[Music] morning everyone I'm so grateful to have this chance to share my interest with you and what I see is an emerging the crop I undertook my my PhD 20 years ago looking at soya and it was a time where I feel that we were towards the end of a journey of evolution I was really focused on fine-tuning Sawyer and making the most subtle of changes in terms of how the meal was processed and where what I'm going to talk about today is an emerging raw material where we're right at the beginning of that journey so I'm going to talk about the role of bioethanol production in producing environmentally sustainable feed materials for our sector so I'll quickly talk about global bioethanol production look at their traditional and products that we can make and then look at how they can be enhanced look at some emerging and different products so sand distillers oil production bioethanol protein concentrates and how we can feed those to poultry and then wrap it up with a quick conclusion in terms of bioethanol production it's a bit of a misnomer really to talk about bioethanol production and it was described really well by rob a bank when they talked about the 4s this idea that we need to reduce food fuel fiber and feed the 4x and they were really trying to position it as bio refining taking a cereal crop and and drawing off all these high-value fractions from it no fraction can be overlooked nothing is a by-product nothing is waste everything must have value so the context of this this examination of bioethanol products is that the world bioethanol margins have really narrowed and bioethanol plants are really motivated to find the next technologies that can improve their their margins are existing co-product technology is sound we have been doing it since 1790 if anyone's been around a Scottish whiskey distillery roughly the same process and happening that's been going on for centuries but their emerging fuel versus food debate this this idea that it's not right to take landmass where we could be growing food for people that don't have food and using it for richer nations to be growing your crops so the food versus fuel debate is immense around first generation bioethanol and something that has to be addressed for it to move forward so and the big picture that I want you to take from this graph is the growth rate it's really growing very very fast once Barnell production took off in about 2000 the growth in plants was amazing and it really staggered around the world so growth is still really high in terms of plants opening in the USA and in China I think the number of plants being built at the moment is enormous whereas in Europe it's staggered a bit but it kind of ebbs and flows around the world but globally the number of plants and opening and our production levels are going up and up the most common feedstock at the moment is maize which is a reflection really of the number of plants in the USA but sugar potato wheats are also used globally so different feedstocks going in the recent sorry the recent commitments to eat an inclusion in transport fuel in countries such as UK China Mexico is really driving up demand for this product so I mentioned earlier on the food versus fuel debate in our first talk and positioned really well that the pressures that we face as ism as a generation of nutritionist now feeding poultry tooth to feed the world we're under massive pressure to make sure it's done in a sustainable way possible so at the moment we've got an bio ethanol that's being produced from food crops I think in future we will go towards nicknamed cellulosic so I feel like I'm offering an interim solution just till our European soya comes online and the reason that the first-generation bioethanol is using these servings cereal crops is is a challenge is because of the food versus fuel debate and also for competing demands for the feedstock going in so when we move over to lignocellulosic and the challenges there are the fact we have a slightly poorer yield and that we are using the residues from agriculture got different feed materials going in and we'll need a massive investment in technology we're a long way off having that and that's the form of the bio ethanol production really online it's an effective contributor to our global need for bio ethanol if you look at this slide here the message from it is look at how little and lignocellulosic is predicted to contribute over the next five years it's an almost vanishingly small contribution to our global bio ethanol and production so where we are at the moment is looking at generation 1.5 this idea that we try and address some of those needs that wrap a bank flag with the 4 s feed fuel food and fibre so we're trying to make the current first generation biofuel plants so they are using cereal crops going in but they're drawing out a lot more high-value feed stuffs before I talk about the streams that we're going to draw off and how we can fine tune them think we need to spend just a few minutes looking at how bio ethanol is made so we start off bringing in brain which is milled and then made into a matched by adding water this is a point where some enzymes are added in to help with liquefaction you get some a different set of enzymes coming in for safar cage and at this point the yeast is added so this is this is brewing or anyone that's interested in beer and here we are going through that big fermentation process this is where the yeast is growing it's not just producing us bioethanol when it ferments is massively increasing in volume that's really important point to remember when you're trying to do the maths about how much material going to end up where there's an enormous growth in that yeast that we put in and then we go through two distillation and then I'm not going to talk any more about the blue half because that's going down bioethanol what we're really interested in is the path of the co products so from that spent wash tank so this is a mixture everything everything that isn't bio ethanol goes into one enormous tank and the first stage that we have is the decanter so what happens here is all the fibrous material that kind of husky bits they tend to sit on top in it of this enormous and VAT that we've got and what they get decanter does is it cuts a top so it separates that all that stuff that's floating on the top de Kamp's it off and sends it down into the top stream there to make pressed cakes or press things getting with the last bit of water out of it and it's made into cake with the watery fraction the thin stage that goes into you evaporators now this is an absolutely key energy stage for the bioethanol pranced this is their least favorite bit of the process the energy that's going into evaporation is absolutely immense and with our sustainability