Feed product and method of making

Abstract

Various aspects disclosed relate to a feed product including less than 25 wt% crude protein; less than 10 wt% starch; greater than 7 wt% glycerin; and greater than 35 wt% neutral detergent fiber.

Description

[0001] FEED PRODUCT AND METHOD OF MAKING CROSS-REFERENCE TO RELATED APPLICATION [1] This application claims the benefit of priority to U.S. Provisional Patent Application Serial No. 63 / 466,974 entitled “FEED PRODUCT AND METHOD OF MAKING,” filed May 16, 2023, the disclosure of which is incorporated herein in its entirety by reference. BACKGROUND [2] As the global human population rises, the demand for animal products also grows. Meeting this demand requires raising increasingly more animals while maximizing utilization of limited resources. These conditions make it desirable to produce an animal feed product that provides adequate nutrition and lower carbon intensity. SUMMARY OF THE INVENTION [3] Various aspects disclosed relate to a feed product including less than 25 wt% protein; less than 10 wt% starch; greater than 7 wt% glycerin; and greater than 35 wt% neutral detergent fiber. [4] Various aspects relate to a method of making a feed product, the method includes dry milling an agriculturally derived grain. The method further includes liquifying the dry milled agriculturally derived grain. The method further includes removing a bran from the liquified dry milled agriculturally derived grain. The method further includes the separate steps fermenting the liquefied dry milled agriculturally derived grain having the bran removed therefrom and optionally drying the removed bran. [5] Various aspects relate to a method of forming a feed product. The feed product includes dry milling an agriculturally derived grain. The method further includes liquifying the dry milled agriculturally derived grain. The method further includes removing a bran from the liquified dry milled agriculturally derived grain. The method further includes the separate steps of fermenting the liquefied dry milled agriculturally derived grain having the bran removed therefrom and optionally drying the removed bran. The feed product includes less than 25 wt% protein; less than 10 wt% starch; greater than 7 wt% glycerin; and greater than 35 wt% neutral detergent fiber. [6] Various aspects relate to a yeast enhanced feed product formed from a reaction mixture. The reaction mixture includes an enhanced protein flour produced from an ethanol fermentation reaction and an enhanced protein and yeast mixture combined to form a yeast enhanced feed. The yeast enhanced feed includes about 40 wt% to about 60 wt% crude protein; and greater than about 1.8 wt% lysine. The product comprises at least 50 wt% protein. [7] Various aspects relate to a feed product formed from a reaction mixture. The reaction mixture includes a syrup and a lignocellulose composition comprising bran from the liquified dry milled agriculturally derived grains, bran from other agriculturally derived grains, rice hulls, soy hulls, cottonseed hulls, nut hulls, bagasse, beet pulp, wheat middlings, or combinations thereof. The syrup includes about 2 wt% to about 6 wt% potassium, about 0.5 wt% to about 5 wt% phosphorous, about 0.3 wt% to about 3 wt% magnesium, about 20 wt% to about 40 wt% water; and greater than about 20 wt% glycerol. The lignocellulose composition includes about 16 wt% to about 26 wt% crude protein, about 40 wt% to about 70 wt% neutral detergent fiber, about 3 wt% to about 15 wt% crude fat, and about 1 wt% to about 7 wt% starch. The feed product may then be densified by various methods. BRIEF DESCRIPTION OF THE DRAWINGS [8] The drawings illustrate generally, by way of example, but not by way of limitation, various aspects of the present invention. [9] FIG. 1 is a flow diagram depicting a method of making a feed product. DETAILED DESCRIPTION OF THE INVENTION

[0010] Reference will now be made in detail to certain aspects of the disclosed subject matter, examples of which are illustrated in part in the accompanying drawings. While the disclosed subject matter will be described in conjunction with the enumerated claims, it will be understood that the exemplified subject matter is not intended to limit the claims to the disclosed subject matter.

[0011] Throughout this document, values expressed in a range format should be interpreted in a flexible manner to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. For example, a range of “about 0.1% to about 5%” or “about 0.1% to 5%” should be interpreted to include not just about 0.1% to about 5%, but also the individual values (e.g., 1%, 2%, 3%, and 4%) and the sub-ranges (e.g., 0.1% to 0.5%, 1.1% to 2.2%, 3.3% to 4.4%) within the indicated range. The statement “about X to Y” has the same meaning as “about X to about Y,” unless indicated otherwise. Likewise, the statement “about X, Y, or about Z” has the same meaning as “about X, about Y, or about Z,” unless indicated otherwise.

[0012] In this document, the terms “a,” “an,” or “the” are used to include one or more than one unless the context clearly dictates otherwise. The term “or” is used to refer to a nonexclusive “or” unless otherwise indicated. The statement “at least one of A and B” or “at least one of A or B” has the same meaning as “A, B, or A and B.” In addition, it is to be understood that the phraseology or terminology employed herein, and not otherwise defined, is for the purpose of description only and not of limitation. Any use of section headings is intended to aid reading of the document and is not to be interpreted as limiting; information that is relevant to a section heading may occur within or outside of that particular section.

[0013] In the methods described herein, the acts can be carried out in any order without departing from the principles of the invention, except when a temporal or operational sequence is explicitly recited. Furthermore, specified acts can be carried out concurrently unless explicit claim language recites that they be carried out separately. For example, a claimed act of doing X and a claimed act of doing Y can be conducted simultaneously within a single operation, and the resulting process will fall within the literal scope of the claimed process.

[0014] The term “about” as used herein can allow for a degree of variability in a value or range, for example, within 10%, within 5%, or within 1% of a stated value or of a stated limit of a range, and includes the exact stated value or range. The term “substantially” as used herein refers to a majority of, or mostly, as in at least about 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.9%, 99.99%, or at least about 99.999% or more, or 100%.

