Progress Report

PROJECT TITLE: Food Grade DDGfor Human Consumption - Value Enhancement of a Corn Co-Product

PROJECT NUMBER:

REPORTING PERIOD: April 30, 2018

PRINCIPAL INVESTIGATOR: Padu Krishnan

ORGANIZATION: South Dakota State University

PHONE NUMBER: 574-440-9215

EMAIL:

1.) PROJECT ACTIVITIES COMPLETED DURING THE REPORTING PERIOD. (Describe project progress specific to goals, objectives, and deliverables identified in the project workplan).

  1. Scale-up. Kilogram scale amounts of food grade FDDG can be processed in-house in a matter of a few days to a week. Processing steps have been optimized to ensure consistency of the final FDDG as defined by color, Water Activity and Moisture content.
  2. A Specification Sheet on a food grade DDG was developed that defines targets for quality in food applications and the range of occurrence of nutritional composition.
  3. Shipment to Taiwan. Eight kilograms of FDDG samples shipped to an overseas potential end user.
  4. Responded to food industry inquiries about food applications. I provided information about FDDG to senior research officials in a food ingredient company (MGP Ingredients) and an enzyme manufacturer (Novozymes).
  5. New products made with DDG. A High Energy Biscuit (HEB) for international food relief programs was developed and comparisons were made with commercial and world food agency food supplements. An abstract is provided in the appendix.
  6. Progress on toxicology. Effects of production processes on the stability and mass balance of known toxicants are being studied in several DDG matrices.
  7. GRAS Status Application. Conversations with Exponent (FDA GRAS status application). I am receiving professional assistance in formulating an application to the FDA.

2.) IDENTIFY ANY SIGNIFICANT FINDINGS AND RESULTS OF THE PROJECT TO DATE.

Figure 1. Wheat based High Energy Biscuits fortified with FDDG for International Emergency Feeding Programs.Photo on left: Control wheat HEB. Photo on right, 25% DDG HEB (top left), 25% Chickpea HEB (top right) and 50% DDG HEB (bottom).

Table 1. Nutritional composition specifications for biscuits designed for use as food supplementsby world food and health agencies (100g serving size).

Agency / Energy/kcal / Protein / Fat / Sugar / fiber / Moisture / Minerals / Ca / Mg / Fe / I / Reference
World Food Program / 400 kcal / 9g / 15g / 10-19g / 2.3g / 4.5% / 3.5g / 250mg / 150mg / 11mg / 75μg / World Food Program (WFP) website
Handbook
USDAI / 462.2 kcal / 10g / 12g / 10-19g / 2.3g / 4.5% / 3.5g / 250mg / 150mg / 11mg / 75μg / USDA website
Handbook
UNICEF / 450 kcal / 10-15g / 15g / 10-15g / 2.3g / 4.5% / 3.5g / 212.5-287.5mg / 127.5-172.5mg / 9.35-12.65 mg / 63.75
-86.25μg / UNICEF website
Handbook

All values are basedon a 100g serving size.

Table 2. Comparison of nutrient composition of commercial High Energy Biscuits (HEB).

Biscuit / Energy/kcal / Protein / Fat / CHO / TDF / Moisture / Reference
DX3600F
18 servings per packet / 200 / 3g/7% / 9gm/23% / 26g/65% / 2g / 3.68%* / Product label
(AIOL)
Mainstay3600
9 servings per container / 400 / 3g / 23g/36% / 46g/15% / 2g / 5.69%* / Product label
(AIOL)
ER bar
9 servings per container / 410 / 7g / 19g/29% / 52g/17% / 2g / 8.25%* / Product label
(AIOL)
SOS Bar
9 servings per container / 410 / 8g/16% / 18g/28% / 53g/18% / 1g / 4.2% / Product label
(AIOL)

Table 3. Nutritional composition of SDSU experimental HEB formulated with All Purpose flour (APF), Chickpea (CP) and Food grade DDG FDDG.

SDSU HEB / Moisture% / Protein% / Fat% / Ash% / TDF% / CHOg / Sugar(g) / Kcal
Control APF / 7.52a / 6.12e / 4.4e / 1.14e / 3.2e / 77.62%a / 28 / 381
75APF-25CP / 5.51b / 8.19d / 6.6d / 1.5d / 4.9d / 73.3%b / 21 / 395
75APF-25D / 5.18b / 11.12c / 9.2c / 1.96c / 6.8c / 65.74%c / 21 / 404
50APF-50CP / 4.62c / 13.42b / 12.43b / 2.47b / 8.9b / 58.16%d / 14 / 416
50APF-50D / 4.36c / 16.6a / 15.38a / 2.93a / 12.6a / 48.13%e / 14 / 423

APF=All-purpose flour, CP=Chickpea flour and D= Food grade DDG.