hats on the idea of driving off all that water we and we know that water resources are going to be a key issue coming up for us and for the next generation so the idea of plowing energy in to drive off all this water it seems unthinkable now really there's a concept but that's what we do at the moment is also a massive bottleneck in the plant so it's a really really time and time and costly process as well so it's it's the most difficult part of the plant but what we end up with after that evaporation is a thick syrup which we then recombine so that two processes are separated we press out there the remaining water out of the fiber and we evaporate off the the watery fraction of the syrup and then we combine it the last little part of this diagram that I want to draw your attention to is that sneaky little arrow that's going back around the DDGS dryer box that's as much as I'm going to say really about the whole process of what happens when we go into that drying vessel what we don't have control of is how quickly it comes back out so the two streams are going in and at the moment that engineering is set up for how how dry is that product for it sent out to make an pellets and then and then cooled and sold is the dried distillers grains and solubles but what we don't know without with our poultry nutrition approach we don't know how long our material has been in there going around and being dried in there there's massive opportunity for burning so that that arrow of it potentially going round and round by an uncontrolled amount that's how a huge source of the variability that we see with DDGS today so the traditional product is dried distillers grains and solubles or distillers wet grains if you've got a system that will allow you to transport without a mold and vast amounts of wet materials if you see it's fairly limited market for distillers grains but dried grains can be transported more easily they're really widely used about ten percent of them end up in Russian to the poultry the rest of it tends to be going into you and cattle production the material here is really challenged in its variability so you've got different feedstocks going in different plants with different slightly different setups and different production and different drying processes so we end up with a really variable product the way we currently manage that variation is to put really conservative nutrient values around it when we then use it in our feed matrices so it's a very limited value at the moment is that our feed material so the first thing that I want to really go into is looking at those two product streams those things that we split and then we recombined so if we look at wheat itself it's got really quite good protein digestibility not very much protein there as there's a proportion of it not very much fiber and lots and lots of starch and then I think about the steps we've been through we've used all that starch to make bio ethanol so when we have the cake there's almost no starch left in it at all but really quite a lot of fiber by now and some protein and when we look at this stage which is that wet and the syrupy proportion we've got and very very high digestibility of proteins that allow our lovely yeasts that we've got in there and we've got really quite high protein content and very very little fiber so this is great there's a poultry feed what lovely stuff move fiber highly digestible protein what's not to like well I tell you what let's mix it back up again with all fiber and then we end up with DDGS so we've got these two separate products screened with with attributes that really attractive for two different markets it was nice fibrous material fairly decent protein that we can put into the cattle markets and we've got this highly digestible protein source and so split off except at the moment it's a very very watery so the traditional product is you combine two back again to make DDGS which has got a reasonably high protein content reasonable digestibility but mix that with a lot of fiber it is good stuff DDGS and there's a lot of work being done to make it better so it's a good source of protein it's got really quite high yeast protein content so it's around about 4% and we know about there's a lot of yeast products on the market we know there's wonderful health and got health attributes that we associate with yeast products and they're high in vitamins the challenge of our form of yeast is that the cell walls be really quite toughened by the alcohol that they've been being with so it's more it's more difficult to get those and those and sell more materials out for the bird to use it's also very high it's also very high in fiber and can be low in essential amino acid so limited amounts of lysine and I've talked quite a bit about that product variability challenge that we have another issue that sometimes pops up when we're talking about DDGS its flowability so when it's being bulk transported it has a tendency to separate out during transport and sometimes there's problems over the pallet quality when you've got DDGS in as part of your and ration that it affects the pallet quality of the final feed material there is some work that's being done to enhance EDG s so to make it into a better higher high quality product the really attractive thing for bioethanol plants about trying to make these streams better is it it's bolt-on technology you're not asking the the plants to actually break into the main system you're asking them to bolt something onto the end which is much more doable than interfering with the main systems that are set up it's not to lower capital costs to fit bolt on technology so something that's been looked at for DDGS is something called the Illusive process where you have a mixture of living and an elutriation column and to separate out a higher protein DDGS and it gives you a product that's about 41% protein and it separates off a hyper high fiber fraction the economic viability of this is good so it's been port is less than five years to pay back on the investment within the plant and when it's been fed and to to boilers that you end up with high metabolizable energy products and good body weight gain improved feed conversion ratio and breast meat yield is comparable to soil but other people have reported when they looked at enhanced DDGS products they've still reported some of those challenges that we associate with a high fiber product even when you've used a process to try and separate with that fiber off if you're not careful we still we still have more fiber than we want in a protein feed material for poultry something that's really emerged in the last five years in the US market it's drawing off the oil so into a product that's been called distillers corn oil about 85 percent