentrated to
form distiller's solubles, which can be added back to and combined
with a distiller's grains process stream and dried. This combined
product in accordance with embodiments of the disclosure may be
marketed as an enhanced fermentation product having increased amino
acid and micronutrient content. It shall be understood that various
concepts of the disclosure may be applied to other fermentation
processes known in the field other than those illustrated
herein.
[0088] Another aspect of the present invention is directed towards
complete fish meal compositions with an enhanced concentration of
nutrients which includes microorganisms characterized by an
enhanced concentration of nutrients such as, but not limited to,
fats, fatty acids, lipids such as phospholipid, vitamins, essential
amino acids, peptides, proteins, carbohydrates, sterols, enzymes,
and trace minerals such as, iron, copper, zinc, manganese, cobalt,
iodine, selenium, molybdenum, nickel, fluorine, vanadium, tin,
silicon, and combinations thereof.
[0089] In a incubation process of the present disclosure, a carbon
source may be hydrolyzed to its component sugars by microorganisms
to produce alcohol and other gaseous products. Gaseous product
includes carbon dioxide and alcohol includes ethanol. The
incubation products obtained after the incubation process are
typically of higher commercial value. In embodiments, the
incubation products contain microorganisms that have enhanced
nutrient content than those products deficient in the
microorganisms. The microorganisms may be present in an incubation
system, the incubation broth and/or incubation biomass. The
incubation broth and/or biomass may be dried (e.g., spray-dried),
to produce the incubation products with an enhanced content of the
nutritional contents.
[0090] For example, the spent, dried solids recovered following the
incubation process are enhanced in accordance with the disclosure.
These incubation products are generally non-toxic, biodegradable,
readily available, inexpensive, and rich in nutrients. The choice
of microorganism and the incubation conditions are important to
produce a low toxicity or non-toxic incubation product for use as a
feed or nutritional supplement. While glucose is the major sugar
produced from the hydrolysis of the starch from grains, it is not
the only sugar produced in carbohydrates generally. Unlike the SPC
or DDG produced from the traditional dry mill ethanol production
process, which contains a large amount of non-starch carbohydrates
(e.g., as much as 35% percent of cellulose and
arabinoxylans-measured as neutral detergent fiber, by dry weight),
the subject nutrient enriched incubation products produced by
enzymatic hydrolysis of the non-starch carbohydrates are more
palatable and digestible to the non-ruminant.
[0091] The nutrient enriched incubation product of this disclosure
may have a nutrient content of from at least about 1% to about 95%
by weight. The nutrient content is preferably in the range of at
least about 10%-20%, 20%-30%, 30%-40%, 40%-50%, 50%-60%, 60%-70%,
and 70%-80% by weight. The available nutrient content may depend
upon the animal to which it is fed and the context of the remainder
of the diet, and stage in the animal life cycle. For instance, beef
cattle require less histidine than lactating cows. Selection of
suitable nutrient content for feeding animals is well known to
those skilled in the art.
[0092] The incubation products may be prepared as a spray-dried
biomass product. Optionally, the biomass may be separated by known
methods, such as centrifugation, filtration, separation, decanting,
a combination of separation and decanting, ultrafiltration or
microfiltration. The biomass incubation products may be further
treated to facilitate rumen bypass. In embodiments, the biomass
product may be separated from the incubation medium, spray-dried,
and optionally treated to modulate rumen bypass, and added to feed
as a nutritional source. In addition to producing nutritionally
enriched incubation products in a incubation process containing
microorganisms, the nutritionally enriched incubation products may
also be produced in transgenic plant systems. Methods for producing
transgenic plant systems are known in the art. Alternatively, where
the microorganism host excretes the nutritional contents, the
nutritionally-enriched broth may be separated from the biomass
produced by the incubation and the clarified broth may be used as
an animal feed ingredient, e.g., either in liquid form or in spray
dried form.
[0093] The incubation products obtained after the incubation
process using microorganisms may be used as an animal feed or as
food supplement for humans. The incubation product includes at
least one ingredient that has an enhanced nutritional content that
is derived from a non-animal source (e.g., a bacteria, yeast,
and/or plant). In particular, the incubation products are rich in
at least one or more of fats, fatty acids, lipids such as
phospholipid, vitamins, essential amino acids, peptides, proteins,
carbohydrates, sterols, enzymes, and trace minerals such as, iron,
copper, zinc, manganese, cobalt, iodine, selenium, molybdenum,
nickel, fluorine, vanadium, tin and silicon. In embodiments, the
peptides contain at least one essential amino acid. In other
embodiments, the essential amino acids are encapsulated inside a
subject modified microorganism used in an incubation reaction. In
embodiments, the essential amino acids are contained in
heterologous polypeptides expressed by the microorganism. Where
desired, the heterologous polypeptides are expressed and stored in
the inclusion bodies in a suitable microorganism (e.g., fungi).
[0094] In embodiments, the incubation products have a high
nutritional content. As a result, a higher percentage of the
incubation products may be used in a complete animal feed. In
embodiments, the feed composition comprises at least about 15% of
incubation product by weight. In a complete feed, or diet, this
material will be fed with other materials. Depending upon the
nutritional content of the other materials, and/or the nutritional
requirements of the animal to which the feed is provided, the
modified incubation products may range from 15% of the feed to 100%
of the feed. In embodiments, the subject incubation products may
provide lower percentage blending due to high nutrient content. In
other embodiments, the subject incubation products may provide very
high fraction feeding, e.g. over 75%. In suitable embodiments, the
feed composition comprises at least about 20%, at least about 25%,
at least about 30%, at least about 35%, at least about 40%, at
least about 45%, at least about 50%, at least about 60%, at least
about 70%, or at least about 75% of the subject incubation
products. Commonly, the feed composition comprises at least about
20% of incubation product by weight. More commonly, the feed
composition comprises at least about 15-25%, 25-20%, 20-25%,
30%-40%, 40%-50%, 50%-60%, or 60%-70% by weight of incubation
product. Where desired, the subject incubation products may be used
as a sole source of feed.
[0095] The complete fish meal compositions may have enhanced amino
acid content with regard to one or more essential amino acids for a
variety of purposes, e.g., for weight increase and overall
improvement of the animal's health. The complete fish meal
compositions may have an enhanced amino acid content because of the
presence of free amino acids and/or the presence of proteins or
peptides including an essential amino acid, in the incubation
products. Essential amino acids may include arginine, cysteine,
histidine, isoleucine, lysine, methionine, phenylalanine,
threonine, taurine, tryptophan, and/or valine, which may be present
in the complete animal feed as a free amino acid or as part of a
protein or peptide that is rich in the selected amino acid. At
least one essential amino acid-rich peptide or protein may have at
least 1% essential amino acid residues per total amino acid
residues in the peptide or protein, at least 5% essential amino
acid residues per total amino acid residues in the peptide or
protein, or at least 10% essential amino acid residues per total
amino acid residues in the protein. By feeding a diet balanced in
nutrients to animals, maximum use is made of the nutritional
content, requiring less feed to achieve comparable rates of growth,
milk production, or a reduction in the nutrients present in the
excreta reducing bioburden of the wastes.
[0096] A complete fish meal composition with an enhanced content of
an essential amino acid, may have an essential amino acid content
(including free essential amino acid and essential amino acid
present in a protein or peptide) of at least 2.0 wt % relative to
the weight of the crude protein and total amino acid content, and
more suitably at least 5.0 wt % relative to the weight of the crude
protein and total amino acid content. The complete fish meal
composition includes other nutrients derived from microorganisms
including but not limited to, fats, fatty acids, lipids such as
phospholipid, vitamins, carbohydrates, sterols, enzymes, and trace
minerals.