[0015] The term “substantially free of” as used herein can mean having none or having a trivial amount of, such that the amount of material present does not affect the material properties of the composition including the material, such that about 0 wt% to about 5 wt% of the composition is the material, or about 0 wt% to about 1 wt%, or about 5 wt% or less, or less than or equal to about 4.5 wt%, 4, 3.5, 3, 2.5, 2, 1.5, 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, 0.1, 0.01, or about 0.001 wt% or less, or about 0 wt%.

[0016] All compositional percentages described herein this document are reported on a dry matter basis unless otherwise specified.

[0017] Various aspects according to the present disclosure relate to a feed product. The feed product can be provided in the form of a pellet. The feed product includes protein, starch, glycerin and a neutral detergent fiber. The protein is present in an amount equal to or less than 25 wt% of the product. For example, the protein can be present in a range of from about 15 wt% to about 25 wt% of the product, about 17 wt% to about 20 wt, less than, equal to, or greater than about 15 wt%, 16, 17, 18, 19, 20, 21, 22, 23, 24, or about 25 wt%. The starch can be present in an amount equal to or greater than 10 wt% of the product. For example, the starch can be present in a range of about 10 wt% to about 30 wt% of the product, about 15 wt% to about 25 wt%, less than, equal to, or greater than about, 10 wt%, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, or about 30 wt%. The glycerin can be present in an amount equal to or greater than 7 wt% of the product. For example, the glycerin can be present in a range of 7 wt% to 20 wt% of the product, about 10 wt% to about 15 wt%, less than, equal to, or greater than about 7 wt%, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or about 20 wt%. The neutral detergent fiber can be present in an amount equal to or greater than 35 wt% of the product. For example, the neutral detergent fiber can be present in an amount in a range of from about 35 wt% to about 70 wt% of the product, about 45 wt% to about 55 wt%, less than, equal to, or greater than about 39 wt%, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, or about 70 wt%.

[0018] The feed product can be formed according as a part of a fermentation method. FIG. 1 is a flow diagram showing process 100, which can be used to form the above described product with is designated by reference number 136 in FIG. 1. In process 100, agriculturally derived grain 102 is milled at miller 104. The agriculturally derived grain can be any suitable grain such as a sorghum grain, a wheat grain, a barley grain, a rice grain, a maize grain, or a mixture thereof. In a specific aspect, the agriculturally derived grain is a maize grain. In certain aspects, miller 104 is a roller mill, hammer mill, or other type of mill. The milled agriculturally derived grain 102 is liquified by passing through slurry tank 106 and liquification tank 108. In slurry tank 106 the grain is mixed with enzymes (e.g., alpha amylase) and a liquid to produce the slurry. The slurry includes oil, protein, starch, fibers, germ, and grit particles.

[0019] The slurry is further liquefied at liquification tank 108 for example by mixing and additional retention time as well as possibly adding additional enzymes (e.g., alpha amylase) to the slurry. The liquified grain is then separated into a solids portion including the fiber, grit, and germ particles of the slurry, and a liquid portion, including the oil, protein, and starch of the slurry. The solids portion is then milled further in apparatus 110 to reduce the size of the fiber, grit, and germ particles and release starch, oil, and protein therefrom. Milling to an optimized or at least controlled size makes it easier to separate the bran in separator 112. Additionally, the milling allows for the optimal capacity and throughput of the bran. After the bran is removed in separator 112, removed lignocellulose composition represented by bran composition 130 is formed. As non-limiting examples the removed lignocellulose composition may be bran from other agriculturally derived grain, rice hulls, soy hulls, cottonseed hulls, nut hulls, bagasse, beet pulp, wheat middlings, or combinations thereof. Separator 112 is a rotary press, a belt press, a screener, or a paddle screener. The separator 112 is able to dewater the bran such that removed bran composition includes about 35 wt% to about 50 wt% solids, about 40 wt% to about 41 wt% solids, less than, equal to, or greater than about 35 wt%, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, or about 50 wt% solids, which subsequently reduces the load on dryers 132. Removed bran composition 130 includes about 50 wt% to about 98 wt% of the neutral detergent fiber from grain 102, about 85 wt% to about 95 wt%, less than, equal to, or greater than about 50 wt%, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, or about 98 wt%. Removed bran composition 130 is not fed into fermenter 114. Thus, the portion fed into fermenter 114 has an extremely low fiber content.

[0020] The non-separated portion is a fermentation feedstock, which is fed into fermenter 114. Removed bran composition 130 includes protein, neutral detergent fiber, crude fat, and starch. The crude protein can range from about 16 wt% to about 26 wt% of composition 130, about 18 wt% to about 23 wt%, less than, equal to, or greater than about 16 wt%, 17, 18, 19, 20, 21, 22, 23, 24, 25, or 26 wt%. The neutral detergent fiber can range from about 35 wt% to about 45 wt% of composition 130, about 40 wt% to about 42 wt%, less than, equal to, or greater than about 35 wt%, 36, 37, 38, 39, 40, 41, 42, 43, 44, or about 45 wt%. The crude fat can range from about 3 wt% to about 15 wt% of composition 130, about 5 wt% to about 10 wt%, less than, equal to, or greater than about 3 wt%, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or about 15 wt%. The starch can range from about 1 wt% to about 7 wt% of composition 130, about 3 wt% to about 5 wt%, less than, equal to, or greater than about 1 wt%, 2, 3, 4, 5, 6, or about 7 wt%. Removed bran composition 130 then may be dried at dryers 132.

