Fermentation byproduct feed formulation and processing

Abstract

Systems and methods are provided which produce an improved distillers, brewers or fermenters grain by-products, including solubles, by determining nutrients and nutrient amounts to be added to a by-product to achieve targeted nutritional values, including bypass protein and amino acid levels, of the nutritionally enhanced grain byproduct after processing. One or more crude protein and/or amino acid content nutrient sources are added to the byproduct to create a nutritionally enhanced by-product mixture. The temperature and/or moisture content of the nutritionally enhanced by-product mixture is adjusted based on an empirically derived relationship that relates RUP as a percent of crude protein to an end product temperature in a predictable and repeatable manner to produce the improved distillers, brewers or fermenters grain byproduct. The products, having enhanced nutrient values of which are predictably ascertained, are made by the disclosed systems and methods.

1 . A method of predictably enhancing the nutrient value of distillers, brewers or fermenters grain byproducts, and of producing a protein feed or feed supplement end product having a crude protein content of over about 30% of the feed or feed supplement end product composition on a dry matter basis, and at least one of (1) a UIP/RUP content of over 50% and up to about 83% of the crude protein, (2) amino acid levels in the crude protein and in the RUP/UIP of greater than 1% and up to about 3% methionine and from about 2% up to about 8% lysine, or (3) a post ruminal digestibility of the UIP/RUP of over 60% and up to about 94%, comprising:
 determining the desirable levels of crude protein, UIP/RUP, amino acids and post ruminal digestibility in an end product;   creating a distillers, brewers or fermenters grain by-product-nutrient source mixture having an enhanced nutrient value by (a) adding one or more crude protein and/or amino acid content nutrient sources comprising canola meal, soybean meal, sunflower meal into wet distillers, brewers or fermenters by-products based on the crude protein, UIP protein, amino acid content, UIP/RUP amino acid content of the added nutrient sources; and (b) adjusting the temperature and/or the moisture content of the enhanced nutrient value by-product-nutrient source mixture based on an empirically derived relationship that relates the UIP as a percent of the crude protein (CP) to an end product temperature in a predictable and repeatable manner to produce said end product.   
   
   
       2 . The end product made by the process of  claim 1 . 
   
   
       3 . The method of  claim 1 , wherein the rumen undegradable protein (RUP/UIP) of the wet byproducts-nutrient-source mixture is increased in a range of from about 27% to about 83%. 
   
   
       4 . The method of  claim 1 , wherein the end product moisture level is in a range from about 0% to about 14%. 
   
   
       5 . The method of  claim 1 , wherein the UIP of the wet byproducts-nutrient-source mixture, on a crude protein basis, is increased by about 115 percent; methionine, as a percentage of UIP, is increased about 30 percent; UIP methionine, as a percentage of dry matter, is increased by about 179 percent; lysine, as a percentage of UIP is decreased by about 3.4 percent; and UIP lysine, as a percentage of dry matter, is increased by about 108 percent. 
   
   
       6 . The method of  claim 1 , wherein the UIP of the wet byproducts-nutrient-source mixture, on a crude protein basis, is increased by about 108 percent; methionine, as a percentage of UIP, is increased about 30 percent; UIP methionine, as a percentage of dry matter, is increased by about 169 percent; lysine, as a percentage of UIP is decreased by about 1.0 percent; and UIP lysine, as a percentage of dry matter, is increased by about 111 percent. 
   
   
       7 . The method of  claim 1 , wherein the distillation and/or fermentation by-product-nutrient source mixture having an enhanced nutrient value is a mixture of about two-thirds wet corn distillers grains and about one third high protein soybean meal. 
   
   
       8 . The method of  claim 1 , wherein the end product crude protein is in a range up to about 54 percent of the end product composition. 
   
   
       9 . The method of  claim 1 , wherein the end product UIP is in a range from about 63% to about 83 percent of the end product composition. 
   
   
       10 . The method of  claim 1 , wherein the UIP content of the end product has a pepsin digestibility in a range of about 74% to about 94%. 
   