[0097] The complete fish meal composition may include complete feed
form composition, concentrate form composition, blender form
composition, and base form composition. If the composition is in
the form of a complete feed, the percent nutrient level, where the
nutrients are obtained from the microorganism in an incubation
product, which may be about 10 to about 25 percent, more suitably
about 14 to about 24 percent; whereas, if the composition is in the
form of a concentrate, the nutrient level may be about 30 to about
50 percent, more suitably about 32 to about 48 percent. If the
composition is in the form of a blender, the nutrient level in the
composition may be about 20 to about 30 percent, more suitably
about 24 to about 26 percent; and if the composition is in the form
of a base mix, the nutrient level in the composition may be about
55 to about 65 percent. Unless otherwise stated herein, percentages
are stated on a weight percent basis. If the HQPC is high in a
single nutrient, e.g., Lys, it will be used as a supplement at a
low rate; if it is balanced in amino acids and Vitamins, e.g.,
vitamin A and E, it will be a more complete feed and will be fed at
a higher rate and supplemented with a low protein, low nutrient
feed stock, like corn stover.
[0098] The fish meal composition may include a peptide or a crude
protein fraction present in an incubation product having an
essential amino acid content of at least about 2%. In embodiments,
a peptide or crude protein fraction may have an essential amino
acid content of at least about 3%, at least about 5%, at least
about 10%, at least about 15%, at least about 20%, at least about
30%, at least about 40%, and in embodiments, at least about 50%. In
embodiments, the peptide may be 100% essential amino acids.
Commonly, the fish meal composition may include a peptide or crude
protein fraction present in an incubation product having an
essential amino acid content of up to about 10%. More commonly, the
fish meal composition may include a peptide or a crude protein
fraction present in an incubation product having an essential amino
acid content of about 2-10%, 3.0-8.0%, or 4.0-6.0%.
[0099] The fish meal composition may include a peptide or a crude
protein fraction present in a incubation product having a lysine
content of at least about 2%. In embodiments, the peptide or crude
protein fraction may have a lysine content of at least about 3%, at
least about 5%, at least about 10%, at least about 15%, at least
about 20%, at least about 30%, at least about 40%, and in
embodiments, at least about 50%. Typically, the fish meal
composition may include the peptide or crude protein fraction
having a lysine content of up to about 10%. Where desired, the fish
meal composition may include the peptide or a crude protein
fraction having a lysine content of about 2-10%, 3.0-8.0%, or
4.0-6.0%.
[0100] The fish meal composition may include nutrients in the
incubation product from about 1 g/Kg dry solids to 900 g/Kg dry
solids. In embodiments, the nutrients in a fish meal composition
may be present to at least about 2 g/Kg dry solids, 5 g/Kg dry
solids, 10 g/Kg dry solids, 50 g/Kg dry solids, 100 g/Kg dry
solids, 200 g/Kg dry solids, and about 300 g/Kg dry solids. In
embodiments, the nutrients may be present to at least about 400
g/Kg dry solids, at least about 500 g/Kg dry solids, at least about
600 g/Kg dry solids, at least about 700 g/Kg dry solids, at least
about 800 g/Kg dry solids and/or at least about 900 g/Kg dry
solids.
[0101] The fish meal composition may include an essential amino
acid or a peptide containing at least one essential amino acid
present in an incubation product having a content of about 1 g/Kg
dry solids to 900 g/Kg dry solids. In embodiments, the essential
amino acid or a peptide containing at least one essential amino
acid in a fish meal composition may be present to at least about 2
g/Kg dry solids, 5 g/Kg dry solids, 10 g/Kg dry solids, 50 g/Kg dry
solids, 100 g/Kg dry solids, 200 g/Kg dry solids, and about 300
g/Kg dry solids. In embodiments, the essential amino acid or a
peptide containing at least one essential amino acid may be present
to at least about 400 g/Kg dry solids, at least about 500 g/Kg dry
solids, at least about 600 g/Kg dry solids, at least about 700 g/Kg
dry solids, at least about 800 g/Kg dry solids and/or at least
about 900 g/Kg dry solids.
[0102] The complete fish meal composition may contain a nutrient
enriched incubation product in the form of a biomass formed during
incubation and at least one additional nutrient component. In
another example, the fish meal composition contains a nutrient
enriched incubation product that is dissolved and suspended from an
incubation broth formed during incubation and at least one
additional nutrient component. In a further embodiment, the fish
meal composition has a crude protein fraction that includes at
least one essential amino acid-rich protein. The fish meal
composition may be formulated to deliver an improved balance of
essential amino acids.
[0103] For compositions comprising DDGS, the complete composition
form may contain one or more ingredients such as wheat middlings
("wheat mids"), corn, soybean meal, corn gluten meal, distiller's
grains or distiller's grains with solubles, salt, macro-minerals,
trace minerals and vitamins. Other potential ingredients may
commonly include, but not be limited to sunflower meal, malt
sprouts and soybean hulls. The blender form composition may contain
wheat middlings, corn gluten meal, distiller's grains or
distiller's grains with solubles, salt, macro-minerals, trace
minerals and vitamins. Alternative ingredients would commonly
include, but not be limited to, corn, soybean meal, sunflower meal,
cottonseed meal, malt sprouts and soybean hulls. The base form
composition may contain wheat middlings, corn gluten meal, and
distiller's grains or distiller's grains with solubles. Alternative
ingredients would commonly include, but are not limited to, soybean
meal, sunflower meal, malt sprouts, macro-minerals, trace minerals
and vitamins.
[0104] Highly unsaturated fatty acids (HUFAs) in microorganisms,
when exposed to oxidizing conditions may be converted to less
desirable unsaturated fatty acids or to saturated fatty acids.
However, saturation of omega-3 HUFAs may be reduced or prevented by
the introduction of synthetic antioxidants or naturally-occurring
antioxidants, such as beta-carotene, vitamin E and vitamin C, into
the feed. Synthetic antioxidants, such as BHT, BHA, TBHQ or
ethoxyquin, or natural antioxidants such as tocopherols, may be
incorporated into the food or feed products by adding them to the
products, or they may be incorporated by in situ production in a
suitable organism. The amount of antioxidants incorporated in this
manner depends, for example, on subsequent use requirements, such
as product formulation, packaging methods, and desired shelf
life.
[0105] Incubation products or complete fish meal containing the
incubation products of the present disclosure, may also be utilized
as a nutritional supplement for human consumption if the process
begins with human grade input materials, and human food quality
standards are observed through out the process. Incubation product
or the complete feed as disclosed herein is high in nutritional
content. Nutrients such as, protein and fiber are associated with
healthy diets. Recipes may be developed to utilize incubation
product or the complete feed of the disclosure in foods such as
cereal, crackers, pies, cookies, cakes, pizza crust, summer
sausage, meat balls, shakes, and in any forms of edible food.
Another choice may be to develop the incubation product or the
complete feed of the disclosure into snacks or a snack bar, similar
to a granola bar that could be easily eaten, convenient to
distribute. A snack bar may include protein, fiber, germ, vitamins,
minerals, from the grain, as well as nutraceuticals such as
glucosamine, HUFAs, or co-factors, such as Vitamin Q-10.
[0106] The fish meal comprising the subject incubation products may
be further supplemented with flavors. The choice of a particular
flavor will depend on the animal to which the feed is provided. The
flavors and aromas, both natural and artificial, may be used in
making feeds more acceptable and palatable. These supplementations
may blend well with all ingredients and may be available as a
liquid or dry product form. Suitable flavors, attractants, and
aromas to be supplemented in the animal feeds include but not
limited to fish pheromones, fenugreek, banana, cherry, rosemary,
cumin, carrot, peppermint oregano, vanilla, anise, plus rum, maple,
caramel, citrus oils, ethyl butyrate, menthol, apple, cinnamon, any
natural or artificial combinations thereof. The favors and aromas
may be interchanged between different animals. Similarly, a variety
of fruit flavors, artificial or natural may be added to food
supplements comprising the subject incubation products for human
consumption.
