JP7576756B2 - Feed manufacturing method - Google Patents

Description

The present invention relates to a method for producing feed.

It is said that feed costs in the livestock industry account for 40 to 70 percent of management costs.
The feed is roughly divided into roughage, mainly consisting of hay, rice straw, and fermented products of these, and concentrated feed, such as corn and soybean oil cake, with 20% of the former and about 90% of the latter dependent on imports from overseas. The proportion of concentrated feed used is 40-60% even in dairy and beef cattle, which are the least, so the structure of the Japanese livestock industry is easily affected by grain prices (Non-Patent Document 1, Non-Patent Document 2).

In recent years, the use of feed produced using food manufacturing by-products (eco-feed) as an alternative to concentrated feed has been attracting attention in order to reduce the impact of grain market fluctuations.

Among food manufacturing by-products, malt lees such as whiskey lees and beer lees are the lees most commonly produced by food manufacturers (Non-Patent Document 3). In particular, whiskey lees production has been on the rise in recent years, coupled with the global boom in Japanese whiskey, and the need for processing it is growing. Because whiskey lees contains a good balance of high-quality dietary fiber and protein, if it could be made more palatable through lactic acid fermentation and sold for use as cattle feed, it would lead to reduced processing costs. For this reason, it has attracted the attention of whiskey factories and the like, regardless of their size.

Japanese Patent Application Publication No. 9-51762

The situation surrounding eco-feed, April 2016, Ministry of Agriculture, Forestry and Fisheries, Livestock Production Bureau, Feed Division (URL: https://bit.ly/3qEn9Zm) Feed Issues for Serious Discussion, July 2014, Ministry of Agriculture, Forestry and Fisheries (URL: https://bit.ly/2OHjLzf) Imai, "Silage Technology for Effective Use of By-products," No. 139, Central Livestock Association (URL: https://bit.ly/2OJnpsM) Kojima, "Contribution: About sugar lees," Farmer's Eye SUMMER 2011 (URL: https://bit.ly/3ceEYsM) Hyogo Prefectural Agriculture, Forestry and Fisheries Technology Center, Awaji Agricultural Technology Center, "[Results information name] Feeding sake lees to lactating cows improves milk productivity" (URL: https://bit.ly/2N20B6P), 2010 Japanese Standard Feed Composition Table (2001)

However, malt lees has an extremely low carbohydrate content (here, the total amount of starch, sugar, and pectin) compared to sake lees, tofu lees, wine lees, etc. (beer lees: about 1-4% in dry matter, Non-Patent Document 4; sake lees: 3-5% in dry matter, Non-Patent Document 5; tofu lees: 21.7%; wine lees: 25.5%, Non-Patent Document 6, calculated as (starch, sugar, and pectin) = NFE - NDF + crude fiber), which makes it difficult for lactic acid fermentation to proceed. To overcome this drawback, for example, large-scale whiskey factories add expensive sugar to whiskey lees to promote fermentation (Non-Patent Document 3), which naturally results in high costs for eco-feed production.

In view of the above problems, the present invention aims to provide a method for producing feed with excellent shelf life at low cost and in a simple manner using malt meal.

One aspect of the present invention, which has been made to achieve the above object, is a method for producing feed, which includes a step of dehydrating malt meal and a step of treating the malt meal with a fibrolytic enzyme. This production method allows for the production of meal feed at low cost and easily.

The malt lees are preferably whiskey lees. Whisky lees are characterized by their high temperature due to the addition of boiling water at the end of the saccharification process, and by the heat dissipation process passing through the optimum temperature range of fibrous enzymes such as xylanase, cellulase, and pectinase (Figures 2, 3, and 4. In this specification, the optimum temperature range is defined as the product of temperature activity and temperature stability). Therefore, the fibrous enzymes are effective against the fibers contained in whiskey lees, and the amount of glucose and oligosaccharides that lactic acid bacteria feed on increases with the fibrous enzyme treatment, making it relatively easy for lactic acid bacteria to grow, making it a feed ingredient that is particularly advantageous for the production method of the present invention.

