1. DDGS: OVERVIEW AND Trends
Kurt A. Rosentrater, Ph.D.
Distillers Grains Technology Council
Iowa State University, Ames, IA USA

2. OVERVIEW Motivations Processes & coproducts Economics & markets
Evolving processes & new opportunities
Other issues

3. MOTIVATIONS

4. MOTIVATIONS
Ruminants or monogastrics
Animal

5. Animal MOTIVATIONS Ruminants or monogastrics Other gases CO2 O2
Water vapor
Feed
Methane
Water
Feces
Urine

6. DDGS IN THE MARKETS
As ethanol industry goes, so goes the supply of coproducts
Balance = key to sustainability
Availability
Price
Livestock producers
Alcohol
manufacturers

7. PROCESSES
&
COPRODUCTS

8. MANUFACTURING Dry Grind Process
40 MG/Y = 150 ML/Y
120 MG/Y = 450 ML/Y

9. ETHANOL COPRODUCTS + Condensed Distillers Solubles
Distillers Dried Grains with Solubles +
Distillers Wet Grains

10. FERMENTATION PRODUCTS
Value Added Grains Course Module
May 2001
FERMENTATION PRODUCTS
Theoretical Yields 1 kg glucose = 0.51 kg ethanol kg carbon dioxide Practical Yields 90 – 95% of theoretical + yeast cell mass + secondary products
Anecdotally:
1 kg corn =
1/3 kg ethanol
+ 1/3 kg CO2
+ 1/3 kg DDGS
Dirk E. Maier, Purdue University, ABE 10

11. Coproduct Composition
DDGS
Unit
Avg SD
Min
Max
Dry matter
% as fed
89.0
1.4
86.6
91.9
Crude protein
% DM
29.5
1.8
25.2
33.5
Amino acids
Arginine
% protein
4.3
0.3
3.4
5.1
Histidine
2.7
0.2
2.2
3.1
Isoleucine
3.8
3.2
Leucine
11.6
0.6
10.1
13.3
Lysine
3.0
2.1
3.7
Methionine
2.0
1.7
Phenylalanine
4.8
5.4
Threonine
0.1
3.3
4.0
Tryptophan
0.8
0.9
Tyrosine
3.9
0.5
4.7
Valine
5.6
NDF
34.2
6.8
18.3
47.4
Fat (ether extract)
11.1
7.1
15.7
Ash
1.0
7.5 Ca
g/kg DM
1.6
5.5 P
7.9
4.9
9.8 K
10.3
1.1
12.7 Mg
0.4
1.9
Na (ppm)
2.4
7.2
Zn (ppm)
mg/kg DM 62 16 43
105
Mn (ppm) 21 8 12 44
Cu (ppm) 6 2 3 10
Fe (ppm)
123 41 70
239
Source:

12. Coproduct Composition
Unit
 Condensed Solubles (CDS)
Thin Stillage
DWG
Dry matter
% as fed
32.0
5.0
35.0
Crude protein
% DM
20.4
17.9
44.0
Amino acids
Arginine
% protein
3.4
Histidine
2.4
Isoleucine
3.5
Leucine
12.0
Lysine
2.6
Methionine
1.9
Phenylalanine
4.6
Threonine
3.2
Tryptophan
0.5
Tyrosine
4.1
Valine
4.4
NDF
4.2
12.5
28.8
Fat (ether extract)
17.3
9.2
5.1
Ash
9.5
6.3 Ca
0.11
0.2 P
1.53 K
2.21
3.9 Mg
0.67
1.1
Na (ppm)
g/kg DM
2.0
1.3
Zn (ppm)
mg/kg DM
61.0
39.0
Mn (ppm)
24.0
6.0
Cu (ppm)
5.2
3.0
Fe (ppm)
76.0
53.0
Source:

13. ECONOMICS
& MARKETS

14. U.S. ETHANOL GROWTH Nov. 1, 2016: 214 plants, 15,608 MG/y
RFS: 15,000 MG/y of corn ethanol by 2015
Corn oil extraction

15. Co-products and Products
MARKETS
Co-products and Products
Dec 2014
Jan 2014
Feb 2015
Dry Mill
Condensed distillers solubles (CDS-syrup)
172,082
162,626
128,057
Corn oil
97,380
105,356
96,347
Distillers dried grains (DDG)
448,551
438,936
405,025
Distillers dried grains with solubles (DDGS)
1,919,823
1,862,550
1,649,534
Modified distillers wet grains (DWG) <65% moisture
1,411,411
1,341,938
1,144,177
Modified distillers wet grains (DWG) 40-64% moisture
503,258
480,134
421,666
Wet Mill
Corn germ meal
75,031
71,492
48,546
Corn gluten feed
329,431
321,768
283,990
Corn gluten meal
94,777
90,617
80,855
44,551
41,961
41,020
Wet corn gluten feed 40-60% moisture
338,077
313,400
274,763
NASS/USDA MONTHLY CO-PRODUCTS PRODUCTION