[0107] The shelf-life of the incubation product or the complete
feed of the present disclosure may typically be longer than the
shelf life of an incubation product that is deficient in the
microorganism. The shelf-life may depend on factors such as, the
moisture content of the product, how much air can flow through the
feed mass, the environmental conditions and the use of
preservatives. A preservative may be added to the complete feed to
increase the shelf life to weeks and months. Other methods to
increase shelf life include management similar to silage management
such as mixing with other feeds and packing, covering with plastic
or bagging. Cool conditions, preservatives and excluding air from
the feed mass all extend shelf life of wet co-products. The
complete feed can be stored in bunkers or silo bags. Drying the wet
incubation product or complete feed may also increase the product's
shelf life and improve consistency and quality.
[0108] The complete feed of the present disclosure may be stored
for long periods of time. The shelf life may be extended by
ensiling, adding preservatives such as organic acids, or blending
with other feeds such as soy hulls. Commodity bins or bulk storage
sheds may be used for storing the complete feeds.
[0109] As used herein, "room temperature" is about 25.degree. C.
under standard pressure.
[0110] The following examples are illustrative and are not intended
to limit the scope of the disclosed subject matter.
EXAMPLES
Example 1
High Quality Soy Protein Concentrate (HQSPC)
[0111] FIG. 1 shows the overall approach to pre-treating white
flakes, converting sugars into cell mass (protein) and gum,
recovering HQSPC and generating aquafeeds (FIG. 2), and testing
resulting aquafeeds in fish feeding trials. White flakes were first
subject to extrusion pretreatment (BRABENDER PLASTI-CORDER SINGLE
SCREW EXTRUDER Model PL2000, Hackensack, N.J.) at 15% moisture
content, 50.degree. C., and 75 rpm to disrupt the structure and
allow increased intrusion of hydrolytic enzymes during subsequent
saccharification. These conditions provided a shearing effect
against the rigged channels on both sides of the barrel, and it had
been observed previously that this resulted in 50-70% greater sugar
release following enzymatic hydrolysis. Extruded white flakes were
then ground through a 3 mm hammermill screen, blended with water to
achieve a 10% solid loading rate, and adjusted to pH 5. After
heating to pasteurize or sterilize the mash, the mash was cooled to
about 50.degree. C. and cellulose and
oligosaccharide-deconstructing enzymes (15 ml total/kg of white
flake) were added to hydrolyze the polymers into simple sugars
(4-24 h hydrolysis). Specific dosages included were 6% CELLIC CTEK
(per gm glucan), 0.3% CELLIC HTEK (per gm total solids), 0.015%
NOVOZYME 960 (per gm solids). The resulting mash was then cooled to
30.degree. C., pH adjusted to 3-5, inoculated with A. pullulans (1%
v/v), and incubated for 4-5 days at 50 to 200 rpm mixing and an
aeration rate of 0.5 L/L/min to convert sugars into protein and
gum. During incubation, samples were periodically removed and
analyzed for sugars, cell counts and gum production. Following
incubation, the pH was increased to 6.5, and ethanol (0.6 L/L
broth) was added to precipitate the gum. The protein, pullulan and
microbial mass (HQSPC) were recovered by centrifugation and dried,
while the supernatant was distilled to recover ethanol, and the
residual liquid chemically assayed for future recycling at the
start of the process. The HQSPC was then tested in feeding trials
with yellow perch, a fish of regional market importance. Test
grower diets were formulated with HQSPC compared to fishmeal and a
competing plant based ingredient. Performance (e.g., growth, feed
conversion, protein efficiency), viscera characteristics, and
intestinal histology were examined to assess fish responses.
HQSPC Using Soy White Flake and Microbial Conversion with A.
Pullulans, Pilot Scale System for the Production of HQSPC.
[0112] The system contained a 675 L bioreactor, a variable speed
progressive cavity pump, a continuous flow centrifuge, and a
1.times.4 meter drying table. Inoculum for use in the 675 L
bioreactor was prepared in two, 5 L NEW BRUNSWICK BIOFLO 3
BIOREACTORS. For each trial 8-10 L quantities of inoculum was
prepared by growing A. pullulan as described for 2-3 days. This
material was used to inoculate larger quantities of extruded and
saccharified white flake prepared in the 675 L bioreactor.
Following incubation, ethanol was added, the mash was centrifuged
to recover the wet solids which were then dried and used in fish
feeding trials. By monitoring performance of the conversion
process, the yield and composition of the HQSPC, several parameters
were observed that significantly affected solids recovery. In the
large scale trials, the parameters as shown in Table 1 were
varied.
TABLE-US-00001 TABLE 1 Pre-Pilot scale trail variables and key
performance parameters. Parameter Trial 1 Trial 2 Trial 3 Trial 4
Trial 5 Trial 6 Extruded yes yes no no no yes Sacc Time (h) 3 3.5 4
7 5 5 Incub pH 4.2 5.1 4.3 4.6 3.05 3.15 Incub Temp (C.) 29-30
29-30 29-30 26-27 29-30 29-30 Aeration (L/L/min) 0.25 0.25 0.25 0.5
0.5 0.5 Incub Time (days) 16 15 3.5 4.5 2 2.5 Solids Recovery (%)
20 16 48 48 60 64 Solids % Protein 75.18 75.04 63.93 61.5 61.61
56.86 Trypsin Inhibitors 0 0 NA NA 16,750 6,538 Supernatant %
Solids 2.5 5 2.1 3.89 2.39 3.4 Supernatant % Protein 78.16 80 71.66
61.47 NA NA
[0113] From the HQSPC yields and protein levels, the following were
noted: 1) an incubation pH of 3-3.5 and temperature of
30-32.degree. C., along with high aeration maximized growth of A.
pullulans and minimized pullulan production, 2) an incubation time
of 4-5 days was optimal for protein content and solids recovery, 3)
longer incubation times increased protein content, but
substantially reduced solids recovery, 4) shorter incubation times
maintained high solids recovery, but limited protein content, and
5) due to the lack of stachyose and raffinose in the end product,
extrusion and/or reduced (omitted) enzymatic saccharification may
be possible.
[0114] Preliminary bench-scale trials in the 5 L bioreactors were
conducted to optimize process conditions. A 10% solid loading rate
of extruded white flake was used and saccharified for 24 h,
followed by inoculation with A. pullulans and incubated at pH 5,
0.5 L/L/min aeration, 200 rpm agitation for 10 days. The extended
incubation time was tested to establish optimal harvest window to
maximize both percent solids recovery and protein content in the
solids. Samples (100 ml) were removed daily and, on alternate days,
were subjected to the following: [0115] Precipitating all solids
with ethanol, centrifuging and drying solids, measuring residual
solids in the resulting supernatant. [0116] Centrifuging the broth
first to recover solids, drying the solids, precipitating the
pullulan from the resulting supernatant and drying.
[0117] The ethanol precipitation first method recovered about 97%
of the solids (soybean solids, cells and gum) using a lab
centrifuge (10,000 g), with about 3% solids remaining in the fluid
phase. The centrifugation first method recovered about 81.7% of
solids (soybean solids and cells), with ethanol precipitation of
the supernatant recovering about 14.8% solids (exopolysaccharide),
and about 3.5% solids remaining in the fluid.
[0118] Through these bench scale trials, levels of protein,
pullulan, and total solids that could be recovered each day were
measured. It was expected that as incubation proceeded, protein and
pullulan levels would increase, but that total solids recovered
would decrease as some nutrients were catabolized into water and
CO.sub.2. Average protein levels of the solids from three
replications are shown in FIG. 3. Protein levels reached 70% by day
3-5, while total solids recovered begin dropping by day 5-6. Thus
it appears that a 4-5 day incubation time may be optimal.
Performance Evaluation of HQSPC as Fish Meal Replacement in Perch
Fish
[0119] Several difference among commercially available SPC were
previously identified, principally in protein and amino acid
composition and anti-nutritional properties, which imparted
variability in growth performance and fish composition. Those
experiments justified the need to develop higher quality SPC
products that would support growth performance equivalent to or
better than diets containing fish meal. A feeding trial was
conducted utilizing yellow perch to provide assessment of two HQSPC
soy products (fermentation trials 5 and 6) in comparison to a
commercial SPC and a Menhaden fish meal control.
