Minnesota Nutrition Conference
`Minnesota Corn Growers Association
`Technical Symposium
`September 11, 2001
`Corn Milling, Processing and Generation of Co-products
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`Corn, a distinctive American crop, developed by the Indians, roasted at 4th of July
`picnics and produced with unparalleled efficiency and dedication by farmers. For every
`five bushels sold, corn processors buy one bushel to process in to corn syrups,
`sweeteners, starches, oils, ethanol and animal feeds. These products in turn become the
`building blocks of thousands of other food and industrial products distributed throughout
`the world. Eighty percent of all corn grown in the US is fed to livestock, poultry and
`fish. Nutritional components of yellow dent corn are well known.
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`Components of Yellow Dent Corn
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`Starch 61.0 %
`Corn Oil 3.8 %
`Protein 8.0 %
`Fiber 11.2 %
`Moisture 16.0 %
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`Currently in an average year the remaining twenty percent or about two billion
`bushels of shelled field corn is transported from individual farms by truck, train and
`barge to industrial corn processing plants. This percentage of “industrial use” versus the
`amount of corn produced has increased over the decades from 9.9% in 1980 to 17.9% in
`1990 to the current 19.7%.
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`10000
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`M M bushel s cor n pr oduced
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`Industr i al usage
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`With the new bio-based product initiatives and our need for renewable energy,
`researchers are looking at corn as a feedstock for other organic chemicals, nutraceuticals
`and biodegradable polymers and fibers. This will continue the trend of increasing
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`
`
`Presented by
`Kelly S. Davis
`Quality Manager
`Chippewa Valley Ethanol Company
`
`SOLENIS EXHIBIT 2002
`Hydrite v. Solenis, IPR2015-01592
`
`Page 1 of 7
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`

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`Minnesota Nutrition Conference
`Minnesota Corn Growers Association
`Technical Symposium
`September 11, 2001
`percentage of corn grown for industrial processes. Educating nutritionists about the
`feeding values of these valuable co-products and getting the improved quality data into
`the new feed formulation programs and literatures is becoming of increased importance.
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`There are two distinct processes for processing corn, wet-milling and dry-milling
`and each process generates unique co-products.
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`The Corn Wet-Milling Process
`Wet-milling processing roots are designed based in production of pure starch.
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`Corn wet milling has developed into an industry that seeks optimum use and maximum
`value from each constituent of the corn kernel. In addition to starch and the other various
`products, as well as the edible corn oil, the industry has become an important source of
`well- defined specialized ingredients used in feed formulations. The contents of the
`different component streams segregated during starch and oil production are recombined
`and processed to yield products serving specific needs of the feed industry.
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`Production of feed co-products from corn wet-milling begins with the delivery of
`shelled corn to the facility. The corn is sampled and quality approved. The corn is off
`loaded to elevator bins through a cleaning system. From the elevator, the corn is
`conveyed to large tanks called steep tanks where it is soaked for 30-50 hours at 120 -
`130°F in a dilute sulfur dioxide solution. This is a closely controlled process that results
`in the softening of the corn kernels. During the soaking, soluble nutrients are absorbed in
`to the water. This water is later evaporated to concentrate these nutrients to become
`Condensed Corn Fermented Extractives. Continuing with the milling process the corn
`germ is removed from the water soaked kernel. The germ is further processed to recover
`the oil. The remaining portion of the germ, Corn Germ Meal (wet or dried), is collected
`for feed use. After the germ has been removed, the rest of the corn kernel is screened to
`remove the bran leaving the starch and gluten protein to pass though the screens. The
`bran is combined with other co-product streams to produce Corn Gluten Feed. This
`starch and gluten slurry is sent to centrifugal separators, which causes the lighter gluten
`protein to float to the top and the heavier starch to the bottom. The gluten protein is
`concentrated and dried to form Corn Gluten Meal, a 60% protein feed. Some of the
`starch is then washed and dried, or modified and dried and marketed to the food, paper
`and textile industries. The remaining starch can be processed into sweeteners or ethanol.
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`Wet-milling produces four major co-products for the feed industry from the
`isolated steep water, bran, germ meal and gluten. Together these co-products represent
`about 25 – 30% of the corn processed.
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`Average Yield Per Bushel
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`Starch 31.5 lbs.
`Gluten Feed 12.5 lbs.
`Gluten Meal 2.5 lbs.
`Corn Oil 1.6 lbs.
`
`
`Presented by
`Kelly S. Davis
`Quality Manager
`Chippewa Valley Ethanol Company
`
`Page 2 of 7
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`

