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Fermentation process co-products : Integrated protein, energy and feedstock recovery Julio Traub 23 January 2013 ICBD Heriot-Watt University, Edinburgh 18 th IBD Video Link Day

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Contents 1.Whisky Process and Industry 2.Whisky co-products: Current and potential markets 3.Experimental Work 4.Conclusions 5.Future Work

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Whisky A Scottish success story Source: Diageo

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Whisky - Waste Fight Club... The are only 2 Rules... 1.Its not waste... Its a co-product!!! 2. Dont touch the process!

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Whisky Production Process Malt Whisky ExtractionFermentationDistillationEvaporationDrying Water Malted barley Yeast Draff Pot ale Spirit (Whisky) Pot ale Syrup

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Draff A good example of the Food vs. Fuel controversy Used as animal feed Cheap, good protein source (21% in DM basis) Can be used as a biofuel

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Pot Ale Typical Properties pH3.5 4.1 Solids3 5 % w/v Yeast count~ 10 8 cells/mL Copper Content2 6 mg/ L BOD12 35 g/ L COD38 62 g/ L Water PROTEINS Yeast Yeast Debris Copper Carbohydrates Sources: Graham, J., et al. (2012), Russell, I. et al (2003)

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Pot Ale Current treatment technologies FertiliserConsented discharge Evaporator Co - product???

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Pot Ale Syrup Evaporated Pot Ale (45% Solids) High capital and running costs Energy intensive (CO 2 emissions) Limited used (mostly Cattle) High copper content = toxic Current Supply ~ 30 50 ktpa Protein ~ 5 - 8 ktpa Commercial products available: Spey Syrup (AB Agri), GP feeds

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UK Animal Feed Demand Total = 10 m tonne in 2010 8.5% 3.2% 9.2% 28.1% Source: http://www.defra.gov.uk/statisticshttp://www.defra.gov.uk/statistics 1.2% 11.5%

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UK- B IOETHANOL P RODUCTION ENSUSVIVERGO Start upMay 2009 Teeside Sep 2012 Hull Investment300 m Raw Materials1 Mt Wheat Production400 m L420 m L Animal Feeds350 k tonne545 k tonne History May 2011 temp closure Sep 2012 reopened Dry390 k tonne Moist130 k tonne Syrup25 k tonne

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Malt Whisky Volumes and Co-products Distillery Capacity [M Lpa/ a] Pot Ale Proteins a [Tonne/ a] Draff Proteins b [Tonne/ a] Protein Value c [/ a] Total28732 K37 K48 m Median2.7302347454 k Max10.51,1761,3511,768 k Min0.055.66.48.4 k a 1 Lpa = 8L Pot Ale 14 g protein = 1L Pot Ale b 1 Lpa = 2.45 kg draff DM = 25%, CP = 21% c 700/ ton

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Aquaculture Feeds Scottish Salmon the other Scottish success story UK Salmon Production 154 k tonne (Atlantic Salmon), 3 rd largest producer in the world ~200 k tonne protein, High dependency on FM/ FO Need for Alternative Feedstuffs Economic and Sustainable Drivers Ideal Candidate Price and Logistics: Availability, handling, shipping, storage Low levels of fibre, High Protein content, Amino Acid Profile, High Digestibility

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DDGSPASSBMFM Crude Protein29 - 35 %34 -38%46 - 50%65 -72% Lysine0.55%2.1%2.69%4.72% Meth + Cyst0.86%0.35%1.18%3.5% Threonine0.81%1.9%1.67%2.5% Amino Acid Analysis what the fish wants... DDGS: Wheat Distillers Dried Grain with Solubles PAS: Pot Ale Syrup SBM: Soy bean Meal FM: Fish Meal

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The Horizon Protein Project Identify Inefficiencies Proteins Markets Optimize Process Product Scale Up Lower Energy Consumption Reduce CO 2 emissions Value added By- products