[0120] Feed Preparations: Seven diets were formulated as follows:
[0121] Diet 1=fish meal control [0122] Diet 2=commercial SPC [0123]
Diet 3=commercial SPC (supplemented with lysine+methionine) [0124]
Diet 4=HQSPC trial 5 [0125] Diet 5=HQSPC trial 5 (supplemented with
lysine+methionine) [0126] Diet 6=HQSPC trial 6 [0127] Diet 7=HQSPC
trial 7 (supplemented with lysine+methionine)
[0128] Approximately 12 kg of each diet were prepared, including 2
kg containing 1 g/100 g chromic oxide for digestability
determinations. The trial diets were formulated to contain
equivalent SPC amounts with an appropriate protein:lipid target of
42:10. Soy Protein Concentrate (SPC, e.g., from Netzcon Ltd.
Rehovot, Israel) with a minimum protein content of 69% is made by
aqueous alcohol extraction of defatted non-toasted white flakes.
SPC is distinctly different from soybean meal, as it contains
traces of oligopolysaccharides and antigenic substances glycinin
and b-conglycinin.
[0129] Large particle ingredients were ground with a Fitzpatrick
comminutator (Elhurst, Ill.) with 0.51 mm screen prior to dry
blending. Dry ingredients were blended for 20 min using a VI-10
mixer with an intensifier bar (Vanguard Pharmaceutical Machinery,
Inc., Spring, Tex.). Dry blended feedstuffs were then transferred
to a Hobart HL200 mixer (Troy, Ohio) where oils and water were
added and blended for about 5 min. Feeds were then screw pressed
using a Hobart 4146 grinder with a 3/16'' die and dried under cool,
forced-air conditions. Following drying, feeds were milled into
pellets using a food processor, sieved to achieve consistent pellet
size, and placed in frozen storage at -20.degree. C. Chemical
analyses of primary protein sources may be seen in Table 2.
TABLE-US-00002 TABLE 2 Composition of the primary protein sources
(g/100 g, dry matter basis (dmb)) incorporated into yellow perch
experimental diets. Menhaden Commercial HQSPC HQSPC Protein Source
Fish Meal SPC Trial 5 Trial 6 Proximate Components Protein 66.77
78.18 61.61 56.86 Moisture* 7.62 9.73 5.14 7.89 Lipid 5.21 0.00
1.70 1.26 Crude Fiber 0.18 10.08 0.81 4.86 Ash 25.33 7.10 8.82 5.21
Amino Acids Alanine 3.97 3.03 2.71 2.66 Arginine 3.69 5.30 2.44
3.65 Aspartic Acid 5.47 8.08 6.72 6.45 Cystine 0.48 0.97 0.87 0.88
Glutamic Acid 7.73 12.51 8.70 8.85 Glycine 4.81 2.96 2.67 2.51
Histidine 1.26 1.84 1.41 1.40 Hydroxylysine 0.27 0.04 0.81 0.10
Hydroxyproline 1.19 0.08 0.10 0.07 Isoleucine 2.73 3.30 2.89 2.92
Lanthionine 0.00 0.02 0.00 0.00 Leucine 4.47 5.61 4.64 4.87 Lysine
4.58 4.56 3.47 3.41 Methionine 1.72 1.00 0.83 0.90 Ornithine 0.14
0.04 0.14 0.04 Phenylalanine 2.51 3.62 2.89 3.08 Proline 3.31 3.65
3.17 2.92 Serine 1.85 3.07 2.28 2.73 Taurine 0.42 0.08 0.09 0.10
Threonine 2.32 2.80 2.36 2.31 Tryptophan 0.58 1.00 0.79 0.82
Tyrosine 2.01 2.57 1.98 2.25 Valine 3.10 2.51 3.13 3.10
Oligosaccharides Raffinose -- 0.00 0.00 0.00 Stachyose -- 0.24 0.00
0.00 Phytic Acid -- 0.23 0.39 0.18 *All ingredients are expressed
on a dry matter basis with the exception of moisture (as is).
Analyses were for crude protein (AOAC 2006, method 990.03), crude
fat (AOAC 2006, method 9903), crude fiber (AOAC 2006, method
978.10), moisture (AOAC 2006, method 934.01) Chromic oxide (AOAC
2006, method 990.08), ash (AOAC 2006, method 942.05), and amino
acids (AOAC 2006, method 982.30 E(a, b, c)).
Pellet Properties
[0130] Samples of each diet were analyzed in triplicate for
moisture (%), water activity (a.sub.w), unit density (kg/m3),
pellet durability index (%), water stability (min), and color (L,
a, b); compressive strength (g), and diameter (mm) were determined
with n=10 replications. Moisture (%) was obtained using standard
method 2.2.2.5 (NFTA, 2001). Water activity (a.sub.w) of 2 g pellet
samples was measured with a Lab Touch a.sub.w analyzer (Nocasina,
Lachen SZ, Switzerland). Three color variables were analyzed with a
spectrophotocolorimeter (Lab Scan XE, HunterLab, Reston, Va.) as
Hunter L (brightness/darkness), Hunter a (redness greenness) and
Hunter b (yellowness/blueness). Unit density (UD) was estimated by
weighing 100 ml of pellets and dividing the mass (kg) by 0.0001
m.sup.3. Pellet durability index (PDI) was determined according to
standard method S269.4 (ASAE 2003). The PDI was calculated as: PDI
(%)=(M.sub.a/M.sub.b).times.100, where M.sub.a was the mass (g)
after tumbling and M.sub.b was the mass (g) before tumbling. Pellet
stability (min) was determined by the static (W.sub.static) method
(Ferouz et al., Cereal Chem (2011) 88:179-188) to mimic pellet
leaching in tanks until they were consumed. Stability was
calculated as loss of weight from leaching/dry weight of initial
sample. Pellet diameter was measured using a conventional caliper.
Pellets were tested for compressive strength using a TA.XT Plus
Texture Analyzer (Scarsdale, N.Y.).
Feeding Trial
[0131] Yellow perch (2.95 g.+-.0.05 SE) were randomly stocked at 21
fish/tank into 28 circular tanks (110 liters) connected in parallel
to a closed-loop recirculating aquaculture system (RAS). The RAS
water flow and quality was maintained with a centrifugation pump
consisting of dual solids sup tanks, bioreactor, bead filter, UV
filter, and heat pump. System water was municipal that is
dechlorinated and stored in a 15,200 L tank. Four replications of
each treatment were applied randomly in tanks. Water flow was
maintained at .about.1.5 L/min/tank. Temperature was maintained at
22.degree. C..+-.1.degree.. Temperature and dissolved oxygen were
measured with a YSI Pro Plus (Yellow Springs Instrument Company,
Yellow Springs, Ohio). Ammonia-nitrogen, nitrite-nitrogen,
nitrate-nitrogen, alkalinity (as CaCO.sub.3), and free chlorine
were tested using a Hach DR 3900 Spectrophotometer (Hach Company,
Loveland, Colo.).
[0132] Fish were fed to satiation by hand twice daily, and feeding
rates were modified according to tank weights, observed growth
rates, and feed consumption assessments. Consumption (%) was
estimated from a known number of pellets fed and by counting
uneaten pellets 30 min after feeding. Collections of uneaten feed
with subsequent dry weights were also used to estimate consumption.
Weekly tank consumption estimates were multiplied by weekly rations
to obtain weekly consumption (g). Palatability of treatments was
determined by the amount of feed consumed or rejected. Tank mass
(+0.01 g) was measured every other week to adjust feed rates and
calculate performance indices. Individual lengths (mm) and weights
(+0.01 g) were also measured every other week on four randomly
sampled fish from each treatment.
[0133] Feed conversion ratio (FCR) was calculated as:
F C R = mass of feed consumed ( dry , g ) growth ( wet , g )
##EQU00001##
[0134] Protein conversion ratio was calculated as:
P E R = growth ( wet , g ) mass of protein consumed ( dry , g )
##EQU00002##
[0135] Fulton-type condition factor (K) was calculated as:
K = _ weight ( g ) _ [ length ( mm ) ] 3 .times. 10 , 000
##EQU00003##
[0136] Specific growth rate (SGR) was calculated as:
S G R = [ ln ( final wt ( g ) ) - ln ( start wt ( g ) ) ] .times.