[0021] The fermentation feedstock is processed and sent to distiller 116. The fermentation process can be a simultaneous saccharification and fermentation step. This simultaneous step is referred to in the industry as “Simultaneous Saccharification and Fermentation” (SSF). In some commercial dry grind ethanol processes, saccharification and fermentation occur separately. Both individual saccharification and SSF can take as long as about 50 to 80 hours. Fermentation converts the sugar to alcohol. The distillate formed at distiller 116 is sent to dehydrator 118 to form ethanol 120. A slurry portion of the product formed at distiller 116 is sent to centrifuge 122. Centrifuge 122 is a large scale centrifuge that dewaters protein product 126 coming from distiller 116. Centrifuge 122 is able to dewater protein product 126 such that protein product 126 ranges from about 35 wt% to about 50 wt% solids, about 43 wt% to about 47 wt%, less than, equal to, or greater than about 35 wt%, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, or about 50 wt%. Protein product 126 can be considered an enhanced protein flour and includes about 40 wt% to about 65 wt% crude protein, about 45 wt% crude protein to about 57 wt% crude protein, less than, equal to, or greater than about 40 wt%, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, or about 60 wt%. Protein product 126 includes equal to or greater than 1.8 wt% lysine. For example, the lysine can range from about 1.8 wt% to about 5 wt% of protein product 126, about 1.8 wt% to about 2 wt%, less than, equal to, or greater than about 1.8 wt%, 1.9, 2, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, or about 5 wt%. Protein product 126 is further processed, for example by rehydration and centrifugation. Protein product 126 then may be fed into dryers 132.

[0022] The liquids portion of the product from centrifuge 122 is sent to separation device 124. The liquids portion includes yeast from the fermentation process. Separation device 124 is able to remove a high degree of solids from the liquid portion and also allowing for more efficient subsequent downstream evaporation due to reduced presence of suspended solids. The resulting product is enhanced protein and yeast mixture 128, which includes about 35 wt% to about 60 wt% crude protein, about 45 wt% crude protein to about 57 wt% crude protein, less than, equal to, or greater than about 35 wt%, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, or about 60 wt%. Mixture 128 includes equal to or greater than 1.8 wt% lysine. For example the lysine can range from about 1.8 wt% to about 10 wt% of mixture 128, about 4 wt% to about 6 wt%, less than, equal to, or greater than about 1.8 wt%, 1.9, 2, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, 6, 6.1, 6.2, 6.3, 6.4, 6.5, 6.6, 6.7, 6.8, 6.9, 7, 7.1, 7.2, 7.3, 7.4, 7.5, 7.6, 7.7, 7.8, 7.9, 8, 8.1, 8.2, 8.3, 8.4, 8.5, 8.6, 8.7, 8.8, 8.9, 9, 9.1, 9.2, 9.3, 9.4, 9.5, 9.6, 9.7, 9.8, 9.9, or about 10 wt%. Mixture 128 then may be fed into dryers 132.

[0023] Liquids that are present following exposure to separation device 124 are sent to evaporation process 138. Evaporation process can include components such as evaporators, tanks, piping, and centrifuges. Evaporation process 138 produces two products. One product produced during the process is distillers corn oil 140. The other product produced is syrup 142. Syrup 142 has a very low water concentration in a range of from about 20 wt% to about 60 wt% water, about 40 wt% to about 60 wt%, less than, equal to, or greater than about 20 wt%, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, or about 60 wt% water. Syrup 142 also includes potassium, phosphorous, magnesium, and glycerol. The potassium can range from about 2 wt% to about 6 wt% of syrup 142, about 3 wt% to about 5 wt%, less than equal to, or greater than about 2 wt%, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, 5, 5.1, 5.2, 5.3, 5.4, 5.5, 5.6, 5.7, 5.8, 5.9, or about 6 wt%. Phosphorus can range from about 0.5 wt% to about 5 wt% of syrup 142, about 1 wt% to about 4 wt%, less than, equal to, or greater than about 0.5 wt%, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, or about 5 wt%. Magnesium can range from about 0.3 wt% to about 3 wt% of syrup 142, about 0.5 wt% to about 2 wt%, less than, equal to, or greater than about 0.3 wt%, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, or about 3 wt%. The glycerol can be equal to or greater than about 20 wt% of syrup 142. For example, the glycerol can range from about 20 wt% to about 60 wt% of syrup 142, about 30 wt% to about 50 wt%, less than, equal to, or greater than about 20 wt%, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, or about 60 wt%.

[0024] The various products formed in process 100 can be useful on their own. Additionally various products can be combined to form products such as product 136 or product 134. For example, product 136 is formed from combining composition 130 with syrup 142. In some examples, product 136 may dried. In examples where product 136 is dried, the drying can be complete or product 136 may be partially dried. Owing to the low moisture content, a pellet can be formed from the combination for composition 130 and syrup 142. The pellet may be formed by various techniques including using a vertical or horizontal pellet mill or an extruder or similar device capable of compressing the material to a sufficiently high bulk density. Highest quality densified pellets are made using hot (about 88 °C) feed directly off a dryer as opposed to reheating it with a steam injection / conditioner as one skilled in the art would typically do. Similarly, milling of the composition that is the subject of this invention is best accomplished with overdried material to improve the brittleness of the feed entering the mill. In some cases a pelleting aid can be included. The pelleting aid can include zeolite, yucca schidigera extract, a silicate, calcium, biochar, diatomaceous earth, demulsifier, emulsifier, xanthan gum, guar gum, or a mixture thereof. Product 136 can also be densified by various other techniques such as milling using a hammer mill, roller mill, disc mill, or other type of mill. Densification of product 136 allows for more product to be placed in a shipping container, reducing shipping cost and carbon intensity of transportation. Densification methods may additionally improve the livestock feeding performance of the product. Additionally, protein product 126 and mixture 128 can be combined to a form yeast enhanced feed 134. Yeast enhanced feed 134 can include 40 wt% to 60 wt% yeast, 45 wt% to 55 wt%, less than, equal to, or greater than about 40 wt%, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, or about 60 wt%.