of the u.s. plants are drawing this off now so they're extracting it from the DDGS and this is just a little health warning to anyone that's formulating with a lot of DDGS at the moment that product has probably changed unless it was evaluated recently so it's going to have a different energy value now because there's a different stream being being drawn off before you get to the the DDGS the end product of this oil it's structurally degraded so it's often used for biodiesel production but is a really good source of unsaturated fatty acids for poultry feed got about 50% linoleic acid and it's been reported to be to be able to maintain both yield and performance and it also improves pellet quality as well so I'm going to spend a few minutes now talking about and some new technologies that are around to try and separate off that protein fraction so we're not going to recombine it we're not going to go through the traditional process of recombining that cake with the the watery material going to look at other ways how did you get that water away from all that lovely yeast and all that lovely wheat or maize protein that we've got the sum of protein that we've got is a mixture of what comes from cereal metallic sauce I put wheat here we could be talking maize and all the yeast that's that's grown so there's a lot of it so that our decanter step has been used to remove as much of the fiber as possible I mean I've got a really least concentrated watery discharge there's a real push-pull here for bioethanol produces or offer for plant managers between how much of the yeast they're trying to recover so where they position their their cut for the getting rid of the fiber they're trying to keep as much of the protein and of the yeast as they can but the tension is between recovery as much as possible and then contaminating some of that with with by leaving too much fiber in so here's a couple of different decisions that have been made so on on your on your right you can see there's a seven and a half percent dry matter to cut so where they've left oh sorry yeah they've left in and really quite a lot of the fiber and you can see when we spin it down we can see what we've got here you can see those those two different fractions so sat on top there's about 4% fiber left in there and then down the bottom we've spun down all the proteins or the yeast proteins and then where there's been a more conservative cut done so they've got a 5% dry after product there's almost no fiber there at all so when we've got our our cuts that we've got rid of the fiber what we've left with is a product that's still only about five percent dry matter so our next decision is how we're going to deal water it there's currently two technologies that have been event invented to do this one is by a continuous discs that centrifugation process you've got those needed disks packed together their stuff is going through it I thought it's amazing lifes or it is like it's like you've got the qualities and the attributes and the Center for you to throwing out the higher and the heavier and letting the water drip through but it's it's it's continuous processes we're not talking about patches it's continuous throughput the second way of doing it it's using machine called the steady canter so this is a horizontal process see and you've got material passing passing through it and it's using a screw spin and that's and once again separating on the basis of weight so um it's throwing out the yeasts and all all the proteins what you end up with then it is a product looking a bit like that so we call it used to cream at this point it's and kind of sludgy stuff and it's about 38 percent dry matter at this point so really a lot of our water has been covered and it can go off and be remediated and put back into the plants and we don't need to evaporate it which is great but there is still Sun there's still a fair amount of water that we need to get rid of now this was talked about in last hope when we're talking about rape how you dry your material or in that case how you recover your hexane we're talking about solvent and solvent removal of the oil there how you how you heat it is absolutely key to the product that you end up with so there are a few options available for this material one is that you spray don't it's a very very expensive option and and well three strikes the most expensive option so spray drying this an intermediate option but you end up a very fine particle size really the only viable option for bioethanol plants is Ving drying so you've got nice material with spray drying or freeze drying but if we're talking about trying to get a product into the market that's coming out to us as poultry feeders at a reasonable value is going to have to be ring dried material and that's the most challenging way of drying it's really really easy to it all the data that I'm sharing with you now is pilot data so it's stuff that we've done in our labs and things where material from pilot plants has been coming to us from around the world we will get better at making this material what I'm sharing with you today are the early steps so whilst we're always comparing to Sawyer as the gold standard we have spent 50 years making Sawyer just the way we want it so we're going to use that as a gold standard and I'm talking in more general terms here about where the pitfalls are where we need to get things better so and over the next few slides I don't think you're going to be taking snaps off of my slides and popping it into matrix tomorrow but it's giving you an idea where the possibilities are and what we need to do I think we need to start a conversation with the bio ethanol plants about what we want so the idea of today is to really get you thinking about where the possibilities are with this product so here's a little bit of our data looking at coefficient of lysine digestibility and you'll see it's pilot data because as ever it wasn't particularly well controlled we got what we could when we could so some of the materials that we've got down the bottom are from from different sources but it shows you how what a mess you can make of drying it so we were asked to evaluate that ring dried Sawyer sorry that ring dried and protein concentrate and it was so obviously you burned sure you want us to evaluate this is going to get such a bad press to your product and we're not we're not talking about the the original materials exactly the point that Anna was making you have to look at the profile of the thing that you grow in her case and in my case it's the yeast cream but what you then do to it and how you treat it enormously affects the end product so when we evaluated that batch of ring dried bioethanol protein concentrate it was enormous ly damaged by the drying