The internal temperature of the malt meal in the process of treating with the above-mentioned fiber-degrading enzyme is preferably 40°C to 65°C. If it is added immediately at an internal temperature within the above range, regardless of whether a fiber-degrading enzyme such as cellulase, xylanase, or pectinase is used, the optimal temperature range will be passed during the heat dissipation process, and the decomposition of poorly soluble fibers such as cellulose contained in the malt meal will proceed quickly, and the glucose and oligosaccharides that the lactic acid bacteria feed on will increase. As a result, the proliferation of lactic acid bacteria will be activated and lactic acid fermentation will proceed quickly, and the proliferation of butyric acid bacteria, E. coli, Salmonella, etc. will be suppressed by the lowering of the pH, and the risk of spoilage of the malt meal will be reduced. Here, the internal temperature means the temperature at the center of the accumulated malt meal, and is the value measured with a thermometer equipped with a sensor that can be inserted to measure the temperature.

The process may also include a step of separately mixing malt distiller produced in the malt crushing process, pot ale syrup remaining in the whiskey distillation process, and/or barley grains produced in the manufacturing process of another barley product. By including such a step, lactic acid bacteria living in the malt distiller or barley grains can be caused to attach to and act on the malt grains or enzyme-treated products, and the sugar content of the pot ale syrup can also be utilized as necessary, further promoting lactic acid fermentation and improving shelf life.

The feed manufacturing method of the present invention is particularly useful for producing cattle feed, because the resulting feed contains plenty of dietary fiber and a moderate amount of soluble sugars, and lactic acid fermentation enhances the palatability of the feed to cattle.

The present invention makes it possible to produce a stable feedstuff easily and at low cost.

Typical beer and whiskey production process. Temperature characteristics of xylanase (Sucrase (registered trademark) X, cited from the Mitsubishi Chemical Corporation Life Solutions Sector website). Temperature characteristics of cellulase (Sucrase (registered trademark) C, cited from the Mitsubishi Chemical Corporation Life Solutions Sector website). Temperature characteristics of pectinase (Sucrase (registered trademark) N, cited from the Mitsubishi Chemical Corporation Life Solutions Sector website).

The following describes the embodiment of the present invention with reference to the drawings.

In this specification, "malt lees" refers to by-products produced in the manufacturing process of fermented malt beverages such as beer and whiskey as shown in FIG. 1, including the residual solids (wort lees, draft) after discharging the sugar liquid produced in the saccharification process performed by adding hot water to malt. Therefore, as long as malt lees contain wort lees, they may further include the residual liquid (pot ale syrup) in the whiskey distillation process and/or the sprouts and husks (malt distiller) removed before malt crushing, or they may include barley milling lees produced in the polishing process of barley products such as pressed barley and pressed barley germ. Incidentally, "malt lees" includes beer lees, whiskey lees, happoshu lees, hoppy lees, etc., and when beer lees and whiskey lees are not distinguished from each other, they are referred to as malt lees.
In this specification, "brewer's lees" is a concept that includes not only the by-product discharged in the process of producing beer as defined by the Liquor Tax Act, but also the by-product discharged in the process of producing happoshu (happoshu lees).

The method for producing feed of the present invention includes a step of dehydrating malt meal. Malt meal is preferably dehydrated in advance for the purpose of improving storage stability and promoting lactic acid fermentation. A commercially available screw press dehydrator can be used for dehydration. The moisture content of malt meal after dehydration is usually 65% to 75%.