   
       11 . The method of  claim 1 , wherein the crude protein range in the end product is from about 30% to about 58%; the UIP range in the end product is from about 63% to about 83% of the crude protein; and the post ruminal pepsin digestibility range is from about 63% to about 94% of the UIP. 
   
   
       12 . The method of  claim 1 , wherein the bypass protein (RUP/UIP) level of the end product is increased to between one and one-fourth times and approximately two and one-half times the original level of the byproduct-nutrient-source mixture, wherein the RUP/UIP in the end product is from about 50% up to about 83% of the crude protein level. 
   
   
       13 . The method of  claim 1 , wherein the temperature is in a range that causes denaturation of the protein of the by-product-nutrient source mixture. 
   
   
       14 . The method of  claim 1 , wherein temperature of the by-product-nutrient-source mixture is adjusted in a range from about 180° F. to about 250° F. 
   
   
       15 . A method of predictably enhancing the nutrient value of distillers, brewers or fermenters grain byproducts, and of producing a protein feed or feed supplement end product having a crude protein content of over about 30% of the feed or feed supplement end product composition on a dry matter basis, and at least two of (1) a UIP/RUP content of over 50% and up to about 83% of the crude protein, (2) amino acid levels in the crude protein and in the RUP/UIP of greater than 1% and up to about 3% methionine and from about 2% up to about 8% lysine, or (3) a post ruminal digestibility of the UIP/RUP of over 60% and up to about 94%, comprising:
 determining the desirable levels of crude protein, UIP/RUP, amino acids and post ruminal digestibility in an end product;   creating a distillers, brewers or fermenters grain by-product-nutrient source mixture having an enhanced nutrient value by (a) adding one or more crude protein and/or amino acid content nutrient sources comprising canola meal, soybean meal, sunflower meal into wet brewers, distillers or fermenters byproducts based on the crude protein, UIP protein, amino acid content, UIP/RUP amino acid content of the added nutrient sources; and (b) adjusting the temperature and/or the moisture content of the enhanced nutrient value by-product-nutrient source mixture based on an empirically derived relationship that relates the UIP as a percent of the crude protein (CP) to an end product temperature in a predictable and repeatable manner to produce said end product.   
   
   
       16 . The end product made by the process of  claim 15 . 
   
   
       17 . A method of predictably enhancing the nutrient value of distillers, brewers or fermenters grain byproducts, and of producing a protein feed or feed supplement end product having a crude protein content of over about 30% of the feed or feed supplement end product composition on a dry matter basis, and a UIP/RUP content of over 50% and up to about 83% of the crude protein, amino acid levels in the crude protein and in the RUP/UIP of greater than 1% and up to about 3% methionine and from about 2% up to about 8% lysine, and a post ruminal digestibility of the UIP/RUP of over 60% and up to about 94%, comprising:
 determining the desirable levels of crude protein, UIP/RUP, amino acids and post ruminal digestibility in an end product;   creating a distillers, brewers or fermenters grain by-product by-product-nutrient source mixture having an enhanced nutrient value by (a) adding one or more crude protein and/or amino acid content nutrient sources comprising canola meal, soybean meal, sunflower meal into wet distillers, brewers of fermenters byproducts based on the crude protein, UIP protein, amino acid content, UIP/RUP amino acid content of the added nutrient sources; and (b) adjusting the temperature and/or the moisture content of the enhanced nutrient value by-product-nutrient source mixture based on an empirically derived relationship that relates the UIP as a percent of the crude protein (CP) to an end product temperature in a predictable and repeatable manner to produce said end product.   
   
   
       18 . The method of  claim 17 , wherein the bypass protein (RUP/UIP) level of the end product that is over 50% and up to about 83% of the crude protein is adjusted and is increased in a range from approximately one and one-fourth times to approximately two and one-half times the bypass protein (RUP/UIP) level in the starting by-product-nutrient-source mixture. 
   
   
       19 . The end product made by the process of  claim 17 . 
   