process but nevertheless this is an example of some data that we've got we fed it through the birds so we did an amino acid digestibility study today 21 this is some freeze-dried material what we've got here is we used a soybean meal as our our gold standard comparator and we actually were given a source of potable material so possible means drinking bio ethanol so this is a material that had come in not from bio ethanol production but from whiskey production very likely and we've got and this was amazed based product so yam perhaps not whiskey but house and drinking earth not for the food sector and and we've also got about the bio ethanol product that was wheat based and we compared this to some work that was done and by widowed acne and cheesy straw in 2007 and they compared wheat itself to DDGS and the message here is that we're getting a product that is more akin to soya so very very different it's nothing like DDGS is a product we really feel we are producing a viable protein source right this second now we don't know how to dry it and it's too expensive but we are we are in this we're in the same ballpark as soya not the same ballpark as the current DDGS so in terms of performance and we've got some some data here firms and broilers up to 14 days it was very early stages a very little material to work with so very very short bird trials and what we showed you is that if you were placing so the P is where we were using a potable alcohol so drinking alcohol product again and where we put it in at graded inclusion levels to replace sources three six or nine percent of the total diet what we found is that no levels actually quite considerably improved feed conversion ratios and when you put it integrated levels it was taking it back up towards where Sawyer was but I find it very interesting that in both the potable and the the bioethanol products they it was it was improving FCR so we ran another study one of the challenges with with this and use yeast protein concentrate is that even when you use ring drying you end up with a very very fine product so palatability is not is not great in in mash format but once you pellet it you you overcome that so it becomes an ax form at this and um not such a problem to enough experience to boilers or turkeys so this is some ring dried material that we ran in a performance study to up to 22 days so we were wanted to gain the placings soya this time we just quickly checked the the per quality and we found that there were were no issues in terms of the final product so now that it's a much like lower fiber product we don't have those challenges that we we saw in the past with DDGS in terms of final product quality and we also found that there was an improvement in FCR once again so all this work was done by white dogs Coley doing her PhD and a couple of other things that she began to look at towards the end were answering other questions question that popped up will me said B what we were talking about using a product coming out of bioethanol production were that having that much yeast in could cause problems with gout rate of problems with too much uric acid and she did a quick study so she looked at blood and urea nitrogen levels and uric acid levels in the blood and she showed there was no effect at all and that was just miss myth-busting really I think there's such different metabolic processes for birds compared to mammals that there was really no issue and on that front with this product something else that she looked at was she looked at digestible phosphorus a real quick and dirty she just looked at the feet of some birds because they were quite young birds he made quite a neat measure of degree of mineralization and what she found wizard where you've gotten a 17% seventeen and a half percent inclusion level of the use protein concentrate that it could actually be used to replace and not 0.5% of the monocalcium phosphate in the dark with no effect so it's worth it's worth it's quite a rounded product and I think when we when if we start to incorporate it into diets that they all be and there'll be other areas of the matrix where it's able to make a contribution so in terms of what next there's no doubt that bioethanol producers are leveraging co-product value against fluctuations and bioethanol market price it was really interesting an interview with with someone from Bloomberg a few months ago and who stated that he didn't see the future of the bio ethanol plants being in the the bio ethanol itself he said it's protein where you will get value from bio ethanol plants is in producing protein for animal feed so and it really is beginning to take off now if you've got sixty billion and liters of annual production that would give you three million tons of this material so we're talking about really quite a lot of material coming onto the market I think I'm I did a quick straw poll this morning I think global production now is about a hundred billion liters so there's there's a lot of this material what we need to do is focus on product quality and I think we need to work with the bio ethanol plants to tell them what we want now is the moment to devise some standards for them so we've got them trained on soil we've trained them that we don't want their trypsin inhibitor activity value of over four we've trained them on you--yes index scores so we know they've burnt the soil for us we need to give them some goalposts to shoot through so we need to be able perhaps maximum fiber level and and digestible lysine levels we need to give them something that tells them that they've got a product that we want I don't think we are so this is a just something that came up in 2013 it was a headline chicken to benefit from biofuels bonanza it didn't really take off as we thought it might at that time I think the tide is changing we're going to end up with a lot of this material so to conclude I think by approach by on our protein concentrate it's its material its potential and for fish and pigs as well as poultry at the moment it's an inconsistent product that we need to sort out because drying is such a challenge there's new streams coming out all the time so there's corn Oscar popped up really really quickly it's a product we might be able to leverage some phosphorous value from from this material and that production volume is really likely to grow but we really do need some benchmarks so thank you very much indeed for listening I'd also like to take this opportunity to thank Don Scala very stylish and she can't be and can't be here at the conference and this time but she put an enormous amount of work not only into generating all this data but she actually produced a really good set of slides for me as well and was so my team at home so thank you very much [Applause]