The method for producing feed of the present invention includes a step of treating malt meal with a fiber-degrading enzyme (hereinafter referred to as the fiber-degrading treatment step). By treating with the fiber-degrading enzyme, the fiber contained in the malt meal is degraded, increasing the amount of glucose and oligosaccharides, and these sugars become food for lactic acid bacteria, facilitating lactic acid fermentation. The fiber-degrading enzyme to be used preferably has an optimum temperature range that includes the temperature at which the enzyme is added to the malt grains, or has an upper limit that is about 5° C. lower than the temperature at which the enzyme is added to the malt grains, taking into account the temperature drop due to heat dissipation from the malt grains. Examples of such cellulases include Sucrase C (manufactured by Mitsubishi Chemical Foods Corporation, optimum temperature range 45° C. to 60° C.), Cellulase T "Amano" 4 (manufactured by Amano Enzyme Co., Ltd.), Cellulase Onozuka R-10 (manufactured by Yakult Pharmaceutical Co., Ltd.), Cellulase XL-531 (manufactured by Nagase ChemteX Corporation), Celluclast 1.5 L (manufactured by Novozymes), and Cellulosin TF (manufactured by HBI); Sucrase N (manufactured by Mitsubishi Chemical Foods Corporation, optimum temperature range 30° C. to 50° C.), Pectinase G "Amano" (manufactured by Amano Enzyme Co., Ltd.), Pectinase SS (manufactured by Yakult Pharmaceutical Co., Ltd.), and Pectinex Ultra. Examples include one or a combination of two or more selected from the group consisting of pectinases such as SP-L (manufactured by Novozymes); and xylanases such as Sucrase X (manufactured by Mitsubishi Chemical Foods, optimum temperature range 35°C to 50°C) and Cellulosin HC100 (manufactured by HBI).

The fibrolytic enzymes can be in the form of either a powder or a water-based spray.
When in powder form, the amount of the fiber-degrading enzyme added is usually 0.05% to 10% by weight based on the weight of the dehydrated malt grains.
When the fiber-degrading enzyme is in the form of a spray, the amount of the fiber-degrading enzyme added may be adjusted so that it is the same amount in terms of powder.

In one embodiment, the fiber degradation process starts with the addition of a fiber-degrading enzyme to the inside of the malt meal, and the internal temperature of the malt meal at this time is preferably 40°C to 65°C. A more preferred lower limit of the internal temperature of the malt meal is 45°C. The fiber-degrading enzyme is more preferably added when the internal temperature of the malt meal is within the above temperature range, close to the optimal temperature of the fiber-degrading enzyme used, and at a temperature where temperature stability is sufficiently maintained (for example, a temperature where the relative activity is preferably maintained at 30% or more, more preferably 50% or more, for 30 minutes or more). During the fiber degradation process, the internal temperature of the malt meal may be maintained within the above temperature range by heating, or may be allowed to drop to below the lower limit of the above temperature range by heat dissipation due to the difference with the outside air temperature without maintaining the temperature.

The fiber decomposition process may include a stirring step. When stirring is performed, it is performed after or while adding the fiber decomposition enzyme, but it is preferable to stir for a short period of time, for example within 5 minutes, in order to minimize the decrease in temperature of the lees due to contact with the outside air.

The fiber decomposition process progresses by allowing the internal temperature of the malt grains to drop and reach room temperature. During this process, the saccharification of the fiber components contained in the malt grains can be promoted. It is usually preferable to ensure that the fiber decomposition process lasts for 12 to 48 hours.

The fiber decomposition process may be carried out with the malt grains in a flexi-con bag exposed to air, but it is preferable to carry out the process in a tank sealed with a lid, and it is even more preferable to carry out the process in a tank that has been degassed and sealed. This is because lactic acid fermentation progresses in parallel with fiber decomposition, and the pH drops early, suppressing the growth of butyric acid bacteria, E. coli, Salmonella, and other bacteria, reducing the risk of the malt grains spoiling.

When the dehydration process and the fiber decomposition process are carried out separately, it is preferable that the time required for the transition between the dehydration process and the fiber decomposition process is as short as possible from the viewpoint of suppressing a decrease in the temperature of the malt meal after the dehydration process or the fiber decomposition process is completed. The transition time is, for example, within 10 minutes, preferably within 5 minutes, and more preferably within 1 minute. When the dehydration process precedes, it is preferable to carry out the fiber decomposition process on the malt meal discharged sequentially from the dehydrator, and when the fiber decomposition process precedes, it is preferable to carry out the fiber decomposition process as a batch process for a sufficient time before sending it to the dehydration process.