100 n ( days ) ##EQU00004##
[0137] Statistical analyses of diets and feeding trial responses
were carried out with analysis of variance (ANOVA, a priori
a=0.05). Significant F tests were followed by a post hoc Tukey's
test to separate treatment means.
Pellet and Feed Results
[0138] Feed formulations were based on HQSPC nutrient analyses from
Trail 3 (Table 1), while all soy protein concentrates were included
equally at 45% (100% fish meal replacement) in trial diets.
Analyses of Trials 5 and 6 were completed after scheduled feeding
trial start date (Table 2), generally resulting in similar but not
isonitrogenous diets. Diets were formulated to contain 42% protein
and 10% lipid, with energy-to-protein (E:P) ratios of 7.91 to 7.94
(kcal/g). Recent analyses showed that crude protein (dmb) was 44.9%
(Diet 1), 43.2% (Diets 2 and 3), 36.8% (Diets 4 and 5), and 37.5%
(Diets 6 and 7). Crude lipid was approximately 10% for all diets.
Amino acid analysis of feeds did not reveal any potential
deficiencies among un-supplemented diets compared to yellow perch
requirements (Table 3).
TABLE-US-00003 TABLE 3 Experimental design, dietary formulations,
and compositions for the perch feeding trials. Diet # Ingredients
(g/100 g, dmb) 1 2 3 4 5 6 7 Menhaden Fish Meal.sup.a 50.0 0.0 0.0
0.0 0.0 0.0 0.0 Commercial SPC 0.0 45.0 45.0 0.0 0.0 0.0 0.0 HQSPC
Trial 5 0.0 0.0 0.0 45.0 45.0 0.0 0.0 HQSPC Trial 6 0.0 0.0 0.0 0.0
0.0 45.0 45.0 Yellow Corn Gluten.sup.b 5.0 5.0 5.0 5.0 5.0 5.0 5.0
Wheat Flour.sup.c 18.0 21.0 21.0 21.0 21.0 21.0 21.0 Wheat
Gluten.sup.b 6.0 5.0 5.0 5.0 5.0 5.0 5.0 CMC.sup.d 5.0 5.0 5.0 5.0
5.0 5.0 5.0 Celufil.sup.d 3.7 3.6 3.6 3.5 3.0 3.5 3.0 Menhaden
Oil.sup.e 4.59 8.19 8.19 8.37 8.37 8.37 8.37 Flax Oil.sup.f 0.51
0.91 0.91 0.93 0.93 0.93 0.93 Vitamin Premix.sup.g 0.5 0.5 0.5 0.5
0.5 0.5 0.5 Mineral Premix.sup.h 0.1 0.1 0.1 0.1 0.1 0.1 0.1
Vitamin C.sup.i 0.05 0.05 0.05 0.05 0.05 0.05 0.05 Choline.sup.j
0.2 0.2 0.2 0.2 0.2 0.2 0.2 Phytase.sup.k 0.037 0.037 0.037 0.037
0.037 0.037 0.037 Brewer's Yeast.sup.l 2.0 2.0 2.0 2.0 2.0 2.0 2.0
L-Lysine.sup.j 0.0 0.0 0.3 0.0 0.3 0.0 0.3 L-Betaine.sup.j 0.5 0.5
0.5 0.5 0.5 0.5 0.5 L-Methionine.sup.j 0.0 0.0 0.2 0.0 0.2 0.0 0.2
Sodium Chloride.sup.m 1.0 1.0 1.0 1.0 1.0 1.0 1.0 Potassium
Chloride.sup.m 0.8 0.8 0.8 0.8 0.8 0.8 0.8 Magnesium Oxide.sup.m
0.05 0.05 0.05 0.05 0.05 0.05 0.05 Calcium Phosphate.sup.m 2.0 1.0
1.0 1.0 1.0 1.0 1.0 Estimated Proximate Composition Protein (%)
42.1 42.2 42.7 42.0 42.5 42.0 42.5 Lipid (%) 10.06 10.01 10.01
10.03 10.03 10.03 10.03 Ash (%) 4.46 3.46 3.46 3.46 3.46 3.46 3.46
Total Energy (kcal) 334.3 334.3 337.1 333.5 336.3 333.5 336.3 E:P
(kcal/g) 7.94 7.93 7.94 7.91 7.94 7.94 7.91 .sup.aSpecial Select,
Omega Protein, Houston, TX; .sup.bConsumers Supply Distribution,
Sioux City, IA; .sup.cBob's Red Mill Natural Foods, Milwaukee, OR;
.sup.dUSB Corporation, Cleveland, OH; .sup.eVirginia Prime Gold,
Omega Protein, Houston TX; .sup.fThomas Laboratories, Tolleson, AZ;
.sup.gARS 702 Premix, Nelson and Sons, Murray, UT; .sup.hSS #3
Trace Mix, Nelson and Sons, Murray, UT; .sup.iU.S. Nutrition,
Bohemia, NY; .sup.jPure Bulk, Roseburg, OR; .sup.kDSM Nutritional
Products, Parsippany, NJ; .sup.lDiamond V Mills, Cedar Rapids, IA;
.sup.mFisher Scientific, Pittsburg, PA.
[0139] Pellet feeds exhibited significant differences in
measurements among treatments except for diameters (Table 4).
TABLE-US-00004 TABLE 4 Physical properties of the feed extrudates.
Diet # Properties 1 2 3 4 5 6 7 MC (% db) 8.5 .+-. 0.2 .sup.a
11.0.+-. 0.3 .sup.b 11.0 .+-. 0.1 .sup.b 14.1 .+-. 0.1 .sup.c 9.9
.+-. 0.1 .sup.d 10.1 .+-. 0.1 .sup.d 12.2 .+-. 0.1 .sup.e a.sub.w
(--) 0.58 .+-. 0.02 .sup.a 0.67 .+-. 0.00 .sup.b 0.69 .+-. 0.00
.sup.c .sup. 0.68 .+-. 0.00 .sup.bc 0.68 .+-. 0.00 .sup.bc .sup.
0.68 .+-. 0.00 .sup.bc 0.74 .+-. 0.01 .sup.d BD (kg/m.sup.3) 634.8
.+-. 3.0 .sup.a 648.6 .+-. 3.2 .sup.b 659.4 .+-. 2.4 .sup.bc 675.4
.+-. 0.5 .sup.d 688.9 .+-. 0.6 .sup.e 669.3 .+-. 2.8 .sup.cd 695.9
.+-. 2.2 .sup.e CS (g) 24.4 .+-. 0.7 .sup.a 56.1 .+-. 1.8 .sup.b
42.9 .+-. 2.3 .sup.c .sup. 44.9 .+-. 3.8 .sup.bc 54.8 .+-. 2.3
.sup.b 67.0 .+-. 2.2 .sup.b 60.1 .+-. 3.9 .sup.b PDI (%) 98.1 .+-.
0.4 .sup.a 98.1 .+-. 0.8 .sup.a 98.1 .+-. 0.7 .sup.a 98.3 .+-. 0.3
.sup.a 99.3 .+-. 0.3 .sup.b 99.5 .+-. 0.2 .sup.b 99.5 .+-. 0.3
.sup.b WSI.sub.still (%) .sup. 10.2 .+-. 0.0 .sup.ab 11.9 .+-. 0.0
.sup.a .sup. 9.1 .+-. 0.0 .sup.ab .sup. 8.9 .+-. 0.0 .sup.ab 9.1
.+-. 0.0 .sup.ab .sup. 8.2 .+-. 0.0 .sup.ab 6.7 .+-. 0.0 .sup.b L
(--) 47.9 .+-. 0.2 .sup.a 58.5 .+-. 0.1 .sup.b 68.5 .+-. 0.5 .sup.c
59.9 .+-. 0.3 .sup.bd 53.7 .+-. 0.2 .sup.e 60.6 .+-. 0.3 .sup.d
63.8 .+-. 0.4 .sup.f a (--) 5.2 .+-. 0.0 .sup.a 2.8 .+-. 0.0 .sup.b
3.2 .+-. 0.1 .sup.c 4.3 .+-. 0.0 .sup.d 4.4 .+-. 0.0 .sup.d 2.9
.+-. 0.0 .sup.b 2.9 .+-. 0.0 .sup.b b (--) 22.8 .+-. 0.1 .sup.a
18.1 .+-. 0.1 .sup.b 20.2 .+-. 0.1 .sup.c 22.8 .+-. 0.1 .sup.a
21.4.+-. 0.1 .sup.d 20.3 .+-. 0.0 .sup.ce 20.7 .+-. 0.1 .sup.e Dia.