Table 4. Sensory evaluation of High Energy Biscuits prepared with wheat, Chickpea flour and Food Grade DDG.

High Energy Biscuits / Color / Aroma / Taste / Texture / Overall
Control APF / 4.39a / 4.36a / 4.39a / 4.22a / 4.34a
75APF-25CP / 4.12a / 3.72b / 3.78b / 4.00a / 4.00a
75APF-25FDDG / 3.87b / 4.28a / 4.28a / 4.08a / 4.18a
50APF-50CP / 4.08a / 3.66b / 3.54c / 4.18a / 3.86b
50APF-50FDDG / 3.78b / 4.18a / 3.87b / 4.12a / 4.12a

APF=All-purpose flour, C=Chickpea flour and FDDG=Food grade DDG.

3.) CHALLENGES ENCOUNTERED. (Describe any challenges that you encountered related to project progress specific to goals, objectives, and deliverables identified in the project workplan.)

Progress is developing on several fronts. We now have access to a supply of DDG without Solubles. In the past, DDGS received from the ethanol plants needed exhaustive washing that consumed considerable volume of solvents.

4.) FINANCIAL INFORMATION (Describe any budget challenges and provide specific reasons for deviations from the projected project spending.)

A No Cost Extension was requested for this project for a period of 6 months. Year 3 will end on Sept 30, 2017. This extension will permit key projects associated with GRAS status application and Toxicology investigations to be completed. The latter studies are done by external parties using products processed by the PI.

5.) EDUCATION AND OUTREACH ACTIVITES. (Describe any conferences, workshops, field days, etc., attended, number of contacts at each event, and/or publications developed to disseminate project results.)

Research publications relating to the use of FDDG in Chinese Steamed Bread and Glycemic response of human subjects consuming FDDG were presented to scientific journals and food technology conferences. A Specification Sheet for Food Grade DDG was developed for product information. This Spec Sheet will accompany shipments of FDDG to provide information about nutritional composition and physical and chemical characteristics that define functionality of FDDG as a food ingredient.

Appendix

Development and optimization of High Energy Biscuits containing high protein ingredients (Chickpea and Food Grade Distillers Grains) for international food relief programs

Abstract: High Energy Biscuits (HEB) are emergency food relief supplements used by humanitarian agencies (WHO, USDAI, UNICEF,etc.) in international emergency food intervention. A wide variety of ingredients are used in HEB including, wheat, corn, soy, milk,peanuts, coconut, etc. Our research explored two high protein- high fiber ingredients, namely, chickpea and distillers dried grains,as they contribute to nutrients with good taste potential. Typically, HEB provided 400-450 Kcals per 100g serving, 3 to 8g protein, 26 to 53g carbohydrates, 9 to 23g fat based on several commercially available HEB. Wheat based HEB fortified with chickpea flour (25% and 50%) and FDDG (25% and 50%) were developed to improve taste, fiber and protein content. FDDG reflects a high protein (38%) and high fiber ingredient (43%TDF) that could be used to enhance nutritive values of emergency relief foods. Chickpea flour had a protein content of 22.3% and a TDF content of (21%). All-purpose flour had a protein and TDF content of 11.9% and 5.24%, respectively. All substitutions were based on replacement of a percentage of all-purpose flour, brown sugar and oil contents in the recipe. Chemical, physical, and sensory evaluations were conducted to determine the efficacy of the fortification. Moisture content of control, CP and FDDG HEB ranged from 4.3 to 7.52% and was sufficiently low for extended shelf life. Increases were noted in protein content in the 4 treatments in contrast to the control all-wheat HEB made with APF. Caloric content CP HEB and FDDG HEB were significantly higher than control HEB. All other nutrients, except for carbohydrates, showed statistically significant increases over the control. A sensory panel (N=50) evaluating all treatments showed FDDG and Chickpea fortified HEB to be acceptable in comparison to the control wheat HEB. HEB containing 25% FDDG holds potential for meeting specifications for High Energy Biscuits used in international emergency feeding programs.