[0025] Product 136 is desirable as it can provide high energy for cattle and other ruminants, which can lower the carbon intensity required to produce livestock offspring, consumable meat, or milk. Product 136 also shows digestibility in excess of 65% as measured by a neutral detergent fiber digestibility assay at 48 hours. Neutral Detergent Fiber (NDF) is the residue or insoluble fraction left after boiling a feed sample in neutral detergent solution. The NDF contains plant cell wall components except for some pectins. The NDF is considered a close estimate of the total fiber constituents of feedstuffs since it measures cellulose, hemicellulose, lignin, silica, tannins and cutins. The hemicellulose, cellulose and lignin represent the fibrous bulk of the forage. Because they give the plant rigidity and enable it to support itself as it grows, these three components are classified as structural carbohydrates. Though lignin is indigestible, hemicellulose and cellulose can be (in varying degrees) digested by microorganisms in animals with either a rumen (e.g., cattle, goats or sheep) or hind-gut fermentation (e.g., horses, rabbits, guinea pigs) as part of their digestive tract. NDF concentration is negatively correlated with dry matter intake (i.e., as NDF in the forage increases, animals will consume less forage). As a result, NDF is often used in formulas to predict the dry matter intake. Neutral Detergent Fiber Digestibility (NDFD) NDFD is a useful measurement for comparing the digestibility of fibers at a fixed interval (typically 30 or 48hrs) Examples

[0026] Various aspects of the present invention can be better understood by reference to the following Examples which are offered by way of illustration. The present invention is not limited to the Examples given herein.

[0027] The properties of Feed Product 1 are described for regulatory purposes as a blend that is the dried combination of corn bran and corn condensed distillers solubles. More specifically, Feed Product 1 includes about 18 wt% to about 22 wt% crude protein; about 2 wt% to about 6 wt% starch; about 6 wt% to about 8 wt% crude fat; and about 35 wt% to about 39 wt% neutral detergent fiber.

[0028] Although data exist in the scientific literature for animal performance of each of these ingredients fed separately, no previous reference or combination of references describe feeding a blend which balances outputs of said ingredients from a dry-grind, cereal grain fuel ethanol plant using this technological combination.

[0029] To evaluate the properties of Feed Product 1, a nine-week field lactation trial was conducted at a commercial dairy farm in the panhandle region of Texas. The objective was determination of the biological and economic efficacy of Feed Product 1 as a ration ingredient. Variables evaluated were dry matter intake (DMI), energy-corrected milk production (ECM), and the feed efficiency of milk production. Holstein-cross cows were stratified by lactational parity and days in milk; only cows in their midlactational period (pens on treatment ration with minimum=624, maximum=645 and five pens on control ration with minimum=1,900 and maximum=1,923) were utilized in the trial. The number of cows varied in each pen due to normal movement of animals due to days in milk (mean= 156 days for cows in the comparison during the trial).

[0002] Table 1 . Rations fed to Holstein-cross dairy cattle.

[0030] Trial rations were formulated to meet or exceed the daily nutrient requirements of a cow consuming 23.6 kg of dry matter and producing 41 kg of energy-corrected milk (NASEM, 2022). Premix was utilized to balance supplemental lysine, methionine, minerals, and vitamins required.

[0031] The formulation strategy applied was adjustment of as few ingredients as possible for the cows fed Feed Product 1 (Table 1), while at once holding all nutrient parameters as close to constant against the control as possible (Table 2). This strategy differs from one where ingredients are exchanged fully on an equal dry matter basis. Said differently, commercial dairy operations tend to value nutrients, not ingredients, and do so in a manner which minimizes feed cost. It should be noted that commercial dairies make weekly ration adjustments due to variability of availability, nutrient concentration, and price of ingredients. Therefore, this type of investigation is sound. Table 2. Formulated nutrient analysis of trial rations.

[0003] Table 3. Analyzed composition of Feed Product 1 fed in the dairy trial (dry matter basis unless otherwise noted) Nutrient Moisture, % 10.2 Metabolizable Energy, Mcal / kg 2.6 Net Energy for Lactation, Mcal / kg 0.8 Crude Protein (CP), % 21.9 Water Soluble Protein, % of CP 34.4 Lysine, % 0.7 Neutral Detergent Fiber (NDF), % of OM 35.9 Acid Detergent Fiber, % 18.8 Crude Fat, % 9.6 Linoleic Acid, % 4.8 Starch, % 1.4 Mono and Disaccharides, % 0.1 uNDF240* 4.5 *Defined by Combs et al. as NDF% that is ruminally indigestible after 240 hours of fermentation

[0032] Feed Product 1 prototype was produced in a single campaign at a commercial ethanol plant and shipped to the dairy prior to the inception of the trial. Nutrient analysis of the test material is shown in Table 3. All other ingredients for feed manufacturing were utilized as per normal operation of the dairy, except for corn distillers dried grains plus solubles (DDGS), which was omitted during the trial period. The rationale for this omission was the linoleic acid concentration of the Feed Product 1. It is shown that Feed Product 1 may exhibit a different lipid profile from conventional DDGS, both in terms of total fat and linoleic acid. Milk producers are cognizant of these lipid parameters because of the biological phenomenon known as milk fat depression (MFD). In brief, excessive linoleic acid in dairy cow rations elicits a reduction in butter fat production. Such a reduction has deleterious effects on the economics of dairy cow operations. For this reason, the inclusion rate of Feed Product 1 in the experimental ration was selected so as not to exceed known maximums for linoleic acid, thereby avoiding MFD and optimizing production economics.

