Grinding & Dispersing

Protein ressources
Opportunities for NETZSCH
International Sales Meeting BF Food & Confectionery, Germany, June 3 to 6, 2019
Frank Maringer
Definition

Definition of Protein - are large biomolecules, or macromolecules, consisting of one or more

long chains of amino acid residues.
- perform a vast array of functions within organisms.
- differ from one another primarily in their sequence of amino acids, which
usually results in protein folding into a specific three-dimensional
structure that determines its activity.
Source: https://en.wikipedia.org/wiki/Protein

Substantial elements for the humans and animals to provide

 essential proteins the body cannot built himself
 strengthen the immune system
 elements to built up muscles
 building blocks for hormones and enzymes

International Sales Meeting F&C | Grinding & Dispersing | June 3 to 6, 2019 2

Proteins

At the end it all ends up in the human food – or pet food

 Meat we eat
 Animals are fed with plant based proteins
 Poor efficiency: per 100 kg feed this edible meat is produced
side note: insects even better 90 kg of insects
 Meat demand worldwide increasing with welfare
 Negative seen also the high greenhouse emission
some sources say 30% of the CO2 emission worldwide Source: seen with customer
based on animal farming BioMar. DK

 Also to consider animal by-products like milk, eggs and cheese

 Plants we eat
 Direct consumption
 Eating habits in Western countries shifting to eat alternatives to meat
 Healthy eating advices put more value to proteins as to carbohydrates

International Sales Meeting F&C | Grinding & Dispersing | June 3 to 6, 2019 3

Value

The quality of a protein is measured in “nutritional value” (for humans)

 number of essential proteins
 quantity of proteins already exist in the body
Nutritional values (for human)
Whey106
Egg 100 reference
Beef 87
Soymilk 86
Beans 73
Wheat 59
Source: www.ernaehrung.de

Hence the value of Protein feed and food depends on

 Nutritional value
 Protein content in the product
 What other functionality the product brings along

International Sales Meeting F&C | Grinding & Dispersing | June 3 to 6, 2019 4

Important for meat production

To get animal based proteins, plant based proteins are fed

 Price sensitive ingredients
 Soy is leading product for animal feed but limited to a view regional sources
(USA - high local use, Brazil, Argentina and much smaller scale other South American countries and Canada)

 Animal feed by far the biggest market for plant based proteins
in Europe approx. 93% of produced protein plants is going into animal feed
China increased their soy import by factor 10 the last 10 years
 Market demands shifting to
 non-GMO animal feed
 organic feed products
 EU is focusing and supporting efforts to replace soy imports with local grown
plants
 In EU 60% of plant based proteins are imported
 The last five years the farm areas for legumes and soy in EU as been tripled

To Note: plant based proteins in human food is increasing 11-14% in the EU by 2018

Source of EU based figures: report from the EU Commission Nov. 2018

International Sales Meeting F&C | Grinding & Dispersing | June 3 to 6, 2019 5

Alternative Sources

Source: ING Economics Department • December 2017:

International Sales Meeting F&C | Grinding & Dispersing | June 3 to 6, 2019 6

Protein enrichment of pulses
Focussing on high the high value part

International Sales Meeting F&C | Grinding & Dispersing | June 3 to 6, 2019 7

Make Proteins available

Products with Products with

high protein content (e.g. insects) low protein content (plant based)

dry wet grinding/ Feed product

dissolving

grind sieving
Process

pack spray drying

Low Protein High Protein
Fraction Fraction

pack
Protein Shifting

International Sales Meeting F&C | Grinding & Dispersing | June 3 to 6, 2019 8

Protein shifting – Process ways for pulses

Two main processes

wet process dry process

Result:
protein content above 80% in the range of 40 – 60 %
called “Isolate”
Source: Pascalle J.M. Pelgrom , Dry fractionation for sustainable
production of plant protein concentrates , University of Wageningen