   
       20 . The end product made by the process of  claim 18 . 
   
   
       21 . A system for predictably enhancing the nutrient value of distillers, brewers or fermenters grain byproducts, and for producing a protein feed or feed supplement end product having a crude protein content of over 30% of the feed or feed supplement end product composition on a dry matter basis, and at least one of (1) a UIP/RUP content of over 50% and up to about 83% of the crude protein of, (2) amino acid levels in the crude protein and in the RUP/UIP of greater than 1% and up to about 3% methionine and from about 2% up to about 8% lysine, or (3) having a post ruminal digestibility of the UIP/RUP of over 60% and up to about 94%, comprising:
 system mixing apparatus for mixing a distillers, brewers or fermenters grain by-product-nutrient source mixture having an enhanced nutrient value by adding one or more crude protein and/or amino acid content nutrient sources comprising canola meal, soybean meal, sunflower meal into wet distillers, fermenters or brewers byproducts based on the crude protein, UIP protein, amino acid content, UIP/RUP amino acid content of the added nutrient sources; and   system adjusting apparatus for adjusting the temperature and/or the moisture content of the enhanced nutrient value by-product-nutrient source mixture based on an empirically derived relationship that relates the UIP as a percent of the crude protein (CP) to an end product temperature in a predictable and repeatable manner to produce said end product.   
   
   
       22 . The system of  claim 21 , wherein the bypass protein (RUP/UIP) level of the end product is increased to between one and one-fourth times and approximately two and one-half times the original level of the byproduct-nutrient-source mixture, wherein the RUP/UIP in the end product is about 50% and up to about 83% of the crude protein levels. 
   
   
       23 . The system of  claim 21 , wherein the system adjusting apparatus is provided for providing the temperature in a range that causes denaturation of the protein of the by-product nutrient source mixture. 
   
   
       24 . A method of predictably enhancing the nutrient value of distillers, brewers or fermenters grain solubles, and of producing a protein feed or feed supplement end product having a crude protein content of over 30% on a dry matter basis of the feed or feed supplement end product composition, and at least one of (1) a UIP/RUP content of over 50% and up to about 83% of the crude protein, (2) amino acid levels in the crude protein and in the RUP/UIP of greater than 1% and up to about 3% methionine and from about 2% up to about 8% lysine, or (3) having a post ruminal digestibility of the UIP/RUP of over 60% and up to about 94%, comprising:
 determining the desirable levels of crude protein, UIP/RUP, amino acids and post ruminal digestibility in an end product;   creating a distillers, brewers or fermenters grain by-product solubles-nutrient source mixture having an enhanced nutrient value by (a) adding one or more crude protein and/or amino acid content nutrient sources comprising canola meal, soybean meal, sunflower meal into wet distillers, brewers or fermenters solubles based on the crude protein, UIP protein, amino acid content, UIP/RUP amino acid content of the added nutrient sources; and (b) adjusting the temperature and/or the moisture content of the enhanced nutrient value solubles-nutrient source mixture based on an empirically derived relationship that relates the UIP as a percent of the crude protein (CP) to an end product temperature in a predictable and repeatable manner to produce said end product.   
   
   
       25 . The end product made by the process of  claim 24 . 
   
   
       26 . A method of predictably enhancing the nutrient value of distillers, brewers or fermenters grain solubles, and of producing a protein feed or feed supplement end product having a crude protein content of over 30% on a dry matter basis of the feed or feed supplement end product composition, and at least two of (1) a UIP/RUP content of over 50% and up to about 83% of the crude protein, (2) amino acid levels in the crude protein and in the RUP/UIP of greater than 1% and up to about 3% methionine and from about 2% up to about 8% lysine, or (3) having a post ruminal digestibility of the UIP/RUP of over 60% and up to about 94%, comprising:
 determining the desirable levels of crude protein, UIP/RUP, amino acids and post ruminal digestibility in an end product;   creating a distillers, brewers or fermenters grain by-product solubles-nutrient source mixture having an enhanced nutrient value by (a) adding one or more crude protein and/or amino acid content nutrient sources comprising canola meal, soybean meal, sunflower meal into wet distillers, brewers or fermenters solubles based on the crude protein, UIP protein, amino acid content, UIP/RUP amino acid content of the added nutrient sources; and (b) adjusting the temperature and/or the moisture content of the enhanced nutrient value solubles-nutrient source mixture based on an empirically derived relationship that relates the UIP as a percent of the crude protein (CP) to an end product temperature in a predictable and repeatable manner to produce said end product.   
   