[0033] The results for this trial are shown in Table 4. No significant differences were detected among test variables at the level of 5% for Type II statistical error. One may state that the two experimental rations fed were of equivalent biological efficacy. For the economic conditions present at the time of the trial, it was determined that Feed Product 1 had an economic value of 108% of DDGS. Table 4. Dairy cow feeding results Test Variable Control Treatment Dry Matter Intake, Kg / head 28.41 27.64 Energy corrected milk production, Kg / head 40.41 39.98 ECM : DMI* 1.42 1.45 *The efficiency of milk production Unless otherwise stated, concentration values for the constituents listed in Table 5 are determined throughout the document according the methods listed in Table 5. Table 5

[0034] The terms and expressions that have been employed are used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the aspects of the present invention. Thus, it should be understood that although the present invention has been specifically disclosed by specific aspects and optional features, modification and variation of the concepts herein disclosed may be resorted to by those of ordinary skill in the art, and that such modifications and variations are considered to be within the scope of aspects of the present invention. Exemplary Aspects.

[0035] The following exemplary aspects are provided, the numbering of which is not to be construed as designating levels of importance:

[0036] Aspect 1 provides a feed product comprising: greater than 0 wt% and less than 25 wt% crude protein; greater than 0 wt% and less than 10 wt% starch; greater than 2 wt% glycerin; and greater than 35 wt% neutral detergent fiber.

[0037] Aspect 2 provides the feed product of Aspect 1, comprising: greater than 0 wt% and less than 23 wt% crude protein; greater than 0 wt% and less than 8 wt% starch; greater than 10 wt% glycerin; and greater than 40 wt% neutral detergent fiber.

[0038] Aspect 3 provides a feed product, comprising: about 15 wt% to about 25 wt% crude protein; about 2 wt% to about 8 wt% starch; about 7 wt% to about 13 wt% glycerin; and about 35 wt% to about 45 wt% neutral detergent fiber.

[0039] Aspect 4 provides a method of making a feed product, the method comprising: dry milling an agriculturally derived grain; liquifying the dry milled agriculturally derived grain; removing a bran from the liquified dry milled agriculturally derived grain; and separately: fermenting the liquefied dry milled agriculturally derived grain having the bran removed therefrom; and optionally drying the removed bran.

[0040] Aspect 5 provides the method of Aspect 4, wherein about 70 wt% to about 98 wt% of the total amount of bran is removed from the liquefied dry milled agriculturally derived grain

[0041] Aspect 6 provides the method of any one of Aspects 4 or 5, wherein about 85 wt% to about 95 wt% of the total amount of neutral detergent fiber is removed from the liquefied dry milled agriculturally derived grain.

[0042] Aspect 7 provides the method of any one of Aspects 4-6, wherein the agriculturally derived grain comprises a sorghum grain, a wheat grain, a barley grain, a rice grain, a maize grain, or a mixture thereof.

[0043] Aspect 8 provides the method of any one of Aspects 4-7, wherein the agriculturally derived grain comprises a maize grain.

[0044] Aspect 9 provides the method of any one of Aspects 4-8, wherein the removed lignocellulose comprises: about 16 wt% to about 26 wt% crude protein; about 40 wt% to about 70 wt% neutral detergent fiber; about 3 wt% to about 15 wt% crude fat; and about 1 wt% to about 7 wt% starch.

[0045] Aspect 10 provides the method of any one of Aspects 4-9, further comprising: distilling the product of the fermented liquefied dry milled agriculturally derived grain to form ethanol and a slurry stream; separating at least a portion of the slurry stream using a centrifuge to produce an enhanced protein flour; separating the centrifuged liquid portion of the slurry stream using a separation device to produce a enhanced protein and yeast mixture; and evaporating the separated liquid portion to form a syrup having less than or equal to 60 wt% water; combining the syrup with the removed bran to form a dryable mixture; and drying the dryable mixture.

[0046] Aspect 11 provides the method of Aspect 10, wherein the syrup comprises: about 2 wt% to about 6 wt% potassium; about 0.5 wt% to about 5 wt% phosphorous; about 0.3 wt% to about 3 wt% magnesium; about 40 wt% to about 60 wt% water; and greater than about 20 wt% glycerol.

[0047] Aspect 12 provides the method of Aspect 11, further comprising combining the syrup and the removed lignocellulose.

[0048] Aspect 13 provides the method of Aspect 12, wherein combining comprises densification, including pelletizing or milling.

[0049] Aspect 14 provides the method of Aspect 13, further comprising contacting the syrup and the removed lignocellulose with a pelleting aid.

[0050] Aspect 15 provides the method of Aspect 14, wherein the pelleting aid comprises zeolite, yucca schidigera extract, a silicate, calcium, biochar, diatomaceous earth, demulsifier, emulsifier, xanthan gum, guar gum, or a mixture thereof.

[0051] Aspect 16 provides the method of any one of Aspects 4-15, wherein dry milling the agriculturally derived grain is accomplished using a roller mill, hammer mill, or other type of mill.

[0052] Aspect 17 provides the method of any one of Aspects 4-16, wherein the removed bran comprises: about 15 wt% to about 30 wt% crude protein; about 40 wt% to about 70 wt% (on a dry weight basis) neutral detergent fiber; about 5 wt% to about 15 wt% crude fat; and about 1 wt% to about 5 wt% starch.

[0053] Aspect 18 provides the method of any one of Aspects 4-17, wherein the yeast enhanced feed, comprises: about 40 wt% to about 60 wt% crude protein; and greater than about 1.8 wt% lysine.

