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January | February 2014 Whisky by-products a sustainable protein source for aquaculture
International Aquafeed is published six times a year by Perendale Publishers Ltd of the United Kingdom. All data is published in good faith, based on information received, and while every care is taken to prevent inaccuracies, the publishers accept no liability for any errors or omissions or for the consequences of action taken on the basis of information published. Copyright 2014 Perendale Publishers Ltd. All rights reserved. No part of this publication may be reproduced in any form or by any means without prior permission of the copyright owner. Printed by Perendale Publishers Ltd. ISSN: 1464-0058
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Table 2. Chemical composition and feeding values of malt distillery by-products. (2) Draff Dry Matter (g kg-1) Crude protein (g kg-1 DM) Ether extract (g kg-1 DM) Crude fibre (g kg-1 DM) Ash (g kg-1 DM) Ca (g kg-1 DM) 258 198 82 173 33 1.7 3.7 1.4 0.9 3.7 10 43 0.02 0.02 10.8 0.80 Pot ale 40 350 22 105 1.6 22.0 6.6 1.1 23.0 6.8 133 17 18 0.11 14.2 0.95
Figure 2: Malt whisky production process a liquid substance that contains typically 5 percent solids and at least 40 percent protein on dry matter basis. A list of distilling byproducts and their definitions are presented in Table 1. Figure 2 shows a simplified process diagram of malt whisky production, which includes raw materials, by-products and the main steps of the process. Whilst whisky by-products have wellestablished markets in Scotland, current uses do not specifically exploit the particular protein content of these materials. Currently, draff and pot ale are used as food for cattle, energy recovery, fertiliser and feedstock for anaerobic digestion. However, in the mediumto long-term, with bioethanol plants (which also produce plentiful cereals by-products) coming online, there will be an increasing competition for distillers. Additionally, current processing technologies rely on energy-intensive methods. Hence, due to increasing energy costs and increased competition, distillers by-products will have a reduced potential value to the whisky industry. Finding alternative markets for these by-products is important from an economic and a sustainability perspective.
P (g kg-1 DM) Mg (g kg-1 DM) Na (g kg-1 DM) K (g kg-1 DM) S (g kg-1 DM) Cu (g kg-1 DM) Mn (g kg-1 DM) Zn (g kg-1 DM) Co (g kg-1 DM) Se (g kg-1 DM) Metabolisable energy value (MJ kg-1 M) Degradability of crude protein
in aquafeeds for several reasons. Economical and nutritional considerations have played a key role in these decisions. Compared to other plant feedstuffs used in aquafeeds (see Table 3), barley has a low protein content (15 percent compared to 49 percent for soybean meal). However, a good amino acid profile makes the barley protein itself a suitable candidate for aquafeed diets.
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Table 3. Typical composition (as-fed basis) of fish meal and various plants feedstuff .(3) Ingredient Fish meal Barley Canola Corn Soya bean meal Wheat Protein (%) 72.0 14.9 38.0 8.5 48.5 12.9 Lipid (%) 8.4 2.1 3.8 3.6 0.9 1.7 Ash (%) 10.4 2.9 6.8 1.3 5.8 1.6 Lysine (%) 5.57 0.44 2.27 0.25 3.08 0.36 Methionine (%) 2.08 0.16 0.70 0.17 0.68 0.21 Cystine (%) 0.74 0.24 0.47 0.22 0.75 0.27
esses with by-products similar to the malt whisky industry, including grain distilleries, breweries and biofuels, could represent a protein source worth more than 200,000 tonnes annually, equivalent to 150-450m in protein sales across the UK.
Malt whisky by-products: pot ale (left) and draff (right) The other essential component in whisky production is yeast. Although the volumes of yeast compared to barley are substantially smaller (typically a 60 to 1 ratio of barley to yeast is used in malt whisky processing), the nutritional properties of yeast are worth considering. Previous articles in International Aquafeed have reviewed the nutritional properties of yeast, but to summarise here, on a dry matter basis yeast can contain up to 50 percent protein. Additionally, other components beneficial to aquaculture can be found in distillers spent yeast such as nucleotides and -glucans. tein output from UK malt whisky could offer up to 70,000 tonnes per annum of proteins to the animal and aquaculture feed markets. Average outputs of whisky by-products are reported in Table 4 below. Typically, solid by-products from malt whisky distillation have a bigger output per litre of pure alcohol than grain whisky distillation, but it is the other way round for liquid by-products. This is explained by the fact that the quantity of starch convertible into glucose is greater in the cereals used for grain whisky than those used for the production of malt whisky.
