SBIR-STTR Award

An opportunity exists to improve the quality of U.S. wheat through more extensive cleaning and also to create a new industry focused on bioprocessing screenings that are extracted when cleaning the wheat. Preliminary analysis shows over $400 million in potential annual sales from bioprocessing 2.5% FM (foreign material) screenings from a 2.3 billion bushel U.S. wheat crop. An additional $200 million would ultimately flow to wheat growers as the cleaning increases wheat value a corresponding 2.5%. Additionally, potential for processing wheat millfeeds (midds) is similar to screenings, upgrading them from a 15% protein feed to a 31% protein supplement as well. This research will assess the following: Feedstock availability, collection, composition and cost. A novel, low-cost process to upgrade protein, produce organic acids and use CO2 in feed. Marketing of the new feed products. The bioprocess envisioned focuses on a proprietary fermentation approach using low-starch feedstocks in a high-solids process, in contrast to conventional ethanol fermentation which has high starch and high water requirements. The focus is on complete feedstock utilization (i.e., minimal CO2 loss) to assure profitability.

Anticipated Results/Potential Commercial Applications of Research:
A key to starting any industrial breakthrough is establishing a commercial success which can be duplicated; only then will capital required to fuel growth be forthcoming. This research project will assess the opportunity and identify and resolve as many impediments as possible to help set the stage for the first commercial plant. Thereafter, a progression of successful plants, following and improving upon the model, would create a new industry, modestly sized initially ($250 to $500 million), but with considerable growth potential. The quality of U.S. wheat would improve steadily as each new plant becomes a market for screenings and midds.

A low value by-product of flour milling--midds--shows great potential as a bioprocessing feedstock to produce high protein feed. Phase I research demonstrated ability to upgrade 18% protein midds to 47% protein concentrate, in part, by hydrolyzing hemicellulose to pentose for high protein yeast propagation, instead of leaving it as an inexpensive source of fiber. In the U.S. 224 flour mills produce 5.13 million tons of midds annually, which, if processed, represent $1.1 billion in sales and $190 million net income potential. The price of midds would rise. A $20/ton increase translates to $.10/bushel, or nearly $235 million more value for American wheat. Equally important are prospects that such processing could be a pretreatment ?bridge' to more economical cellulosic biomass-to-ethanol processing. Recovering a significant co-product feed credit greatly improves biomass potential. Wheat screenings could also be processed, helping improve wheat quality and value. Research in Phase II focuses on a prototype plant large enough to provide product samples for feed trials necessary to support commercial expansion of the bioprocess. The prototype plant will also establish operational costs for determining profit potential in commercial plants.

Anticipated Results/Potential Commercial Applications of Research:
As noted in Phase I, the key to industrial breakthroughs is establishing a duplicable commercial success that attracts capital and fuels expansion. Phase II focuses on a prototype plant capable of being expanded to a small commercial plant, which would in turn, produce products in sufficient volume to establish market acceptance. Thereafter, a progression of new and improving plants would create a new industry with net income potential of $190 million annually. The value and quality of American wheat would improve by both increasing flour mill by-product value and by creating a strong market for screening from more thoroughly cleaned wheat