[0054] Aspect 19 provides the method of any one of Aspects 4-18, further comprising: combining the enhanced protein flour and the enhanced protein and yeast mixture to produce a yeast enhanced feed; and drying the yeast enhanced feed.

[0055] Aspect 20 provides a method of forming a feed product, the feed product comprising: dry milling an agriculturally derived grain; liquifying the dry milled agriculturally derived grain; removing a bran from the liquified dry milled agriculturally derived grain; and separately: fermenting the liquefied dry milled agriculturally derived grain having the bran removed therefrom; and optionally drying the removed bran, wherein the feed product comprises: less than 25 wt% crude protein; less than 10 wt% starch; greater than 7 wt% glycerin; and greater than 35 wt% neutral detergent fiber.

[0056] Aspect 21 provides the method of Aspect 20, wherein about 50 wt% to about 98 wt% of the total amount of neutral detergent fiber is removed from the liquefied dry milled agriculturally derived grain.

[0057] Aspect 22 provides the method of any one of Aspects 20 or 21, wherein about 50 wt% to about 95 wt% of the total amount of neutral detergent fiber is removed from the liquefied dry milled agriculturally derived grain.

[0058] Aspect 23 provides the method of Aspect 20, wherein the agriculturally derived grain comprises a sorghum grain, a wheat grain, a barley grain, a rice grain, a soybean hull, a maize grain, or a mixture thereof.

[0059] Aspect 24 provides the method of any one of Aspects 20-23, wherein the agriculturally derived grain comprises a maize grain

[0060] Aspect 25 provides the method of any one of Aspects 20-24, wherein the removed lignocellulose comprises: about 16 wt% to about 26 wt% crude protein; about 40 wt% to about 70 wt% neutral detergent fiber; about 3 wt% to about 15 wt% crude fat; and about 1 wt% to about 7 wt% starch.

[0061] Aspect 26 provides the method of any one of Aspects 20-25, further comprising: distilling the product of the fermented liquefied dry milled agriculturally derived grain to form ethanol and a slurry stream; separating at least a portion of the slurry stream using a centrifuge to produce an enhanced protein flour; separating the centrifuged liquid portion of the slurry stream using a separation device to produce an enhanced protein and yeast mixture; and evaporating the separated portion to form a syrup having less than or equal to 60 wt% water; combining the syrup with the removed bran to form a dryable mixture; and drying the dryable mixture.

[0062] Aspect 27 provides the method of Aspect 26, wherein the syrup comprises: about 2 wt% to about 6 wt% potassium; about 0.5 wt% to about 5 wt% phosphorous; about 0.3 wt% to about 3 wt% magnesium; Vitamin A; 40 wt% to about 60 wt% water; and greater than about 20 wt% glycerol.

[0063] Aspect 28 provides the method of Aspect 27, further comprising combining the syrup and the removed lignocellulose.

[0064] Aspect 29 provides the method of Aspect 28, wherein combining comprises densification, including pelletizing or milling.

[0065] Aspect 30 provides the method of Aspect 29, further comprising contacting the syrup and the removed lignocellulose with a pelleting aid.

[0066] Aspect 31 provides the method of Aspect 30, wherein the pelleting aid comprises zeolite, yucca schidigera extract, a silicate, calcium, biochar, diatomaceous earth, demulsifier, emulsifier, xanthan gum, guar gum, or a mixture thereof.

[0067] Aspect 32 provides the method of any one of Aspects 20-31, wherein dry milling the agriculturally derived grain is accomplished using a roller mill, hammer mill or other type of mill.

[0068] Aspect 33 provides the method of any one of Aspects 20-32, wherein the removed bran comprises: about 15 wt% to about 30 wt% crude protein; about 40 wt% to about 70 wt% neutral detergent fiber; about 5 wt% to about 15 wt% crude fat; and about 1 wt% to about 5 wt% starch.

[0069] Aspect 34 provides the method of any one of Aspects 20-33, wherein the yeast enhanced feed comprises: about 40 wt% to about 60 wt% crude protein; and greater than about 1.8 wt% lysine.

[0070] Aspect 35 provides the method of any one of Aspects 20-34, further comprising: combining the enhanced protein flour and the enhanced protein and yeast mixture to produce a yeast enhanced feed; and drying the yeast enhanced feed.

[0071] Aspect 36 provides a product formed from a reaction mixture, the reaction mixture comprising: an enhanced protein flour produced from an ethanol fermentation reaction; and a yeast enhanced feed, comprising: about 40 wt% to about 60 wt% crude protein; and greater than about 1.8 wt% lysine, wherein the product comprises at least 50 wt% crude protein.

[0072] Aspect 37 provides a feed product formed from a reaction mixture comprising: a syrup comprising: about 2 wt% to about 6 wt% potassium; about 0.5 to about 5 wt% phosphorous; about 0.3 wt% to about 3 wt% magnesium; about 20 wt% to about 40 wt% water; and greater than about 20 wt% glycerol; and a removed lignocellulose composition comprising: about 16 to about 26 wt% crude protein; about 40 wt% to about 70 wt% neutral detergent fiber; about 3 wt% to about 15 wt% crude fat; and about 1 wt% to about 7 wt% starch.

[0073] Aspect 38 provides the feed product of Aspect 37, wherein the syrup comprises: about 3 wt% to about 5 wt% potassium; about 1 wt% to about 3 wt% phosphorous; about 0.6 to about 2 wt% magnesium; about 25 wt% to about 35 wt% water; and greater than about 30 wt% glycerol.

[0074] Aspect 39 provides the feed product of any one of Aspects 37 or 38, wherein the removed lignocellulose composition comprises: about 19 wt% to about 23 wt% protein; about 42 wt% to about 65 wt% neutral detergent fiber; about 5 wt% to about 10 wt% crude fat; and about 3 wt% to about 5 wt% starch.

