Alcohol Education and Processing Effects of Small Grains

1. Alcohol Education and Processing Effects of Small Grains Craig Pilgrim Global Marketing Manager EPAC conference Billings, Montana June 26, 2012

2. Outline • Lallemand (brief overview) • Educational Aspects • Schools and learning • Example of training • Small grains • Production values • Composition • Starch and Non Starch Polysaccharides • Enzymes and viscosity • Processing issues • Fermentation issues • Summary

3. Lallemand in 2012 • Develops, produces and markets yeasts, bacteria and other ingredients derived from those microorganisms for: • bakeries (65% of sales) • wine, beer and alcohol producers (as well as fuel ethanol industry) • animal and human nutrition industries, pharmaceutical industry • other food and agricultural industries • Over 2500 employees (of which 70+ in R&D) in over 35 countries on 5 continents

4. Our core activity Yeast Bacteria Development, production and marketing of… …and their derivatives

5. Ethanol Technology Institute Publications Educational Activities

6. The Alcohol School – Toulouse/Montreal • Now in 31st year of running this class • Organized by Prof Graeme Walker, Ethanol Technology Institute • Non-commercial • Mix of internal and reputable guest speakers • Directed towards: • Senior operational staff • Laboratory staff • Experienced operators/Shift leads • Agenda covers whole process at mid to high level • Some new technology/developmental topics included

7. The Operators’ School • In fourth year of operation. • Mix of lectures and hands on demonstrations • Organized by the Ethanol Technology Institute • Non-commercial • Directed towards operators and less experienced managers/shift leads • Predominantly in house trainers • Agenda covers complete process including both batch and continuous • Significant aspect of troubleshooting including worked examples/role play

8. The Alcohol Textbook Ethanol Technology Institute publishes “The Alcohol Textbook” • The most comprehensive book on alcohol production. • Team of internal and external writers. Edited by Dr. Mike Ingledew, Glen Austin and Dave Kelsall. • 5th edition recently published.

9. Example of educational training • Why training and educational aspect? • Been a part of landscape for more than 30 years • Focus on increasing operations knowledge, better trained personnel • Focus on Montreal is more North America and related grain processing • Corn as main substrate • Focus in Toulouse is more on Rest of World • Small grains is the main topic • The rest of this presentation will discuss aspects of small grain processing and those educational opportunities.

10. Global Small Grain Production United States Department of Agriculture, Avg. 2008-2010 Crop Years

11. Raw material usage in US • Corn is KING! • Majority of ethanol producing facilities are using corn. • Some plants, based on locations are using milo, sorghum, barley or wheat. • Inherent issues using small grains • Depending on grain, starch content might be less • Processing could be a bit more difficult • Equipment usage and wear • Viscosity • However, in other parts of the world, small grains are prevalent.

12. Raw Material Usage for EU • Mostly wheat, sugar beet juice, barley and maize. • Small grains effect production costs. • To minimize costs, blends of products may be used. Source: eBio

13. Grain Composition Wheat Triticale Rye Barley Corn Sorghum

14. Small grain challenge Starch granules Protein matrix Outer wall (-Glucan and pentosan) Protein middle lamella Inner cell wall (-Glucan) The small grains contain high concentrations of Non Starchy Polysaccharides (NSPs) which, have high water-binding capacity leading to increased mash viscosity The small grains contain high concentrations of NSPs which, have high water-binding capacity leading to increased mash viscosity Endosperm Cell Structure Source: Novozymes

15. Grain Composition

16. Starch Structure Amylose High rigidity High viscosity Amylopectin

17. Starch breakdown • “Normal” starch breakdown is relatively easy using heat and enzymes. • Long chained polymers known as “dextrins” are broken down with alpha amylase. This reduces viscosity fairly quickly and easily. • Once that happens, another enzyme is added at fermentation known as glucoamylase. • This breaks down the long chains into single glucose units. • Glucose is the primary and preferred source of sugar used by yeast to convert to ethanol.

18. Non Starch Polysaccharides of Cereal Grains • Arabinoxylan: Especially in wheat, rye and barley. Xylan backbone with L-arabinofuranose (L-arabinose in 5-atom ring form) • Beta-glucan: Linear unbranched beta-D-glucose with one beta-1,3 every 3 or 4 beta-1,4 linkages; in bran of grains

19. Cereal Grain Non-starch Polysaccharides Need enzymes Need enzymes Source: Novozymes

20. Viscosity Reducing Enzymes Composition of Grains Needs Xylanase Needs Beta Glucanase Can be converted to fermentable sugars • Beta Glucans and Pentosans are the main cause of high mash viscosities • These “Hemicelluloses” also create problems in thin stillage evaporation and dewatering of fermentation solids Source: Genencor

21. NSP Comparison in various grains

22. Non Starch Polysaccharides of Grains-Impact on processing grains to ethanol- • Grains like rye, barley, triticale and wheat contain high levels of hemicelluloses (Beta Glucans, Pentosans) = high viscosity due to high water-binding capacity • Consequences: This reduces the efficiency of • Heat exchange operation • Centrifugal separation of solids • Evaporation • Mass transfer in fermentation • Limited solids concentration in mashing • Negative effect on the energy balance of the process. (lower solids, higher water content, lower ethanol yield, etc.) • Residual Hemicelluloses may contribute to fouling of heat exchangers and distillation equipment Source: Genencor

23. Composition of Non Starch Polysaccharides of Cereal Grains * Depending on extraction conditions and specific composition

24. Summary - Processing Small Grains • Milling may be slightly different on equipment wear depending on substrate and variety. • Because of viscosity issues with NSP’s, secondary enzymes will have to be used. (Barley and rye definitely, wheat, depending on variety). • Because of viscosity issues, % solids in fermentation may have to be lower than compared to corn. • Dryhouse may have to be equipped to handle slightly larger volumes and lowers solids syrup. • Seasonal and strain differences in substrate will effect processing more than compared to corn (fairly constant)

25. Fermentation • Should be fairly comparable to corn or any other starch substrate fermentation. • Things to look for include: • Lower solids fermentations. • Foaming may vary due to substrate and age • Because small grains composition, fermentation yield may decrease because of availability of fermentable sugars.

26. Fermentation • Time • Nutrients • Antifoam

27. Fermentation • Time • May take slightly longer due to viscosity issues, mass transfer issues, sugar composition, etc. • May be offset due to lower solids required in some cases. • Nutrients • Antifoam

28. Fermentation • Time • Nutrients • Usually comparable to corn, but nutrient package may have to be used as well • Antifoam FAN values normalized to 20% DS Thomas and Ingledew, 2006

29. Fermentation • Time • Nutrients • Antifoam • Due to lower inherent oil levels in these substrates, foaming may be an issue. • Antifoams may have to be used in fermentation. • Corn oil could be used as well. Depending on what DDGS are used for.

30. Summary • Small grains can be used for ethanol production • Not prevalent in US, but could be used if necessary. • Dependant on areas of US that could grow the crops. • There are some inherent challenges to using small grains. • Mainly viscosity issues and starch content • Small grains are successfully used in other parts of the world for biofuels production.

31. Summary • Education and Training are key in understanding various processes and substrates. • This is type of presentation you would see in our various schools. • For more information, please see www.ethanoltech.com