Adding Value to Adding Value to MolassesMolasses

Donal Day and C. ChungDonal Day and C. Chung Audubon Sugar Institute Audubon Sugar Institute

Factory Operations Seminar 2007Factory Operations Seminar 2007

GoalGoal

Upgrade the value of molasses by Upgrade the value of molasses by converting the sugar to a higher value converting the sugar to a higher value productproduct

Target Market-Quality Liquid FeedsTarget Market-Quality Liquid Feeds Others- Human and poultry feedsOthers- Human and poultry feeds

BackgroundBackground

We have patented a process that We have patented a process that produces an oligosaccharide mixture produces an oligosaccharide mixture from sugar.from sugar.

This mixture has shown beneficial effects This mixture has shown beneficial effects in animal (poultry) nutritionin animal (poultry) nutrition

L. mesenteroidesL. mesenteroides B-742B-742 ( (ATCC ATCC 13146)13146)

Synthesizes a highly branched dextran Synthesizes a highly branched dextran from sucrosefrom sucrose

High yields of oligosaccharide from sucrose High yields of oligosaccharide from sucrose in presence of maltose by acceptor in presence of maltose by acceptor reactionreaction

Fructose conversion to mannitolFructose conversion to mannitol

Oligosaccharide Production-Process Flow

Fermentation with L. mesenteroides ATCC 13146

Cell separation

Product polishing by chromatography

Oligosaccharide product

Deionization and Decolorization

Mannitol crystallization

Input : maltose 50 g/L sucrose 100 g/L, saltsOutput : oligosaccharides 80.1 g/L (82.3 % theoretical yield) mannitol 37.6 g/L (70.1 % conversion)

86.4 % mannitol recovered

Ca 2+ ion exchange

98.8 % purity

Oligosaccharide DistributionOligosaccharide Distributionby DPby DP

0

5

10

15

20

25

30

35

40

1 2 3 4 5 6 7 8

%%

Degree of Polymerization

Postulated structures of isomaltooligosaccharides

DP, Degree of Polymerization

DP3 (panose).

-1,6

oo

oo

o

ooo

o

o

ooo

o

-1,4 -1,3 (?)

o (glucose).

Isomalto(gluco)oligosacIsomalto(gluco)oligosaccharide Processcharide Process

• Rapid, simple and economical production method

• Readily Scalable

• High production of glucooligosaccharides and mannitol

Proposed Mechanism of Proposed Mechanism of Action Action

IMO slows starch utilization IMO slows starch utilization

(hence growth of undesirable microflora)(hence growth of undesirable microflora)

Growth of desirable microflora favoredGrowth of desirable microflora favored

Intestinal pH drop produces “wash-out” of Intestinal pH drop produces “wash-out” of non-favored speciesnon-favored species

Acts as a Acts as a -glucosidase inhibitor, blocking -glucosidase inhibitor, blocking maltose translocationmaltose translocation

In Vivo ExperimentationIn Vivo Experimentation

Toxicity and weight gain in ratsToxicity and weight gain in rats

LSULSU

Weight gain, Salmonella loading in poultry Weight gain, Salmonella loading in poultry (broilers) - USDA, Athens, Ga.(broilers) - USDA, Athens, Ga.

Rat Toxicity TrialsRat Toxicity Trials

No toxicity seenNo toxicity seen No abnormal No abnormal

physiology on physiology on sacrificesacrifice

Animals liked the Animals liked the materialmaterial

Feed Efficiency Rats

0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

1 2 3 4 5

week

wei

ght g

ain/

gm fo

od

Control

5%

10%

Body Fat-(12 rats)Body Fat-(12 rats)

0

0.5

1

1.5

2

2.5

3

Control IMO (30%) RS (30%)

wg

t/w

gt%

Blood Triglycerides (12 Blood Triglycerides (12 rats)rats)

00.10.20.30.40.50.60.70.80.9

1

Control IMO (30%) RS (30%)

mg

/ml

1% Nc diet, 2 trials 21 1% Nc diet, 2 trials 21 day old poultry day old poultry (averages)(averages)

ControlControl TestTest

Feed EfficiencyFeed Efficiency

Weight gain/unit feedWeight gain/unit feed0.580.58 0.670.67

Cecal pHCecal pH 5.815.81 6.636.63

Salmonella loadingSalmonella loading cfu/bird x 107cfu/bird x 107

360360 3.13.1

Estimated Product ValueEstimated Product Value

Nutraceutical - unknownNutraceutical - unknown Target market - Poultry ProductionTarget market - Poultry Production

Cost attributable to foodborne illness due to poultry Cost attributable to foodborne illness due to poultry about $2 billion/annumabout $2 billion/annum

Corn Syrup ReplacementCorn Syrup Replacement Crude-animal feed supplementCrude-animal feed supplement Refinery molasses-healthy baking productRefinery molasses-healthy baking product

Mannitol ($3.32/lb)Mannitol ($3.32/lb)

Costs and Returns Costs and Returns (Material)(Material)per Kg of Productper Kg of Product

Carbon Source (as pure compounds)Carbon Source (as pure compounds) Sucrose $0.29Sucrose $0.29 Maltose $0.83Maltose $0.83

Total Total $1.12$1.12 Products (pure)Products (pure)

Oligosaccharide $9.03 (est)Oligosaccharide $9.03 (est) Mannitol $1.59Mannitol $1.59

Total $9.59Total $9.59

Molasses ProcessMolasses Process

Production of Nc, in situ, in molassesProduction of Nc, in situ, in molasses Process (Blackstrap)Process (Blackstrap)

DilutionDilution FermentationFermentation Concentration.Concentration.

Market- QLFMarket- QLF

Time (hr)

0 5 10 15 20 25 30

g/L

0

20

40

60

80

100

120

140

160

Mannitol fructose sucrose maltose Glucooligosaccharides

Cel

l mas

s (g

/L)

0

1

2

3

4

Cell mass

Production-Fermentation

Process-Pilot ProductProcess-Pilot Product

BlackstrapBlackstrap ModifiedModified

BrixBrix 84.184.1 71.271.2

Sucrose %Sucrose % 37.737.7 11.511.5

RS %RS % 15.315.3 12.812.8

IMO %IMO % 00 13.113.1

Ash %Ash % 16.716.7 15.915.9

ProteinProtein ndnd ndnd

What’s Next?What’s Next?

Contacting QLF to set up trials of Contacting QLF to set up trials of material in their process.material in their process.

Investigation of “health benefits” of new Investigation of “health benefits” of new material in animal marketmaterial in animal market

Pure Material- pursuing possibility of Pure Material- pursuing possibility of GRAS status with FDAGRAS status with FDA

Research into human food applications Research into human food applications

AcknowledgementAcknowledgement

This work was supported in part by the This work was supported in part by the American Sugar Cane LeagueAmerican Sugar Cane League

Dr. Roy Martin and Kathleen McCutcheon Dr. Roy Martin and Kathleen McCutcheon for their help with the rat studiesfor their help with the rat studies

Dr. Greg Siragusa , USDA, Athens, Ga for Dr. Greg Siragusa , USDA, Athens, Ga for his help with the poultry trialshis help with the poultry trials