(mm) 2.2 .+-. 0.0 .sup.a 2.1 .+-. 0.1 .sup.a 2.1 .+-. 0.0 .sup.a
2.0 .+-. 0.0 .sup.a 2.0 .+-. 0.0 .sup.a 2.0 .+-. 0.0 .sup.a 2.0
.+-. 0.0 .sup.a Values given are means (.+-.SE) associated with
treatment means. Values not significantly different (P > 0.05)
have same letter within a given row. MC (% db) = moisture content
;a.sub.w (--) = water activity; BD (kg/m.sup.3) = unit density; CS
(g) = compressive strength; PDI (%) = pellet durability index;
WSI.sub.still (%) = water solubility index in still water; L (--) =
Hunter brightness; a (--) = Hunter yellowness; b (--) = Hunter
redness; Dia. (mm) = diameter.
[0140] Moisture content (MC) ranged from about 8.49% (Diet 1) to
about 14.07% (Diet 4). MC contributes an effect on other
characteristics, such as PDI, compressive strength, and color. No
apparent correlation between MC and other variables were
identified.
[0141] Water activity, a measure of unbound water in pellets, was
high (about 0.58 to about 0.74), with Diet 1 (fish meal)
significantly lower (about 0.58) and Diet 7 significantly higher
(about 0.74) than all other treatments. Values over 0.6 indicate
low storage stability and may allow microbial growth to
proliferate. Feeds were stored in a freezer at -20.degree. C.
[0142] Unit density (BD), a measure of feed weight per unit volume,
ranged from about 634.87 to about 695.9. Diet 1 (fish meal) had a
lower DB, and while not being limited by theory, this is most
likely due to lower inclusion of fish oil and fish meal. Soy
protein concentrate diets had higher BDs because they contained
more oil to amend lipid requirements.
[0143] Compressive strength (CS) was calculated as peak fracture
force of the stress-strain curve from a perpendicular axial
direction. CS varied significantly from about 24.36 to about 67.03.
Diet 1 (fish meal) exhibited the lowest compressive strength (about
24.36). While not being limited by theory, this is most likely
attributable to the heterogeneity of the pellets, which results
from the pelleting process (e.g., screw pressed rather than
extruded). Extrusion cooks the feed with a combination of moisture,
pressure, temperature, and mechanical shear. This process
gelatinizes starches, which can increase CS substantially.
[0144] Pellet Durability Index (PDI) was very high in all diets
(about 98.05% to about 99.48%), with no significant difference
between treatments. These high PDI values may be the result of high
MC, as well as carboxymethylcellulose (CMC) binder addition.
[0145] Water Solubility Index (WSI) was low in all diets (about
9.65 to about 14.43), with Diet 4 exhibiting the highest value,
which was significantly different than the lowest, Diet 7, at about
9.65. Due to the nature of screw-pressed compared to extruded
feeds, WSI was expected to be low. Extruded feeds are more water
stable due to gelatinization of starches, reducing water
penetration.
[0146] Hunter color parameters (L, a, b) revealed similarities with
growth performance. Hunter a (redness) was highest in diet 1 (5.15)
and lowest in Diet 2 (2.80), Hunter b (yellowness) was highest in
Diet 4 (22.81) and Diet 1 (22.76) and lowest in Diet 2 (18.07).
Hunter L (brightness) was highest in Diet 3 (68.48) and lowest in
Diet 1 (47.91). Lighter color feeds have been found to contain
higher concentrations and greater availability of lysine compared
to darker feeds.
Fish Performance
[0147] Diet 6 provided the most comparable results to Diet 1
(fishmeal) in growth performance. Growth performance was
significantly different between treatments in all categories (Table
5).
TABLE-US-00005 TABLE 5 Performance Aspects. Diet WG SGR S TC FCR
PER K 1 102.1 .+-. 8.0.sup.a 1.66 .+-. 0.1 .sup.a 100.0 .+-. 0.0
.sup.a 450.2 .+-. 5.8 .sup.a 1.27 .+-. 0.05 .sup.a 1.76 .+-. 0.06
.sup.a 1.06 .+-. 0.01 .sup.ab 2 12.6 .+-. 6.4 .sup.b 0.55 .+-. 0.12
.sup.b 82.3 .+-. 0.6 .sup.b 140.9 .+-. 4.7 .sup.b 2.59 .+-. 0.49
.sup.b 0.98 .+-. 0.17 .sup.b 1.01 .+-. 0.02 .sup.a 3 23.7 .+-. 1.3
.sup.bc 0.59 .+-. 0.04 .sup.bc 96.4 .+-. 0.3 .sup.a 181.6 .+-. 2.5
.sup.bc .sup. 2.0 .+-. 0.09 .sup.ab 1.17 .+-. 0.06 .sup.b 1.02 .+-.
0.03 .sup.ab 4 46.6 .+-. 8.3 .sup.cd 1.06 .+-. 0.12 .sup.c 94.1
.+-. 0.5 .sup.abc 283.4 .+-. 8.9 .sup.bc 1.6 .+-. 0.04 .sup.a 1.7
.+-. 0.04 .sup.a 1.11 .+-. 0.04 .sup.ab 5 49.1 .+-. 11.0 .sup.cd
1.10 .+-. 0.14 .sup.d 92.9 .+-. 0.3 .sup.abc 306.3 .+-. 11.2
.sup.ac .sup. 1.73 .+-. 0.10 .sup.ab 1.59 .+-. 0.10 .sup.a 1.14
.+-. 0.03 .sup.b 6 84.4 .+-.2.4 .sup.ae 1.48 .+-. 0.05 .sup.ad 98.8
.+-. 0.3 .sup.ac .sup. 451.5 .+-. 13.4 .sup.a 1.43 .+-. 0.04 .sup.a
1.87 .+-. 0.05 .sup.a 1.07 .+-. 0.03 .sup.ab 7 61.8 .+-. 4.8
.sup.de 1.28 .+-. 0.12 .sup.ad 94.1 .+-. 0.6 .sup.abc 338.1 .+-.
10.8 .sup.ac 1.58 .+-. 0.03 .sup.a 1.69 .+-. 0.03 .sup.a 1.06 .+-.
0.02 .sup.ab Mean weight gain (WG, %), specific growth rate (SGR),
survival (S, %), total consumption (TC, g), food conversion ratio
(FCR), protein efficiency ratio (PER), and Fulton-type condition
factor (K) values for perch fed experimental diets. Values given
are means (.+-.SE) associated with the treatment means. Values not
significantly different (P > 0.005) have the same letter within
a given column.
[0148] Supplemented diets (Diets 3 and 5) were slightly better than
their un-supplemented counterparts, except for Diets 6 and 7. Diet
6 outperformed Diet 7 in all aspects. While not being bound by
theory, this could be the result of timing issues associated with
the bioavailability of crystalline amino acid supplements.
[0149] Weight Gain (WG) was highest for Diet 1 (fishmeal at
102.1%), followed by Diets 6 and 7 (84.4% and 61.8%, respectively).
Diets 2 and 3 (commercial SPC) exhibited the lowest WG (12.62% and
23.69%, respectively). Specific Growth Rate (SGR) paralleled WG
results. SGR was highest in Diet 1 (1.66) and lowest in Diet 2
(0.55).