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Research Work AnalyticalProcess Design &Optimization Economical Modelling Solid content pH Yeast count Particle size Protein content Metal Analysis (Cu, Fe, Zn, Mn) Cell disruption Protein Purification and Concentration Solid/ liquid separation Cost and Capital estimation Economical Analysis (NPV, IRR, etc.) Protein Markets

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Process Selection Potential processes identified: 1.Pot Ale Barley Protein Fraction 2.Pot Ale Yeast Protein Fraction 3.Pot Ale Barley + Yeast Fractions 4.Pot Ale + Draff Barley Proteins 5.Pot Ale + Draff Barley + Yeast Fractions

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Process Overview Barley + Yeast Fractions PROTEINS Enzymatic Treatment High Pressure Homogeniser Centrifugation Filtration Ion Exchange Chromatography Pot Ale Water PROTEINS Yeast Yeast Debris Copper Carbohydrates Extraction Purification

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Experimental Work Protein Content and Distribution

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Experimental Work Copper analysis

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To disrupt or to not disrupt That is the question... YesNo Wasted Protein ~30% of total protein content Favourable AA profile Yeast high in Lysine (close to FM) Better end-product price Cost + Capital Homogeniser, enzymes, bioreactor Wasted MineralsDownstream processes Micronisation, nucleic acids, etc. Buffers More cost and capital! Other value added chemicals Glucans, chitins, phenols Toxicity Copper: ~70% bound to cells

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Experimental Work Protein Purification and Concentration Buffers: PBS, lactic acid, citric acid Cation and anion exchange pH elution: 4-7 Elution mode: Gradient and Step Flowrate: 1 5 ml/ min

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Conclusions so far... Pot Ale is a co-product Valuable proteins are currently underused at least 20 million pa across Scotland Current whisky co-product treatment technologies are unsustainable Expensive and energy intensive Increasing supply with static demand New markets: Salmon (?!)

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Conclusions contd so far... More understanding of what is needed for Salmon Feeds AA, minerals, fibres, nutritional properties Yeast cell fraction has not yet proved to be a viable option High copper, Low protein but it must NOT be wasted Draff proteins may increase feasibility of the project, but with some controversies and problems

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Sustainable protein sources Carbon Emissions Energy Efficiencies Added Value Co- products Cost Savings Industrial Symbiosis Academic Research

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Future work Proteins IEC: Columns (media, size), pH, flow rate Protein Identification (SDS-Page, AA analysis) Cell disruption Combined method Scale up Enzymatic Treatment Metal Analysis Protein and metal binding affinity

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Acknowledgments The Horizon Proteins Team Nik Willoughby Lydia Campbell Paul Hughes Alan Harper Dawn Maskell Jane White Sara Bags www.horizonproteins.com

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Acknowledgments Heriot-Watt University (SLS + EPS) Eileen McEvoy James Bryce Margaret Stobie Sean McMenamy Steve Euston Vicky Goodfellow Glenkinchie and North British Distilleries

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Industrial Partners, Collaborators and Sponsors

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QUESTIONS?

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Some (Scottish) thoughts.... Some hae meat and canna eat, And some wad eat that want it, But we hae meat and we can eat, And sae the Lord be thankit. Robert Burns (1759 1796)

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Experimental Work Cell Disruption Source: Sara Bags (2012)

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Malt Whisky Distillery size distribution Source: SWA

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Protein Markets Fish Meal and Soybean Meal Source: http://www.indexmundi.comhttp://www.indexmundi.com Last 12 months FM: up 55% SBM: up 48%

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Protein Markets Salmon Price Last 12 months: up 17% Down 30% since Apr-11 Source: http://www.indexmundi.comhttp://www.indexmundi.com

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Experimental Work Cell Disruption

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Distribution of copper in soluble fraction of pot ale Supernatant separated into low and high MW fractions using Amicon Ultra-15 Centrifugal filter tubes Retentate (>3 or 10 KDa) Filtrate (