[0075] Aspect 40 provides the feed product of any one of Aspects 1-39, wherein the feed product possesses a digestibility greater than 65% as measured by a dNDF48 neutral detergent fiber digestibility assay.

[0076] Aspect 41 provides the method of Aspect 28, further comprising ensiling the contacted syrup and the removed lignocellulose.

[0077] Aspect 42 provides a method of making a feed pellet with enhanced strength by introduction of induced gas cooling at a discharge of the pellets from a pellet mill die

[0078] Aspect 43 provides the method of any of Aspects 13-42, wherein carbon emissions related to transportation, manufacturing, or both of the feed product subjected to densification are less than those of a corresponding feed product that is not subjected to densification.

[0079] Aspect 44 provides the method of Aspect 43, wherein the feed product subjected to densification comprises more nutrients than a corresponding feed product having a volume substantially equivalent to the volume of the feed product subjected to densification.

[0080] Aspect 45 provides the method of any of Aspects 13-44, wherein a temperature of the feed product subjected to densification is in a range of from about 80 °C to about 100 °C.

[0081] Aspect 46 provides the method of any of Aspects 13-44, wherein a temperature of the feed product subjected to densification is in a range of from about 85 °C to about 90 °C.

[0082] Aspect 47 provides the method of any of Aspects 13-44, wherein the feed product subjected to densification is not subjected to external heating prior to densification.

Claims

CLAIMS What is claimed is:

1. A feed product comprising: greater than 0 wt% and less than 25crude protein; greater than 0 wt% and less than 10 wt% starch; greater than 2 wt% glycerin; and greater than 35 wt% neutral detergent fiber.

2. The feed product of claim 1, comprising: less than 23 wt% crude protein; less than 8 wt% starch; greater than 10 wt% glycerin; and greater than 40 wt% neutral detergent fiber.

3. A feed product comprising: about 15 wt% to about 25 wt% crude protein; about 2 wt% to about 8 wt% starch; about 7 wt% to about 13 wt% glycerin; and about 35 wt% to about 45 wt% neutral detergent fiber.

4. A method of making a feed product, the method comprising: dry milling an agriculturally derived grain; liquifying the dry milled agriculturally derived grain; removing a bran from the liquified dry milled agriculturally derived grain; and separately: fermenting the liquefied dry milled agriculturally derived grain having the bran removed therefrom; and optionally drying the removed bran.

5. The method of claim 4, wherein about 70 wt% to about 98 wt% of a total amount of bran is removed from the liquefied dry milled agriculturally derived grain.

6. The method of claim 4 wherein about 85 wt% to about 95 wt% of a total amount of neutral detergent fiber is removed from the liquefied dry milled agriculturally derived grain.

7. The method of claim 4, wherein the agriculturally derived grain comprises a sorghum grain, a wheat grain, a barley grain, a rice grain, a maize grain, or a mixture thereof.

8. The method of claim 4, wherein the agriculturally derived grain comprises a maize grain.

9. The method of claim 4, wherein the removed lignocellulose comprises: about 16 wt% to about 26 wt% crude protein; about 40 wt% to about 70 wt% neutral detergent fiber; about 3 wt% to about 15 wt% crude fat; and about 1 wt% to about 7 wt% starch.

10. The method of claim 4, further comprising: distilling the product of the fermented liquefied dry milled agriculturally derived grain to form ethanol and a slurry stream; separating at least a portion of the slurry stream using a centrifuge to produce an enhanced protein flour; separating the centrifuged liquid portion of the slurry stream using a separation device to produce a enhanced protein and yeast mixture; and evaporating the separated liquid portion to form a syrup having less than or equal to 60 wt% water; combining the syrup with the removed bran to form a dryable mixture; and drying the dryable mixture.

11. The method of claim 10, wherein the syrup comprises: about 2 wt% to about 6 wt% potassium; about 0.5 wt% to about 5 wt% phosphorous; about 0.3 wt% to about 3 wt% magnesium;about 40 wt% to about 60 wt% water; and greater than about 20 wt% glycerol.

12. The method of claim 11, further comprising combining the syrup and removed lignocellulose.

13. The method of claim 12, wherein combining comprises densification, including pelletizing or milling.

14. The method of claim 13, further comprising contacting the syrup and the removed lignocellulose with a pelleting aid.

15. The method of claim 14, wherein the pelleting aid comprises zeolite, yucca schidigera extract, a silicate, calcium, biochar, diatomaceous earth, demulsifier, emulsifier, xanthan gum, guar gum, or a mixture thereof.

16. The method of claim 4, wherein dry milling the agriculturally derived grain is accomplished using a roller mill, hammer mill, or other type of mill.

17. The method of claim 4, wherein the removed bran comprises: about 15 wt% to about 30 wt% crude protein; about 40 wt% to about 70 wt% (on a dry weight basis) neutral detergent fiber; about 5 wt% to about 15 wt% crude fat; and about 1 wt% to about 5 wt% starch.

18. The method of claim 4, wherein the yeast enhanced feed, comprises: about 40 wt% to about 60 wt% crude protein; and greater than about 1.8 wt% lysine.

19. The method of claim 4, further comprising: combining the enhanced protein flour and the enhanced protein and yeast mixture to produce a yeast enhanced feed; and drying the yeast enhanced feed.

20. A method of forming a feed product, the feed product comprising: dry milling an agriculturally derived grain; liquifying the dry milled agriculturally derived grain; removing a bran from the liquified dry milled agriculturally derived grain; and separately: fermenting the liquefied dry milled agriculturally derived grain having the bran removed therefrom; and optionally drying the removed bran, wherein the feed product comprises: less than 25 wt% crude protein; less than 10 wt% starch; greater than 7 wt% glycerin; and greater than 35 wt% neutral detergent fiber.