[0150] Protein Efficiency Ratio (PER) was highest in Diet 6 (1.87),
followed by Diet 1 (1.76) and Diet 4 (1.70). Diets 2 and 3 had the
lowest PERs of 0.98 and 1.17, respectively. PER was better in
un-supplemented Diets 4 and 6 than in supplemented diets 5 and
7.
[0151] Feed conversion ratio (FCR) followed a similar pattern, with
Diets 1 and Diet 6 being lowest (1.39 and 1.59, respectively).
These FCR values indicate very high nutritional feed quality. Diets
2 and 3 had the highest FCR (2.91 and 2.24, respectively).
[0152] Total consumption (dmb) was highest with Diet 6 (451.5 g)
and Diet 1 (450.20 g) and lowest with Diet 2 (140.91) and Diet 3
(181.60). All diets were fed to satiation. Diets consumption was
deemed indicative of palatability, which is also the reason for
significantly lower survival for fish on Diet 2 (82.29%). Survival
was 100% for Diet 1 and 98.81% for Diet 6.
[0153] Fulton's Condition Factor (K) was highest for Diet 5 (1.14)
and lowest for Diet 2 (1.01). All HQSPC diets met or exceeded the
fishmeal control for this specific performance parameter.
Commercial SPC diets were lower than all other diets.
Other Assays
[0154] End of trial analyses may include final growth, FCR, PER,
consumption, and examination for nutrition deficiencies via
necropsy. Plasma assays may be completed for lysine and methionine
using standard methods. Individual fish may be euthanized by
cervical dislocation in order to quantify muscle ratio,
hepatosomatic index, viscerosomatic index, fillet composition, and
hind gut histology (enteritis inflammation scores). Protein and
energy availability of trial diets may be estimated using chromic
oxide (CrO.sub.3) marker within the feed and fecal material. Fecal
material may be collected via necropsy from the lower intestinal
tract.
[0155] The apparent digestibility coefficients (ADC) for the
nutrients in the test diets may be calculated using the following
formula:
A D C test ingredient = A D C test diet + [ ( A D C test diet - A D
C ref diet ) .times. ( 0.7 .times. D ref 0.3 .times. D ingr ) ]
##EQU00005##
[0156] where Dref=% with nutrient (kJ/g gross energy) of reference
diet mash (as is) and Dingr=% nutrient (kJ/g gross energy) of test
ingredient (as is).
SUMMARY
[0157] Screw-pressed compound feeds for yellow perch were
exemplified using two HQSPC diets, a fish control meal, and a
commercial soy protein concentrate (SPC). The HQSPC-based diets had
comparable performance to fish meal and outperformed the commercial
SPC. Growth and conversion performance exceeded expectations, given
crude protein content in the HQSPC diets was approximately 7% less
than the fish meal control and 6% less than the commercial SPC.
Thus, the HQSPC diets may serve as a complete replacement for fish
meal.
Performance Evaluation of HQSPC as Fish Meal Replacement in Rainbow
Trout
[0158] In addition to the yellow perch results above, a 90-day
feeding trial was conducted using a domesticated rainbow trout
strain (Shasta). Table 6 summarizes the protein targets by fish
species and size. These dietary protein targets or levels (%) may
be used in the formulation of experimental diets for these
commercially important finfish.
TABLE-US-00006 TABLE 6 Protein targets for various finfish by
weight range. Weight ranges (g) Species <20 20-200 200-600
600-1,500 >1,500 Atlantic salmon 48 44 40 38 34 Pacific salmon
55 45 40 38 38 Rainbow trout 48 40 38 38 36 Channel catfish 44 36
32 32 28 Nile tilapia 40 34 30 28 26
[0159] Trout were fed a control fish meal diet or a diet replacing
70% of fish meal (Diet 2--35% inclusion) with an HQSPC product
(Trial 6) (see Table 7).
TABLE-US-00007 TABLE 7 Test Diet Formulations Used in a Rainbow
Trout Feeding Trial Diet 1 Diet 2 Ingredient (g) Omega prime
special select 40 15 HQSPC 0 35 Yellow corn gluten 20 16 Wheat
flour 15 11 Carboxymethylcellulose 6.7 3 Vitamin premix 1.5 1.5
Trace mineral premix 1.5 1.5 Stay-C 0.5 0.5 DVAqua 0.1 0.1
Methionine 0 0.2 Sodium chloride 0.5 0.5 Potassium chloride 0.5 0.5
Magnesium oxide 0 0 Calcium phosphate 0 0.5 Menhaden oil 13.7 14.7
Proximates Protein 42.87 42.89 Fat 16.37 16.38 Fiber 0.61 2.14 Ash
12.31 8.15 Kcal 398.54 398.68 E:P 9.30 9.29
[0160] The 35% inclusion level was used to exceed the 30% inclusion
recommended for other soy protein concentrates, such as Selecta
SPC60. This trial using isocaloric, isonitrogenous diets
demonstrated equivalent performance between the control and test
diet provided.
[0161] Table 8 summarizes the observed rainbow trout performance
characteristics during the 90-day feeding trial. Diet 2, containing
HQSPC, showed no decline in weight gain or feed
conversion/efficiency and there were no mortalities (100%
survival). These observations replicate the results observed in the
yellow perch trials.
TABLE-US-00008 TABLE 8 Performance trails for rainbow trout using
HQSPC. FM:HQSPC (%) Diet 1 (40:0) Diet 2 (15:35) Start weight (g)
795 .+-. 67 882 .+-. 44 End weight (g) 3,400 .+-. 216 3,706 .+-.
172 Gain (g) .sup. 2,605 .+-. 149 ab 2,824 .+-. 133 a Gain (%)
327.7 320.2 Food fed (g) 3,608 .+-. 189 3,880 .+-. 68.sup. FCR 1.39
.+-. 0.06 a .sup. 1.38 .+-. 0.07 a Mortality (%) 0.0 + 0.0 0.0 +
0.0 Values given are means (.+-.SE) associated with the treatment
means.
SUMMARY
[0162] Screw-pressed compound feeds for rainbow trout were
exemplified using an HQSPC diet and a fish control meal. In this
trial the HQSPC-based diets had comparable performance to fish
meal. Again, these data show that the HQSPC diets exceeded the
expected results using SPC (e.g., HQSPC may be used at
concentration greater than a 30% inclusion level), and may serve as
an efficacious replacement for fish meal.
Example 2
Production of HP-DDGS Using Microbial Conversion
[0163] The effects of extrusion on improving saccharification of
DDGS using a single screw extruder (BRABENDER PLASTI-CORDER
EXTRUDER Model PL2000, Hackensack, N.J.) with barrel length to
screw diameter of 1:20 and a compression ratio of 3:1 was
investigated (FIGS. 4 and 5). It was determined that 25% DDGS
moisture content, temperature of 100.degree. C. to 160.degree. C.,
and screw speed of 200 rpm resulted in a 36% sugar recovery from
corn fiber (FIG. 5). The performance of various NOVOZYME
lignocellulose deconstructing enzymes was separately evaluated and
it was found that 6% CELLIC CTEK2 (per gm glucan) and 0.3% CELLIC
HTEK2 (per gm total solids) resulted in sugar recoveries up to 70%.
These pretreatment and saccharification conditions may be used to
generate HP-DDGS. Next options such as co-culturing with
cellulase-producers to reduce the need for added enzymes may be
carried out, as well as using fed-batch bioreactors to reduce
processing costs.
[0164] Evaluating growth and gum production of the microbe on the
carbohydrates found in soybean meal was carried out and it was
found that protein content can be increased from 42% to at least
60% by using the approach as disclosed herein. This showed that the
microbe (e.g., A. pullulans) can efficiently convert a broad range
of difficult to metabolize oligosaccharides into cell mass (i.e.,
protein) and a microbial gum. This effort with soybean meal was
initiated based on prior studies that evaluated production of a
range of microbial gums (exopolysaccharides) from corn processing
byproducts such as whole stillage, thin stillage, and condensed
corn solubles. Through this work, a variety of microbial strains
have been accumulated that efficiently grow on various corn
processing byproducts and produce high levels of cell mass and gums
from the available sugars. Key operational parameters and
lower-cost gum recovery methods have been identified and developed.