International Sales Meeting F&C | Grinding & Dispersing | June 3 to 6, 2019 9

Dry Shifting – not as good as Wet Process

protein rich fine product starch rich coarse product

 Small starch particles still in  Proteins stick to starch particles

 Some starch particles cracked  Proteins are agglomerated

Pictures from protein shifting of Chickpea

International Sales Meeting F&C | Grinding & Dispersing | June 3 to 6, 2019 10

Process - comparison

Wet process - Isolates Dry process – protein fractioning

 Processed with chemicals  Only mechanical treatment
 Drying process required  No heat treatment during separation
 Controlled heat treatment to achieve
certain properties
Plus
Plus
 High Protein content in product
 Remains natural structure and
Minus
properties
 Proteins denatured
(Aminosequence not change but orientation do - irreversible)  Less energy requirements
 High energy consumption  No chemicals and water required
 High water consumption Minus
 Lower protein content as wet
 Level product dependent

International Sales Meeting F&C | Grinding & Dispersing | June 3 to 6, 2019 11

Dry Protein-Shifting not new

With flour protein shifting is used since decades

 Due it´s plant nature starch and protein content is varying
 But consumers expecting constant quality

Common process to achieve a constant flour property for selling:

 Milling the flour to d97 < 200 µm
 A part of the flour stream is
 Milled further down to d99 = 40 – 80 µm
 Then separated into
 Low protein fraction – protein content 7 – 9 % and
 High protein fraction – protein content 15 – 25 %
 Depending on the main flour properties one of these fractions is added to
adjust the properties of the final flour

International Sales Meeting F&C | Grinding & Dispersing | June 3 to 6, 2019 12

Dry Protein-Shifting – Product preparation

 Product needs to be prepared

 Free of impurities
 Dehulled to < 1% remaining hulls
 Hulls are
 Very difficult to grind and may accumulate in the mill (in case of CSM)
 Are responsible for high wear!

 Start:
Proteins are part of the cell together with starch and cell structure
Example: Pea Example: Lupine

International Sales Meeting F&C | Grinding & Dispersing | June 3 to 6, 2019 13

Dry Protein-Shifting – 1st Grinding

 Cell structure is cracked

 Exact top cut is important to destroy all cells and agglomerates
 Target: starch and proteins are all separated but not destroyed
 Typical fineness: d97 = 40-80 µm
 General rule: as finer as better the yield
 Not too fine to destroy the starch
 Starch is very hard to grind
 a remarkable drop of throughput will be seen if grinding too fine

Example: Pea
Source: Dry fractionation for sustainable production of plant protein concentrates, University of Wagening

Topic of presentation | Grinding & Dispersing | Date created 14

Grinding methods

Using (counter) pin disc mill Using classifier mill

Still to find in flour mills (Bühler uses it)

pin disc mill 1 1x Classifier

mill only

pin disc mill 2

pin disc mill 3 2x CSM 900

for Chickpea

Disadvantage: Advantage:
 No exact top cut and loss of yield  Exact top cut and optimum yield
 High energy consumption and machinery  Less energy consumption and machinery
efforts efforts
 High temperature treatment  Very little temperature increase

International Sales Meeting F&C | Grinding & Dispersing | June 3 to 6, 2019 15

Dry Protein-Shifting – 2nd Classifying

 Separation by
 Weight
 Size
 Exact adjustment of cut point necessary
 Good separation between particles important

Comparison of efficiency between

CFS Standard and CFS HD-S
CFS 5100 HD-S based on Chickpea
for Chickpea

International Sales Meeting F&C | Grinding & Dispersing | June 3 to 6, 2019 16

Dry Protein-Shifting – complete process I

In-line process – often used for flour

Plus
 minimal machinery
 Energy consumption less then
separated processes
Minus
 Only one air flow for both process
 No fine tuning on the classification
 Protein content lower as with
separated process

However: mainly customers are asking for maximum content and yield!
This is not the right process to fulfill this request!

International Sales Meeting F&C | Grinding & Dispersing | June 3 to 6, 2019 17

Dry Protein-Shifting – complete process II

Two stage process

Plus
Raw Peas

 Separated air flows

 Each process can be optimum Peeling
Machine

adjusted to the product Peeled

Peas

 Highest possible protein content peelings

Fines

and yield Explosion

Protection valve Classifier Peletizer

Minus Explosion
Protection valve
Classifier Mill Coarse

 More machinery
 Higher energy consumption as In-line

NETZSCH preferred process!