16. Current Feedings Rates in the U.S.
1 tonne of DDGS can replace 1.22 tonnes of corn/soybean meal (or more)
Estimates may not match current feeding levels
Prices change
Potential consumption rates are based on the price of DDGS not being a barrier to use

17. Current Feedings Rates in the U.S.
Beef Cattle:
Maximum potential inclusion rate: 20-50%
2007 recommendations: 22%
Dairy Cows:
Maximum potential inclusion rate: 10-30%
2007 recommendations: 8%
Swine:
Maximum potential inclusion rate: 10-50%,
2007 recommendations: 10%
Poultry (Layers, Broilers, Turkeys):
Maximum potential inclusion rate: 10-15%
2007 recommendations: N/A

18. Based on data provided by Cheryl Anderson, DTN
DDGS IN THE MARKETS
Based on data provided by Cheryl Anderson, DTN

19. Based on data provided by Cheryl Anderson, DTN
DDGS IN THE MARKETS
Based on data provided by Cheryl Anderson, DTN

20. Based on data provided by Cheryl Anderson, DTN
DDGS IN THE MARKETS
Based on data provided by Cheryl Anderson, DTN 20

21. Based on data provided by Cheryl Anderson, DTN
DWG IN THE MARKETS
Based on data provided by Cheryl Anderson, DTN

22. Based on Hoffman and Baker (2010) and U.S. Grains Council (2014)
DDGS IN THE MARKETS
Based on Hoffman and Baker (2010) and U.S. Grains Council (2014)

23. Based on Hoffman and Baker (2010) and U.S. Grains Council (2014)
DDGS IN THE MARKETS
Based on Hoffman and Baker (2010) and U.S. Grains Council (2014)

24. EVOLVING PROCESSES & NEW OPPORTUNITIES

25. FRACTIONATION Component Biofuel Fractionation Coproducts Proteins Oils
Fibers

26. FRACTIONATION

27. EVOLVING COPRODUCTS
Source: Dairy One, 2015

28. EVOLVING COPRODUCTS
Source: Dairy One, 2015

29. EVOLVING PROCESSES Oil extraction New enzymes New chemicals
New treatments

30. EVOLVING PROCESSES Oil extraction from CDS or stillage
10-12% down to 5-8% fat (or less)
BUT: every 1% fat reduction = $3-$6 /ton livestock diet increase (impact on the livestock producer)
Jan. 2012: 47% of ethanol plants extracting oil
Aug. 2014: ~85%
Nov. 2016: ~94%
Now:
1 kg corn =
1/3 kg ethanol
+ 1/3 kg CO2
+ 1/3 kg DDGS
kg oil

31. EVOLVING PROCESSES
Fiber & protein separation
From the DDGS or DDG

32. DDGS FRACTIONATION
a) Original DDGS; b) big DDGS; c) pan DDGS

33. DDGS FRACTIONATION DDGS fiber Protein: 42% db Lipid: 1.7% db
NDF: 52% db
Ash: 4.0% db

34. EVOLVING PROCESSES
Fiber & protein separation
Upstream may be better

35. EVOLVING COPRODUCTS
Using coproducts (wet or dry) to grow other organisms
Algae
Single-cell proteins
Fermentation of DDGS & soybean meal
Fungal cells for protein

36. AQUACULTURE Tremendous untapped opportunity – 200 MMT/year
DDGS ~ 1/10 to 1/20 the price of fish meal
Tilapia
Perch
Trout
Nile Tilapia
Yellow Perch
Rainbow Trout 36

37. OTHER ISSUES

38. Saccharomyces cerevisiae
YEAST CELLS
How much protein addition?
Probiotic/prebiotic effects?
Bauerfeind et al. (1944)
4 x 109 cells/g dried syrup (CDS)
~ 20% of syrup
Ingeldew (1999)
DDGS by mass: 3.9%
5.3% of the DDGS protein
Belyea et al. (2004)
50% of the DDGS protein
Han and Liu (2010)
Up to 20% of the DDGS protein
Giving away protein in the DDGS
Saccharomyces cerevisiae

39. YEAST CELLS How many residual microbes? A B C Lactic-acid bacteria
Aerobic heterotrophs
Yeasts and molds

40. CHINA

41. FDA

42. INCLUSION RATES $

43. FINAL THOUGHTS DDGS is critical to
Ethanol plant profitability
Livestock producers
Key to business sustainability
Need to produce a feed ingredient that livestock producers desire
Producing quality DDGS (with low variability) is what livestock need

44. FINAL THOUGHTS

45. THANK YOU Questions? Comments? Kurt Rosentrater
Distillers Grains Technology Council
Iowa State University
(515)