The enzyme-treated product that has undergone the fiber decomposition process usually contains lactic acid bacteria derived from the raw materials or the distillery environment, and these lactic acid bacteria consume the sugars contained in the enzyme-treated product to carry out lactic acid fermentation (lactic acid fermentation process). It is usually preferable to secure a time for the lactic acid fermentation process of 2 to 7 days. The fiber decomposition process and the lactic acid fermentation process will proceed simultaneously in parallel unless the enzyme is inactivated, but the enzyme may be inactivated first before carrying out lactic acid fermentation.

The lactic acid fermentation process can be carried out by packaging the enzyme-treated material in a flexi-con bag and exposing it to air, but it is preferable to carry out the process in a tank with a lid on, and it is even more preferable to carry out the process in a degassed and sealed tank. This is because lactic acid fermentation also progresses quickly, and the lowering of the pH inhibits the growth of bacteria such as butyric acid bacteria, Escherichia coli, and Salmonella, reducing the risk of spoilage of the malt grains.

During the period from the start of the dehydration process to the end of the fiber decomposition process, or during the period from the start of the fiber decomposition process to the end of the dehydration process, or during the lactic acid fermentation process that runs parallel to the fiber decomposition process, malt distiller produced during the malt crushing process, pot ale syrup remaining in the whiskey distillation process, or barley grains produced during the manufacturing process of another barley product may be mixed separately. This is to allow the lactic acid bacteria that live in the malt distiller or barley grains to attach to and act on the malt grains and enzyme-treated products, and to promote lactic acid fermentation by also utilizing the sugar content of the pot ale syrup as necessary. The amount to be added may be within a range that does not significantly reduce the temperature of the malt grains and does not upset the nutritional balance.

A commercially available microbial preparation containing lactic acid bacteria may be added separately to the malt grains undergoing the fiber decomposition process, or to the enzyme-treated product that has undergone the fiber decomposition process.

The method for producing a feed of the present invention may include a step or stage of adjusting the pH of the malt meal prior to the fiber decomposition process, during the fiber decomposition process, prior to the lactic acid fermentation process, and/or during the lactic acid fermentation process. When adjusting the pH, it is preferable to set it in the range of 3.0 to 4.5 from the viewpoint of promoting lactic acid fermentation while suppressing the proliferation of butyric acid bacteria and the like. A more preferable lower limit of the pH is 3.6, and a more preferable upper limit of the pH is 4.2. The pH here is a value measured with a commercially available pH meter. Examples of pH adjusters include organic acids such as formic acid and lactic acid, mineral acids such as hydrochloric acid, and inorganic bases such as sodium hydroxide.

The resulting lactic acid fermented product can be used as is without going through a drying process, but it can also be used as feed for cattle, pigs, and other livestock by adding pot ale syrup or the like, and combining it with eco-feed that is not derived from malt meal, or with other concentrated feed, so long as the nutritional balance is not affected.

Example 1
In the whiskey manufacturing process, after discharging the saccharification liquid from the malt saccharification tank, 90°C hot water was poured over it to discharge the remaining sugar. The whiskey lees (wort squeezed lees) remaining in the tank as a by-product, about 113.6 kg (water content 83%), were immediately scraped out of the tank and sequentially fed into the hopper of a commercially available screw press dehydrator (DM-25, manufactured by Kawaguchi Seiki Co., Ltd.) for dehydration treatment, and adjusted to about 100 kg of dehydrated lees (water content 73%) and discharged. At that time, cellulase (Sucrase (registered trademark) C, manufactured by Mitsubishi Chemical Foods Co., Ltd.) was added little by little to the dehydrated lees with an internal temperature of about 65°C that were sequentially discharged from the outlet of the dehydrator into a flexible container bag, and the fiber decomposition process was advanced so that 100 g of sucrase was added by the time 100 kg of dehydrated lees were discharged. The obtained enzyme additive was left to stand until the internal temperature decreased to room temperature, whereby the enzyme decomposition treatment was performed, and at the same time, lactic acid fermentation was advanced. Six days after the addition of the enzyme, the enzyme/fermentation treated product was subjected to feed analysis, and the results are shown in Table 2. The dried product was obtained by drying with hot air at 100° C. or less.