Conclusion
Scotch whisky and Scottish aquaculture could develop beneficial industrial synergies. The proteins found in whisky by-products are nutritionally comparable to proteins used in the currently available fish feed ingredients, and their potential volumes are enough to satisfy the Scottish salmon farming industry and achieve substantial protein sourcing benefits, in economical and sustainability terms. Whisky by-products can offer a sustainable supply of suitable protein to the aquaculture industry. There is a need to identify appropriate and sustainable techniques to obtain these proteins on an industrial scale. At Horizon Proteins, a Scottish research team is developing a sustainable process for protein recovery that could have much more financial viability than traditional treatment technologies for whisky by-products. The savings are not only shown economically, but through the significant reduction in energy requirements in processing, reducing the increasingly important global warming impact of the overall process.
Potentially
Potentially
140m p.a.
Market value
Considering all the malt whisky distilleries in Scotland, proteins contained in pot ale could potentially supply at least 40,000 tonnes per annum. Including draff, the combined pro-
The market value of whisky by-product will depend on several factors including their protein and moisture content. Ultimately however, their price will be driven by international prices for fish and soybean meal. Based on these factors and current protein prices, it could be estimated that Table 4. By products outputs per litre of pure alcohol (2) protein recovery from malt Malt Grain whisky co-products could be worth up to 140m Solid by-products 3.5-5.5 kg 1.0-1.25 kg per annum across Scotland. Other fermentation procLiquid by-products 8.8-11.5 L 16-21 L
22 | INTERNATIONAL AQUAFEED | January-February 2014
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farm is bound to produce 7,000 tonnes be grown in anothutilising an area of 57 hectares (see Figure 2). er unit in Portugal Nevertheless, recent production problems recently acquired that have arisen have unfortunately compro- for the purpose. mised this turbot farm to attain full capacity Beginning production in 1997, the Aquacria production already this year. The Acuinova layout is a double row of Pisccolas facility was eight production units. Each production unit has the third flatfish one juvenile pavilion and eight growth pavilions. unit constructed in In the overhead shot of Figure 2, the juvenile Portugal. This highpavilions are coloured darker than the growth tech flatfish farm is pavilions. Each juvenile pavilion (see Figure 3) located in Torreira in has 30 40 m2 tanks for 10-100 g turbot, making the north of Portugal, a total of 480 juvenile tanks, and each growth and is the only aquapavilion in turn has 20 113 m2 growth tanks for culture facility in the fish from 100 gr. to commercial size in a total country operating of 1,248 growth tanks (see Figure 4). At full with shallow raceway capacity it will create more than 200 direct and system technology in conjunction with 600 indirect jobs. Ten-gram juvenile turbot are brought a recirculation aquaweekly from one of the Spanish companys culture system (RAS) turbot hatcheries to Acuinova Mira. Fish are for the growth out automatically and manually fed, up to twelve phase of Senegalese M ade i n G e rm y production, times daily with juveniles and up to four times sole an an rm daily in the grow-out phase, until they reach allowing REAL the fish BREW to ER substantially the commercial size of 1-1.5 kg which may farm S YEAST its environlast between 600 and 750 days. Acuinova reduce has two pumping stations, the water intake is mental impact (see located 2.4 km offshore, each one equipped Figures 6, 7). In 2011, during with nine 250 kW pumps providing a 10.8 m3 per second water flow, enough to provide a the management of For Leiber`s specialty yeast products, daily water supply for a city the size of Madrid. its previous ownMade Germany is afarm, seal ers, of quality. the flatfish farm Another in Portuguese turbot Piscicultura do Rio Alto, located in Estela in began its expansion northern Portugal (see Figure 5), produced policy, which was Multibiotic effect Leiber already concluded. turbot from 1993 to 2011, of when it was yeast decided to abandon turbot production and Therefore, producvitality, health and performance farm Senegalese sole instead. At present, this tion of Senegalese for fish. aquaculture unit is undergoing major modifica- sole will be substantions after being bought this year by a Spanish tially increased, with company (Sea8 Porto) to be converted into an output of 350-400 a hatchery for Senegalese sole, which will tonnes estimated for
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I N C O R P O R AT I N G F I S H FA R M I N G T E C H N O L O G Y
Successful moisture control in aquatic feeds Current challenges and opportunities in amino acid nutrition of salmonids Whisky by-products:
a sustainable protein source for aquaculture
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