   
       27 . A method of predictably enhancing the nutrient value of distillers, brewers or fermenters grain solubles, and of producing a protein feed or feed supplement end product having a crude protein content of over 30% on a dry matter basis of the feed or feed supplement end product composition, and (1) a UIP/RUP content of over 50% and up to about 83% of the crude protein, (2) amino acid levels in the crude protein and in the RUP/UIP of greater than 1% and up to about 3% methionine and from about 2% up to about 8% lysine, and (3) having a post ruminal digestibility of the UIP/RUP of over 60% and up to about 94%, comprising:
 determining the desirable levels of crude protein, UIP/RUP, amino acids and post ruminal digestibility in an end product;   creating a distillers, brewers or fermenters grain by-product solubles-nutrient source mixture having an enhanced nutrient value by (a) adding one or more crude protein and/or amino acid content nutrient sources comprising canola meal, soybean meal, sunflower meal into wet distillers, brewers or fermenters solubles based on the crude protein, UIP protein, amino acid content, UIP/RUP amino acid content of the added nutrient sources; and (b) adjusting the temperature and/or the moisture content of the enhanced nutrient value solubles-nutrient source mixture based on an empirically derived relationship that relates the UIP as a percent of the crude protein (CP) to an end product temperature in a predictable and repeatable manner to produce said end product.   
   
   
       28 . The method of  claim 27 , wherein the bypass protein (RUP/UIP) level of the end product that is over 50% and up to about 83% of the crude protein is increased to approximately 2.44 times the bypass protein (RUP/UIP) level in the wet distillers, brewers, distillers or fermenters grains before the crude protein, and/or amino acid content nutrient sources are added. 
   
   
       29 . The end product made by the process of  claim 27 . 
   
   
       30 . The end product made by the process of  claim 28 . 
   
   
       31 . A system for predictably enhancing the nutrient value of distillers, brewers or fermenters solubles, and for producing a protein feed or feed supplement end product for having a crude protein content of over 30% on a dry matter basis of the feed or feed supplement end product composition, and at least one of (1) a UIP/RUP content of over 50% and up to about 83% of the crude protein, (2) amino acid levels in the crude protein and in the RUP/UIP of greater than 1% and up to about 3% methionine and from about 2% up to about 8% lysine, or (3) having a post ruminal digestibility of the UIP/RUP of over 60%, and up to about 94% comprising:
 system determining mixing apparatus for mixing a distillers, brewers or fermenters grain by-product solubles-nutrient source mixture having an enhanced nutrient value by adding one or more crude protein and/or amino acid content nutrient sources comprising canola meal, soybean meal, sunflower meal into wet distillers, brewers or fermenters solubles based on the crude protein, UIP protein, amino acid content, UIP/RUP amino acid content of the added nutrient sources; and   system adjusting apparatus for adjusting the temperature and/or the moisture content of the enhanced nutrient value solubles-nutrient source mixture based on an empirically derived relationship that relates the UIP as a percent of the crude protein (CP) to an end product temperature in a predictable and repeatable manner is provided for producing said end product.   
   
