Economic simulation modeling of reprocessing alternatives for corn masa byproducts

Increasing production of corn masa for tortillas, chips, and related snack foods is resulting in large quantities of organic residuals requiring environmentally sound management. These byproduct streams appear suitable for use as livestock feed material, thus eliminating landfilling costs. Possibilities for developing livestock feed include direct shipping to livestock feeding facilities, blending prior to shipping, extrusion processing, pellet mill processing, and dehydration. To assess the viability of these options for reprocessing masa byproducts as livestock feed materials, an economic model was developed and applied to each of these alternatives. Through a series of simulation runs with this model, it was determined that direct shipping was by far the most inexpensive means of recycling masa processing residuals (10–57 $/Mg). Other alternatives examined in increasing order of costs included blending prior to shipping, extrusion, pellet mill processing (3–15, 5–18, and 4–18 times greater than direct shipping, respectively), while dehydration was clearly cost-prohibitive (33–81 times greater). Bagged feed was slightly more expensive to produce than bulk feed (1.1 times greater), and reprocessing costs increased as delivery distance increased, due to increased labor, equipment, and fuel costs, but decreased as byproduct generation rate increased, due to the development of the economies of scale. Alternately, based on a tipping fee of 50 $/Mg, the total estimated cost to landfill ranged from 65 to 112 $/Mg. Based on this cost analysis, direct shipping and feeding to livestock is the recycling option of choice for masa processing byproducts. Although specific details of process configurations and associated costs will vary, similar results are likely for other high moisture food processing residuals destined for utilization as livestock feed or components thereof.     

Considerations for Manufacturing Bio-Based Plastic Products

One engine that drives the United States’ economic growth is an ever-increasing demand for manufactured products, both at home and abroad. This increase has created a major concern for the environment in terms of disposing used goods and ensuring that these products are safe. As environmental concerns grow, however, renewable resources are gaining increasing attention, especially as industrial ecology and product biodegradability gain importance. Added to this, biological materials are increasingly being utilized to replace traditional materials in manufacturing. To aid both educators as well as researchers, this paper examines several considerations that are essential for manufacturing plastic products that contain biomaterials. These include the selection of materials, the selection of manufacturing processes, manufacturing costs, and the quality of final products. Additionally, several standard methods that are commonly used for the determination of mechanical and physical properties are compiled; thus this paper should be a useful resource for both educators and researchers. The trends discussed here and their implications are critical for those involved in manufacturing, because contrary to conventional wisdom, simultaneously meeting the material production needs of our society, as well as that of the environment are not mutually-exclusive.     

Influence of Suspended Clay Minerals and Humic Matter on the Solid Phase Extraction Efficiency of Selected Pesticides from Water

The purpose of this investigation was to determine the influence of humic acids (HA) and Ca-montmorillonite (CaM) on the solid-phase extraction (SPE) efficiency of atrazine, alachlor and α-cypermethrin from water samples at various pH-values. The nature and intensity of binding of the studied pesticides to CaM were determined by X-ray diffraction analysis and termogravimetric analysis (TGA) test. The studied pesticides eluted from discs were analysed by thin-layer chromatography (TLC). The effects of CaM and humic acid were generally pH-dependent and acted independently in extraction efficiency influence. Lower recovery of pesticides was observed at higher pH values when CaM was ≥0.1 g and was attributed to greater dispersion of clay, increased surface area and subsequent adsorption. Concentrations of dissolved organic carbon (DOC) in humic acid had less effect on the extraction efficiency when water was at pH 8 compared to water at pH 2, which was probably due to greater nonpolar interactions of the pesticides to the charge-neutralized humic acid molecule.     

Properties of Distillers Grains Composites: A Preliminary Investigation

Interest in renewable biofuel sources has intensified in recent years, leading to greatly increased production of ethanol and its primary coproduct, Distillers Dried Grain with Solubles (DDGS). Consequently, the development of new outlets for DDGS has become crucial to maintaining the economic viability of the industry. In light of these developments, this preliminary study aimed to determine the suitability of DDGS for use as a biofiller in low-cost composites that could be produced by rapid prototyping applications. The effects of DDGS content, particle size, curing temperature, and compression on resulting properties, such as flexural strength, modulus of elasticity, water activity, and color were evaluated for two adhesive bases. The composites formed with phenolic resin glue were found to be greatly superior to glue in terms of mechanical strength and durability: resin-based composites had maximum fiber stresses of 150–380 kPa, while glue composites had values between 6 kPa and 35 kPa; additionally, glue composites experienced relatively rapid microbial growth. In the resin composites, both decreased particle size and increased compression resulted in increased mechanical strength, while a moderate DDGS content was found to increase flexural strength but decrease Young’s modulus. These results indicate that DDGS has the potential to be used in resin glue-based composites to both improve flexural strength and improve potential biodegradability.     