Based on this body of work, and the knowledge that the strains of
microbes produce a broad range of hydrolytic enzymes, robust
processes have been identified that allow for effective conversion
DDGS into HP-DDGS (e.g., A. pullulans strain NRRL No. 50793).
[0165] For pretreatment, the conventional, dryfrac, and/or low oil
DDGS are extruded in a single screw extruder (BRABENDER
PLASTI-CORDER EXTRUDER Model PL2000, Hackensack, N.J.) with a
barrel length to screw diameter of 1:20 and a compression ratio of
3:1. DDGS samples (adjusted to 25% moisture), the temperature of
feed, barrel, and outlet sections of extruder is held at
100.degree. C. to 160.degree. C., and screw speed is set at 200
rpm, providing a shearing effect against the ridged channels on
both sides of the barrel. These selected levels of temperature,
screw speed and moisture were based on optimized conditions defined
previously that resulted in 36% sugar release from corn fiber due
to disruption of the DDGS matrix.
[0166] Extruded conventional and dryfrac DDGS is mixed with water
to achieve a solid loading rate of at least 5% in a 5 L NEW
BRUNSWICK BIOFLO 3 BIOREACTOR (3-4 L working volume) at a pH of
5.8. After autoclaving and cooling, the slurry is saccharified
using a cocktail of NOVOZYME enzymes for which preliminary data has
previously been collected. Dosages to be used in the initial trials
includes 6% CELLIC CTEK2 (per gm glucan) and 0.3% CELLIC HTEK2 (per
gm total solids). Saccharification is conducted for 24 h at
50.degree. C. and 150 rpm to solubilize the fibers and
oligosaccharides into simple sugars. The temperature is then
reduced to 35.degree. C., the pH is adjusted to 4.0 (to optimize
cell growth), and the slurry is inoculated with 2% (v/v) of a 24 h
culture of the microbe. The slurry is aerated at 0.5 L/L/min and
incubation is continued until sugar utilization ceases (96-120 h
anticipated). The following parameters are then evaluated: [0167]
1) replacing the cellulase enzymes with cellulase producing
microbes that would be co-cultured with the microbe; [0168] 2)
maximizing initial solid loading rate; and [0169] 3) adding more
extruded substrate during either saccharification and/or the
microbial conversion phases (i.e., fed-batch operation) to minimize
net enzyme dosage, maximize protein and gum concentrations, and
minimize product recovery costs.
[0170] During incubation, samples are removed at 6-12 h intervals.
Samples for HPLC analysis are boiled (to inactivate enzymes),
centrifuged, filtered through 0.22-.mu.m filters, placed into
autosampler vials, and frozen until analysis. These samples are
assayed for carbohydrates and organic solvents using a WATERS HPLC
system. Samples are subjected to microbial counts to assess
microbial populations. Samples are also assayed for levels of
cellulose and hemicellulose using National Renewable Energy
Laboratory procedures.
[0171] The converted slurry is then subjected to ethanol
precipitation and centrifugation to separate the protein, microbial
gum and microbial biomass (HP-DDGS) from the remaining culture
fluid. While not being bound by theory, the presence of a
precipitating gum improves the efficiency of centrifugation in
recovering suspended solids. The composition of the HP-DDGS is then
determined and used in fish feeding trials. Ethanol is recovered
from the liquid stream via distillation, and the residual liquid is
chemically analyzed to assess potential uses (e.g., incorporation
into the HP-DDGS or biogas production).
[0172] The HP-DDGS so produced contains a microbial gum to serve as
a binding agent and potentially as an immunostimulant. Other
hydrolytic enzymes excreted by the microbe should release peptides,
amino acids, and any remaining lipids, thereby increasing feed
intake, growth performance, and nutrient utilization in fish
feeding trials.
Evaluation of the Performance of HP-DDGS as a Fish Meal Replacement
in Perch Feeds
[0173] Conventional and dryfrac HP-DDGS from the above are analyzed
for nutritional competencies in view of requirements of targeted
species, especially focusing on yellow perch. Samples will be
subjected to chemical analyses: proximate analysis, Van Soest
fibers, insoluble carbohydrates, amino acids, fatty acids, and
minerals. This ensures that nutritional benchmarks have been
satisfied. Any anti-nutritional properties (e.g., phytic acid
content) of HP-DDGS are compared with current DDGS and provide a
basis for further process modification.
[0174] Complete practical diets are formulated using conventional
and dryfrac HP-DDGS in accordance with known nutrient requirements
for yellow perch (e.g., 32% protein, 8% lipid). Basal mineral and
vitamin premixes for plant-based diets are used to ensure that
micro-nutrient requirements are met. Any supplements (as deemed
necessary by analysis) are evaluated by comparing to an identical
formulation without supplementation; thus, the feeding trial is
done in a factorial design to account for supplementation effects.
All feeding trials include a fish meal-based control diet and diets
containing graded levels of HP-DDGS. Pellets for feeding trials are
produced using the lab-scale single screw extruder (BRABENDER
PLASTI-CORDER EXTRUDER Model PL2000).
[0175] Replication of four experimental units per treatment are
used in all feeding trials (60 to 120 days each). Trials are done
in 110-L circular tanks (20 fish/tank) connected in parallel to a
closed-loop recirculation system consisting of a solids sump,
bioreactor, and filters (100 .mu.m bag, carbon and ultra-violet)
driven by a centrifugal pump. Heat pumps are used as required to
maintain optimal temperatures for species-specific growth. Water
quality (e.g., dissolved oxygen, pH, temperature, ammonia and
nitrite) is monitored in all systems.
[0176] Experimental diets are delivered according to fish size,
split into two-to-five daily feedings. Growth performance is
determined by total mass measurements taken at one-to-four weeks
(depending upon fish size and trial duration); rations are adjusted
in accordance with gains to allow satiation feeding and to reduce
waste streams. Consumption is assessed biweekly from collections of
uneaten feed from individual tanks. Uneaten feed is dried to a
constant temperature, cooled, and weighed to estimate conversion
efficiency. Protein, energy, and phosphorous digestibility are
determined from fecal material manually stripped during the
midpoint of each experiment or via necropsy from the lower
intestinal tract at the conclusion of a feeding trial. Survival,
weight gain, growth rate, health indices, feed conversion, protein
and energy digestibility, protein efficiency, and phosphorous
utilization are compared among treatment groups. Proximate analysis
of necropsied fish is done to compare composition of fillets among
dietary treatments. Analysis of amino and fatty acids is done as
needed for fillet constituents, according to the feeding trial
objective.
[0177] Statistical analyses of diets and feeding trial responses
are completed with an a priori a=0.05. Analysis of performance
parameters among treatments is done with appropriate analysis of
variance or covariance (Proc Mixed) and post hoc multiple
comparisons, as needed. Analysis of fish performance and tissue
responses are assessed by nonlinear models.
Determining Preliminary Mass Balance, Energy Requirements, and
Costs.
[0178] Inputs and outputs of the conventional and dryfrac HP-DDGS
conversion process are monitored and used to establish a process
mass balance. Similarly, energy requirements for the process are
measured and/or estimated to calculate total energy use. Together,
these inputs are used to assess preliminary costs, which are
compared to conventional and dryfrac HP-DDGS value.
[0179] All of the references cited herein are incorporated by
reference in their entireties.
[0180] From the above discussion, one skilled in the art can
ascertain the essential characteristics of the invention, and
without departing from the spirit and scope thereof, can make
various changes and modifications of the embodiments to adapt to
various uses and conditions. Thus, various modifications of the
embodiments, in addition to those shown and described herein, will
be apparent to those skilled in the art from the foregoing
description. Such modifications are also intended to fall within
the scope of the appended claims.
* * * * *