   
       32 . A system for predictably enhancing the nutrient value of distillers, brewers or fermenters solubles, and for producing a protein feed or feed supplement end product for having a crude protein content of over 30% on a dry matter basis of the feed or feed supplement end product composition, and at least two of (1) a UIP/RUP content of over 50% and up to about 83% of the crude protein, (2) amino acid levels in the crude protein and in the RUP/UIP of greater than 1% and up to about 3% methionine and from about 2% up to about 8% lysine, or (3) having a post ruminal digestibility of the UIP/RUP of over 60% and up to about 94%, comprising:
 system determining mixing apparatus for mixing a distillers, brewers or fermenters grain by-product solubles-nutrient source mixture having an enhanced nutrient value by adding one or more crude protein and/or amino acid content nutrient sources comprising canola meal, soybean meal, sunflower meal into wet distillers, brewers or fermenters solubles based on the crude protein, UIP protein, amino acid content, UIP/RUP amino acid content of the added nutrient sources to create an enhanced nutrient value by-product-nutrient source mixture of the distillation or fermentation byproducts; and   system adjusting apparatus for adjusting the temperature and/or the moisture content of the enhanced nutrient value solubles-nutrient source mixture based on an empirically derived relationship that relates the UIP as a percent of the crude protein (CP) to an end product temperature in a predictable and repeatable manner is provided for producing said end product.   
   
   
       33 . A system for predictably enhancing the nutrient value of distillers, brewers or fermenters solubles, and for producing a protein feed or feed supplement end product having a crude protein content of over 30% on a dry matter basis of the feed or feed supplement end product composition, and a UIP/RUP content of over 50% and up to about 83% of the crude protein, amino acid levels in the crude protein and in the RUP/UIP of greater than 1% and up to about 3% methionine and from about 2% up to about 8% lysine, and having a post ruminal digestibility of the UIP/RUP of over 60% and up to about 94%, comprising:
 system determining mixing apparatus for mixing a distillers, brewers or fermenters grain by-product solubles-nutrient source mixture having an enhanced nutrient value by adding one or more crude protein and/or amino acid content nutrient sources comprising canola meal, soybean meal, sunflower meal into wet distillers, brewers or fermenters solubles based on the crude protein, UIP protein, amino acid content, UIP/RUP amino acid content of the added nutrient sources; and   system adjusting apparatus for adjusting temperature and/or the moisture content of the enhanced nutrient value solubles-nutrient source mixture based on an empirically derived relationship that relates the UIP as a percent of the crude protein (CP) to an end product temperature in a predictable and repeatable manner is provided for producing said end product.   
   
   
       34 . The system of  claim 33 , wherein the system adjusting apparatus for providing a bypass protein (RUP/UIP) level of the end product that is over 50% and up to 83% of the crude protein increases the bypass protein (RUP/UIP) level to approximately 2.44 times the bypass protein (RUP/UIP) level in the wet distillers, brewers, or fermenters grain by-product solubles before the crude protein, and/or amino acid content nutrient sources are added. 
   
   
       35 . A method for accurately predicting and manipulating nutrient parameters of a distillers, brewers or fermenters grain byproduct or solubles, comprising:
 determining desirable levels of crude protein, UIP/RUP, amino acids and post ruminal digestibility in a final nutritionally enhanced byproduct;   adding nutrients to the byproduct to produce an intermediate nutritionally enhanced byproduct; and   adjusting the temperature and/or the moisture content of the intermediate enhanced byproduct based on an empirically derived relationship that relates the UIP as a percent of the crude protein to an end product temperature in a predictable and repeatable manner to produce the final nutritionally enhanced byproduct having predicted nutrient parameters.   
   
   
       36 . A system for accurately predicting and manipulating nutrient parameters of a distillers, brewers or fermenters grain byproduct or solubles, comprising:
 system determining apparatus for determining desirable levels of crude protein, UIP/RUP, amino acids and post ruminal digestibility in a final nutritionally enhanced byproduct;   system mixing apparatus for adding nutrients to the byproduct to produce an intermediate nutritionally enhanced byproduct; and   system adjusting apparatus for adjusting the temperature and/or the moisture content of the intermediate enhanced byproduct based on an empirically derived relationship that relates the UIP as a percent of the crude protein to an end product temperature in a predictable and repeatable manner to produce the final nutritionally enhanced byproduct having predicted nutrient parameters.