A review of corn masa processing residues: generation, properties, and potential utilization

The production of corn masa-based products in the US has been increasing over the last several years, and as a result, so has the quantity of waste materials being generated from this industry. Although currently landfilled, these byproduct streams may have potential for value-added processing and utilization, which are options that simultaneously hold the promise of increased economic benefit for masa processors as well as decreased potential pollution for the environment. Fundamental to any byproduct development effort is knowledge of the characteristics of the residue stream, because physical and chemical properties are vital for the proper design of subsequent processing operations and applications. Data for masa byproduct materials are currently not readily available, however. Thus, the objective of this study was to fully investigate, review, and summarize the existing literature in order to develop a comprehensive knowledge base for these residue streams. The most substantial findings from this study were that masa residues currently are not being utilized as coproducts, but instead are being landfilled; they have a high fiber content, and thus much untapped potential exists for its extraction and value-added utilization vis-à-vis human and industrial applications, including phytosterol and ethanol production. It was also determined that masa byproducts, due to the high fiber content, may also be suitable for use as livestock feed additives, especially for ruminant animals that can digest these materials. Furthermore, due to substantial calcium content, masa byproducts could also potentially be used as a calcium resource. Under current processing practices, though, these residues have very high moisture contents. Before they can be effectively and economically utilized, they must be dehydrated in order to reduce transportation costs, decrease microbial activity, and increase shelf life.     

Compression Molding of Phenolic Resin and Corn-based DDGS Blends

With the rapid growth in the ethanol fuel industry in recent years, considerable research is being devoted to optimizing the use of processing coproducts, such as distillers dried grains with solubles (DDGS), in livestock diets. Because these residues contain high fiber levels, they may be amendable to incorporation into bio-based composites. Thus, the goal of this study was to demonstrate the viability of using corn-based DDGS as a biofiller with phenolic resin, in order to produce a novel biomaterial. DDGS was blended with phenolic resin at 0, 10, 25, 50, 75, and 90%, by weight, and then compression molded at 51 MPa (3.7 tons/in²) and 174 °C (345°F). Molded specimens were then tested for tensile strength. Tensile yield strengths ranged from 32 MPa (4,700 psi) to 7.6 MPa (1,100 psi), while the engineering strain ranged from 0.6% to 1.25%. Results indicate that DDGS concentrations between 25% and 50% retained sufficient mechanical strength and thus represent reasonable inclusion values. Additionally, data were similar to those from other studies that have investigated biofillers. Follow-up studies should quantify the effects of altering molding parameters, including molding pressure, temperature, and time, as well as pretreatment of the DDGS. Additionally, strength of the DDGS composites should be optimized through the use of coupling agents or other additives. Mention of a trade name, proprietary product, or specific equipment does not constitute a guarantee or warranty by the United States Department of Agriculture and does not imply approval of a product to the exclusion of others that may be suitable.     

Cradle-to-Grave Life Cycle Assessment and Techno-Economic Analysis of Polylactic Acid Composites with Traditional and Bio-Based Fillers

This research focused on life cycle assessment (LCA) and techno-economic analysis (TEA) comparisons of polylactic acid (PLA) composites, in order to compare organic to inorganic fillers. Organic fillers included DDGS, flax, hemp, rice husks, and wood, and were compared against inorganic fillers (glass and talc) for PLA-based composites. This study utilized LCAI and TEA methodology to estimate and quantify costs, emissions, and energy intensity (EI) associated with material acquisition, processing, transport, and end-of-life treatment used during plastic composite production. Emission categories analyzed include global warming potential (GWP), air acidification (AA), air eutrophication (AE), water eutrophication (WE), ozone layer depletion (OLD), air smog (AS), high carcinogens (HC), and high non-carcinogens (HNC). To achieve a “Cradle-to-Grave” perspective, two models were meshed, the plastic comparator (PC) and EIO-LCA (EIO), to simulate the EI and emissions associated over the entire life cycle. Based assumptions used, this research has shown that utilizing land fill end-of-life treatment and glass filler composite was the most environmentally harmful option, and maintained the highest economic impact, for all impact categories during PLA composite production. Alternatively, both DDGS and wood filler composites paired with recycling end-of-life treatment were shown to be the least environmentally damaging method and incurred the lowest cost of all PLA composites considered. This study also suggests that utilization of organic bio-based fillers produces a lower economic/environmental impact, and EI, compared to utilization of inorganic fillers in PLA composites. Accordingly, this research has demonstrated the impact of LCA/TEA paired analysis when assessing the bioplastic and biocomposite processing, which may be utilized as a precursor for parallel research undertakings.