International Sales Meeting F&C | Grinding & Dispersing | June 3 to 6, 2019 18

Competition

For complete production lines – turn key

 Engineering companies, selecting machinery suppliers
 Bühler mainly for flour and rice

For complete systems = scope of NTT

 Alpine, offering the same concepts and scope as we do
 When looking into Internet others advertising for shifting like NOLL

For single process steps basically

 Each supplier who is offering classifier mills and classifier equipment

International Sales Meeting F&C | Grinding & Dispersing | June 3 to 6, 2019 19

Customer questions

Recent customers always asking what max. values we can achieve in terms of
 protein content in the high protein fraction
 yield of high protein fraction = output

We are sure that with our technology we can achieve all the highest values BUT
 how is the content measured:
 NIR (high accuracy – we do with NFT), Dumas (total Nitrogen content, standardized)
 Dry or wet mass based
 to consider: the protein content in a raw material varies up to +/- 4%
 and as usual:
it´s a natural product – ability to separate proteins depends on……

International Sales Meeting F&C | Grinding & Dispersing | June 3 to 6, 2019 20

Dry Protein-Shifting - NTT knowledge base

With some customers we did some extended trials incl. Protein measurements:
Product
 Flour (for further details see appendix 1)
 Grinding for high protein: optimum d99 = 40 - 45 µm
 Protein content: in the range of 24 – 26%
 Yield fine fraction: in the range of 25 - 30%
 Load for classification 0,3 - 0,4

 Chickpea
 Grinding for high protein: optimum d97 = 70 - 80 µm
 Protein content: in the range of 48– 58%
 Yield fine fraction: in the range of 15 - 30%
 Load for classification: 0,3 - 0,4
 Reference throughput: CSM 900 = 3.250 kg/h at d98 = 57 ± 8 µm
CSM 900 = 5.000 kg/h at d97 = 100 µm

International Sales Meeting F&C | Grinding & Dispersing | June 3 to 6, 2019 21

Dry Protein-Shifting – not good for all pulses

The before mentioned process is commercially valuable for

 Cereals have wide range of starch particle sizes
 Legumes (peas and beans) have quite narrow starch particle size distribution
 Oil content needs to be low to avoid sticking – soya needs to be defatted first!
 Particle size of starch and protein are substantially different Example: Pea
cow peas: high amount of small starch particle
faba beans: large starch particle

 Oil seeds like lupine is the other extreme

 No starch particles Example: Lupine

 proteins are in a carbon hydrate environment

 For classification particle differences are not enough

Therefore the applicable process parameters

depending on the plant to be handled!!

International Sales Meeting F&C | Grinding & Dispersing | June 3 to 6, 2019 22

Protein shifting – References

International Sales Meeting F&C | Grinding & Dispersing | June 3 to 6, 2019 23

Proteins from oil seeds
Improve value of waste

International Sales Meeting F&C | Grinding & Dispersing | June 3 to 6, 2019 24

Proteins from oil seeds

 Oil from seeds is an increasing market

 Since now focus on oil production
 Press cake is waste and low price item
 Amount of press cake is huge
 Companies are looking to make money
out of the waste
 Proteins remained in the press cake Global plant based oil production

Palm oil
Rape oil
Source: www.proplanta.de
Soy oil
Sunflower oli

International Sales Meeting F&C | Grinding & Dispersing | June 3 to 6, 2019 25

Proteins from press cakes

 More and more requests coming from Europe

 In research status – needs to be proven that cost are competitive
 Advantage: products already dry < 3 - 8%
 High fiber content – can make grinding difficult

ATTENTION
Process to achieve the press cake is important if grindable or not
 Cake from excenter press or extruder the oil content is high > 10 – 15%
→ impossible to grind without cryogenic help
→ too expensive
 Cake from filter press give oil content < 8%
→ grinding with CONDUX or CSM possible

Source: www.proplanta.de

International Sales Meeting F&C | Grinding & Dispersing | June 3 to 6, 2019 26

Potential product: Sunflower

We are in discussion to have a joint proactive investigation with STET, USA

Goal: evaluate the cost to increase the protein content
Product in focus: SUNFLOWER
 Nutritional value close to soy
 Seen as replacement of Soy bean
 to be GMO free
 Cost is lower then soy meal
 But protein content is lower than soy meal

Typcial composition of Higher price of Soy meal based

sunflower press cake on higher protein content

Both taken from presentation ST Equipment & Technology, Needham, USA

International Sales Meeting F&C | Grinding & Dispersing | June 3 to 6, 2019 27

Protein-Shifting from press cakes - Experiences

Till now this is a new field for us!