In Table 1, it was found that beer lees, which can be considered to be the same as the malt squeezed grains in the whiskey production process in terms of components, contain substantially no NFC, whereas the fermented product obtained by the feed production method of the present invention contains 13.7% NFC (non-fibrous carbohydrates) in dry matter. From this comparison, it can be seen that the non-fibrous carbohydrates contained in the enzyme-treated product do not contain substantially pectin, but are sugars containing oligosaccharides. At the same time, lactic acid and acetic acid were produced without producing butyric acid, which is thought to be one of the causes of putrid odor. This suggests that while the proliferation of butyric acid bacteria was suppressed, lactic acid bacteria that remained in the malt lees or attached to the enzyme-treated product at the distillery may have consumed some of the sugars produced by the enzyme treatment and proliferated by heterolactic fermentation. The obtained enzyme-treated product had a low pH, high nutritional value, and was highly palatable and digestible to cattle, and was found to be of very high quality as an eco-feed that replaces part of cattle feed, especially concentrated feed.

Example 2
An enzyme/fermentation treated product was obtained in the same manner as in Example 1, except that the temperature of the hot water poured after discharging the saccharified liquid was 70°C, the internal temperature of the dehydrated cake discharged from the dehydrator was about 40°C, and the enzyme agent added was Sucrase X (manufactured by Mitsubishi Chemical Foods Corporation). As in Example 1, the quality of the obtained enzyme/fermentation treated product was high in palatability and digestibility for cattle, and it was found to be of extremely high quality as an eco-feed that can replace part of cattle feed, especially concentrated feed.

The embodiment of the present invention is not limited to the above embodiment, and not all of the configurations described in the above embodiment are essential requirements of the present invention. The present invention can take various forms such as modifications within the scope of the technical concept. Depending on the internal temperature of the malt meal at that time, the dehydration process may be carried out simultaneously with the fiber decomposition process, or one of them may be carried out first. If the fiber decomposition process precedes the dehydration process, the water obtained in the dehydration process contains sugar, and therefore may be added to the subsequent lactic acid fermentation process or feed for use. It is also acceptable to carry out the fiber decomposition process simultaneously with the lactic acid fermentation process. The warm water obtained in the dehydration process may be used to keep a container containing an enzyme additive warm and promote the enzyme reaction.

According to the feed production method of the present invention, even relatively small-scale craft beer factories or whiskey factories can easily produce highly palatable livestock feed at low cost, and the reduction in processing costs has great industrial applicability.

Claims (5)

A method for producing a feed comprising the steps of dehydrating malt grains and treating the dehydrated malt grains having a moisture content of 65 to 75% with a fiber-degrading enzyme. The method for producing a feed according to claim 1, further comprising a lactic acid fermentation step of lactic acid fermenting the sugar contained in the obtained enzyme-treated product with lactic acid bacteria . 3. The method for producing a feed according to claim 1 or 2 , wherein the malt grains are whiskey grains. The method for producing a feed according to any one of claims 1 to 3 , wherein the internal temperature of the malt meal is 40°C to 65°C at the stage of adding the fibrous enzyme in the step of treating with the fibrous enzyme. 5. The method for producing a feed according to claim 1, further comprising a step of separately mixing malt distiller produced in the grinding step, pot ale syrup remaining in the whiskey distillation step, and/or barley milled cake produced in a step of producing another barley product.

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