Distillation Process
The
starch source is ground and then fermented to ethanol. About one-third of the dry matter remains as
the feed product. As a result, all the
nutrients (protein, energy, fiber, and phosphorus) are increased three-fold
because most grains contain approximately two-thirds starch.
Wet Versus Dried Distillers Grains
Comparing
the feeding of distillers wet and dry grains, research has found no differences
in feed intake or milk production.
On-farm observations indicate that the main considerations between the use of wet versus dried distillers grains are handling and costs. Dried can be stored for long periods while wet distillate grains can be kept 3-4 days in summer (7 days or longer in winter). Preservatives can be purchased that will extend the shelf life to two weeks. Beyond that time surface mold will grow and it will be unpalatable.
The FFDS-250-01 produces thin stillage and wet distillate grains (WDG). Larger ethanol plants need to dry the distillate grains for sale and transportation (an expensive, energy intensive step that is unnecessary unless stored for more than 3 days.)
Consumption Recommendations - Cattle
Wet
and dried distillers’ grains can replace up to 50% of corn grain in beef cattle
diets without affecting animal performance.
Distillers
grains are almost devoid of starch, but nonetheless a good source of energy,
protein, fiber, and phosphorus.
Distillers grains are a good source of ruminally undegradable protein
(RUP).
Thin
stillage (the liquid left over from distillation) can be fed direct or diluted
with water but is most beneficial when it completely replaces water as a
drinking source.
Table
1 shows how a ration would changed when distillate grains are substituted for
corn grain:
Table
1 is from an August 2005 article from the Iowa Beef Center of Iowa State
University.
If 20 lbs of wet distillers grains is used per
head of cattle, the FFDS-250-01 can supply 200 cattle and replace 2000 lbs of
corn (36 bushel) per day.
Cattle
gain an average of .2 lbs / day more with the wet distillers grain diet.
Other
Options: Taking 2000 lbs wet distillate
grains (with 65% moisture content) and mixing it with 790 lbs of corn stalks
(at 10% moisture content) would result in a blend of approximately 50% dry
matter, 18% protein, 65% TDN, 6% lipids, 0.15% Ca, 0.5% P, and 0.5% Sulfur.
Consumption Recommendations - Swine
Maximum
level for inclusion for DDGS are:
1. Nursery Phase (>15 lbs) –
25%
2. Grow-Finish Pigs (50 to 250
lbs) – 20%
3. Developing Gilts – 20 %
4. Gestating Sows – 50%
5. Lactating Sows – 20%
6. Boars – 50%
These
percentages are for dried distillate grains.
To convert to wet distillate grains, double the pounds of distillate
grains as it is 50% water.
Compounds
in corn DDGS may provide some gut health benefits for pigs. Produced field reports indicate that 5% to
10% DDGS in grow-finish swine diets helps minimize mortality and growth
problems stemming from ileitis, a gastrointestinal disease that is not
prevented with subtherapeutic antibiotic use.
Phosphorous is present in higher concentration in distillate
grains. Swine have a greater Phosphorous
requirement than beef or dairy cattle.
Don’t
use distillate grains on baby pigs.
Distillate grains’ by products carry several features that limit use in
swine diets. The high fiber content
curtails use in baby pig feed and distillate grains have a lower metabolizable
energy content due to less starch.
Adding
200 lbs of DDGS or 600 lbs of wet distillate grain to 1 ton of complete swine
feed will replace about 177 lb of corn, 20 lb of soybean meal (at 44%) and 6
lb. of dicalcium phosphate.
The
wet distillate grains produced by the FFDS-250-01 would supplement the feed of
500 to 1000 pigs per day.
Turkey and Chicken Usage
Trials
suggest DDGS contains unidentified growth factors that improve growth,
reproduction and feed intake. Turkeys
and chicken that were fed at least 10% DDGS in their diets showed improved
growth and reproduction.
Fermentation Procedure
Overview
1. 100 bushels of corn are
ground into a coarse cornmeal. (Other
substrates should be ground, mashed, or shredded as appropriate to the
substrate. Save all the juices, if any,
as sugar is water soluble.)
2. Fill one 1500 gallon
cracking tank 2/3 full of water. Slowly
add the corn meal while stirring.
3. Adjust pH if necessary to
obtain a range suitable for the alpha amylase enzyme. Add the enzyme and stir.
4. Align valves to allow for
heat.
5. Push the “Start
Fermentation” button. The control panel
and heater will add heat via coils until the tank comes to a boil for 15
minutes.
6. The FFDS-250-01 system will
monitor the heating and cooling process.
When the cracking is complete, cooling water will fill the second
cracking tank via the cooling coils of the first, recovering the heat for the
next batch.
7. Once the water has cooled to
140 deg. F, add sulfuric acid (same as is used in fish tanks) to obtain a pH
suitable for the gluco amylase enzyme.
Add the enzyme and stir.
8. Add remaining 1/3 water and
transfer to two fermentation tanks via the transfer pump.
9. Add water to fill the
fermentation tanks and cool the tanks to 90-100 deg. F.
10. Add the brewer’s yeast and
let ferment in the two fermentation tanks for 2 days.
Straining Procedure Overview
1. Transfer wort from the
fermentation tank through the strainer.
2. Take the distillate grains
and feed to livestock, store temporarily, or compost.
3. Gather liquid wort in the
liquid wort tank in preparation for distillation.
Distillation Procedure Overview
1. Align tank from which the
liquid wort will be drawn.
2. Push “Start Distillation”
button on the distillate control panel.
3. Ensure adequate room is
available for ethanol in the ethanol storage tank. Add denaturing agent.
4. Ensure flow to condenser is
satisfactory.
References
Schroeder,
Distillers Grains as a Protein and Energy Supplement for Dairy Cattle. Feburary 2003.
Bernick,
Yum Yum! Feburary 2003.
Hutjens,
Distillers Grain Opportunities. Feburary
2002.