Trials with Sunflower has been done often
Targets to get a meal - not for protein shifting!

Due to conversations with customers probably other fctory needs to be

considered
 Proteins stick to the fiber
 Fiber briddleness depends on it´s moisture
 As more dry as more bridle → as more fibers are destroyed during grinding
 Protein content in fine fraction is reduced
 Target is to have elastic enough fibers and achieve that proteins “jump off” the
fiber during grinding
 Fineness probably in the range of d97 = 200 µm
 Sifting with normal screener

International Sales Meeting F&C | Grinding & Dispersing | June 3 to 6, 2019 28

Proteins from insects
a new challenge

International Sales Meeting F&C | Grinding & Dispersing | June 3 to 6, 2019 29

Proteins from insects

 > 2.000 species eaten from 2 Billion people

 Either larva, caterpillar or adult
 Protein content: 40 - 80%
 High nutrition: contains all essential proteins Cricket

 Fat content: 12 – 42%!!!!!!!!!!!

 Feed influence composition
 Use as
 fish feed to reduce fishmeal
Grasshopper
 soy replacement
 nowadays additive for pastry and bakery

Mealworm

International Sales Meeting F&C | Grinding & Dispersing | June 3 to 6, 2019 30

Processing methods

 Powder direct from insect

 Dry process: drying – grinding → meal
Advantage: no loss of proteins
 Wet process: drying – dissolving – drying – grinding → meal
Disadvantage: loss of proteins in wet media
 Difficulty: high fat content, difficult to handle powder
 Demands for grinding: avoid heating up to not destroy proteins

 Increase protein content by defatting with Hexan

 to <3 - 10 % fat content
 Does not influence the technical properties of the meal

 Achieve protein isolate

 Take defatted powder from above – extraction – separation – precipitation → meal
 max. 97 % protein content possible
Source: BfR-Symposium: International Symposium on Insects as Feed,
Food and Non-Food September 12, 2016 in Magdeburg

International Sales Meeting F&C | Grinding & Dispersing | June 3 to 6, 2019 31

Proteins from insects – NTT experience

 We tried dry grinding path from Cricket

 Due to high fat content we tried manual cryogenic grinding
 Used lab CUM100 with pin disc and highest speed
 Result
 Skin parts remained intact
 Therefore particle fineness measured with oil but was max. 1 mm
 Due to high fat content and body shells fine grinding of adult seems impossible

Conclusion:
 Grinding of adult insects < 800 µm seems not possible
 Grinding of larva might be better – to be tested
 Get involved into the more sophisticated wet process as grinding is required
there as well but product is defatted

International Sales Meeting F&C | Grinding & Dispersing | June 3 to 6, 2019 32

Appendix 1 – flour selection table

Proteinshifting
Comparison between grinding energy and achievable product quality
Feed product Typical wheatflour Typ 550 (European type)
Parameter Dimension
Finenss with Classifyer Mill CSM d99 in
micron 80 80 80 55 55 55 47 47 47 39 39
Specific grinding energy kWh/t 42 42 42 75 75 75 84 84 84 110 110
Divided product flow after Coarse
classification fraction % 65 74 67 65 68 70 66 77 70 72 75
(low protein
content)
Fine fraction
(high protein % 35 26 33 35 32 30 34 23 30 28 25
content)
Protein content Coarse % 9,4 9,1 9,5 7,5 7,7 7,6 7,6 7,6 8,4 7,5 7,7
Fine % 15,7 19,5 15,6 19,9 20,1 20,6 22,7 24,7 24,3 24,9 26,3
Specific grinding energy in respect to high
protein fraction kWh/t 120 161 127 214 234 250 250 360 280 390 440

International Sales Meeting F&C | Grinding & Dispersing | June 3 to 6, 2019 33

Appendix 1 – Protein shifting for flour selection table

Please Note: the Classifier size will be individually selected, based on the actual throughput

International Sales Meeting F&C | Grinding & Dispersing | June 3 to 6, 2019 34