21. The method of claim 20, wherein about 50 wt% to about 98 wt% of the total amount of neutral detergent fiber is removed from the liquefied dry milled agriculturally derived grain.

22. The method of claim 20, wherein about 50 wt% to about 95 wt% of the total amount of neutral detergent fiber is removed from the liquefied dry milled agriculturally derived grain.

23. The method of claim 20, wherein the agriculturally derived grain comprises a sorghum grain, a wheat grain, a barley grain, a rice grain, a soybean hull, a maize grain, or a mixture thereof.

24. The method of claim 20, wherein the agriculturally derived grain comprises a maize grain.

25. The method of any one of claims 20-24, wherein the removed lignocellulose comprises: about 16 wt% to about 26 wt% crude protein; about 40 wt% to about 70 wt% neutral detergent fiber;about 3 wt% to about 15 wt% crude fat; and about 1 wt% to about 7 wt% starch.

26. The method of claim 20, further comprising: distilling the product of the fermented liquefied dry milled agriculturally derived grain to form ethanol and a slurry stream; separating at least a portion of the slurry stream using a centrifuge to produce an enhanced protein flour; separating the centrifuged liquid portion of the slurry stream using a separation device to produce an enhanced protein and yeast mixture; and evaporating the separated portion to form a syrup having less than or equal to 60 wt% water; combining the syrup with the removed bran to form a dryable mixture; and drying the dryable mixture.

27. The method of claim 26, wherein the syrup comprises: about 2 wt% to about 6 wt% potassium; about 0.5 wt% to about 5 wt% phosphorous; about 0.3 wt% to about 3 wt% magnesium; Vitamin A; 40 wt% to about 60 wt% water; and greater than about 20 wt% glycerol.

28. The method of claim 27, further comprising combining the syrup and the removed lignocellulose.

29. The method of claim 28, wherein combining comprises densification, including pelletizing or milling.

30. The method of claim 29, further comprising contacting the syrup and the removed lignocellulose with a pelleting aid.

31. The method of claim 30, wherein the pelleting aid comprises zeolite, yucca schidigera extract, a silicate, calcium, biochar, diatomaceous earth, demulsifier, emulsifier, xanthan gum, guar gum, or a mixture thereof.

32. The method of claim 20, wherein dry milling the agriculturally derived grain is accomplished using a roller mill, hammer mill or other type of mill.

33. The method of claim 20, wherein the removed bran comprises: about 15 wt% to about 30 wt% crude protein; about 40 wt% to about 70 wt% neutral detergent fiber; about 5 wt% to about 15 wt% crude fat; and about 1 wt% to about 5 wt% starch.

34. The method of claim 20, wherein the yeast enhanced feed comprises: about 40 wt% to about 60 wt% crude protein; and greater than about 1.8 wt% lysine.

35. The method of claim 20, further comprising: combining the enhanced protein flour and the enhanced protein and yeast mixture to produce a yeast enhanced feed; and drying the yeast enhanced feed.

36. A product formed from a reaction mixture, the reaction mixture comprising: an enhanced protein flour produced from an ethanol fermentation reaction; and a yeast enhanced feed, comprising: about 40 wt% to about 60 wt% crude protein; and greater than about 1.8 wt% lysine, wherein the product comprises at least 50 wt% crude protein.

37. A feed product formed from a reaction mixture comprising: a syrup comprising: about 2 wt% to about 6 wt% potassium;about 0.5 wt% to about 5 wt% phosphorous; about 0.3 wt% to about 3 wt% magnesium; about 20 wt% to about 40 wt% water; and greater than about 20 wt% glycerol; and a removed lignocellulose composition comprising: about 16to about 26 wt% crude protein; about 40 wt% to about 70 wt% neutral detergent fiber; about 3 wt% to about 15 wt% crude fat; and about 1 wt% to about 7 wt% starch.

38. The feed product of claim 37, wherein the syrup comprises: about 3 wt% to about 5 wt% potassium; about 1 wt% to about 3 wt% phosphorous; about 0.6 wt% to about 2magnesium; about 25 wt% to about 35 wt% water; and greater than about 30 wt% glycerol.

39. The feed product of claim 37, wherein the removed lignocellulose composition comprises: about 19 wt% to about 23 wt% protein; about 42 wt% to about 65 wt% neutral detergent fiber; about 5 wt% to about 10 wt% crude fat; and about 3 wt% to about 5 wt% starch.

40. The feed product of claim 1, wherein the feed product possesses a digestibility greater than 65% as measured by a dNDF48 neutral detergent fiber digestibility assay.

41. The method of claim 28, further comprising ensiling the contacted syrup and the removed lignocellulose.

42. A method of making a feed pellet with enhanced strength by introduction of induced gas cooling at a discharge of the pellets from a pellet mill die.

43. The method of claim 13, wherein carbon emissions related to transportation, manufacturing, utilization, or all of the feed product subjected to densification are less than those of a corresponding feed product that is not subjected to densification.

44. The method of claim 43, wherein the feed product subjected to densification comprises more nutrients than a corresponding feed product having a volume substantially equivalent to the volume of the feed product subjected to densification.

45. The method of claim 13, wherein a temperature of the feed product subjected to densification is in a range of from about 80 °C to about 100 °C.

46. The method of claim 13, wherein a temperature of the feed product subjected to densification is in a range of from about 85 °C to about 90 °C.

47. The method of claim 13, wherein the feed product subjected to densification is not subjected to external heating prior to densification.

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