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`Minnesota Nutrition Conference
`Minnesota Corn Growers Association
`Technical Symposium
`September 11, 2001
`
`• Condensed Corn Fermented Extractives or Corn Steep Liquor is a high-energy
`liquid feed ingredient. The protein value analyzes at 25% on a 50% solids basis.
`This product is sometimes combined with the corn gluten feed or may be sold
`separately as a liquid protein source for beef or dairy rations. It also can be used
`as a pellet binder and is a source of B-vitamins and minerals.
`• Corn Germ Meal typically analyzes at 20% protein, 2% fat, and 9.5% fiber. It
`has an amino acid balance that makes it valuable in poultry and swine rations. It
`is also used as a carrier of liquid feed nutrients.
`• Corn Gluten Feed is a medium protein ingredient composed of the bran and
`fibrous portions. It may or may not contain the condensed corn extractives. This
`product is also sold as wet or dry. The bran and condensed extractives
`(sometimes germ meal) are combined and dried in a rotary dryer. The dried corn
`gluten feed is made into pellets to facilitate handling. It analyzes typically as 21%
`protein, 2.5% fat, and 8% fiber. Wet corn gluten feed (45% dry matter) is
`similarly combined but not dried. It is a perishable product in 6 –10 days and
`must be fed or stored in an anaerobic environment. These feeds are widely used
`in complete feeds for dairy and beef cattle, poultry, swine and pet foods.
`• Corn Gluten Meal is a high protein concentrate typically supplied at a 60%
`protein, 2.5% fat and 1% fiber. It is a valuable source of methionine. Corn gluten
`meal also has a level of xanthophylls, which offers the poultry feed formulators an
`efficient yellow pigmenting ingredient. Corn gluten meal also is an excellent
`cattle feed providing a high level of rumen bypass protein.
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`The Corn Dry-Milling Process
`The beverage ethyl alcohol distilling industry in the late 19th century pioneered
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`the recovery of the nutrients from grains, which had undergone fermentation. It was
`immediately recognized as an excellent source of dairy cattle feed. Ethyl Alcohol was a
`critical item during WWII for the manufacturing of munitions. The beverage alcohol
`industry was asked to meet the demand. Obviously, cereal grains were an important
`commodity for livestock feed as well as human food and it was necessary to recover
`these nutrients remaining after the fermentation process. The world oil crisis in the
`1970’s and recent clean air legislation have contributed to an expanded dry-mill industry.
`Currently legislative issues are before Congress that could triple the demand for ethanol
`as an oxygenate component in gasoline. This increased ethanol demand will likely come
`from the dry-milling of corn thereby offering an increased amount of co-products.
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`Shelled corn arrives at the facility and is accepted through quality check
`procedures. The mashing and fermentation of the corn is mechanically simple but from a
`chemical and biological process are quite complex. The corn is cleaned of foreign
`materials and hammer milled to a medium-coarse to fine grind meal. This corn meal is
`then mixed with fresh and recycled waters in known ratios to form a slurry. The pH (5-6
`pH) and temperature (180 -195°F) is adjusted and an alpha amylase enzyme is added to
`facilitate the hydrolysis of the cornstarch to dextrin (long chain sugars). This process
`step is referred to as liquefaction. After complete liquefaction of the starch the mash is
`“cooked” to kill unwanted lactic acid producing contaminating bacteria. The mash is
`
`Presented by
`Kelly S. Davis
`Quality Manager
`Chippewa Valley Ethanol Company
`
`Page 3 of 7
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`

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`Minnesota Nutrition Conference
`Minnesota Corn Growers Association
`Technical Symposium
`September 11, 2001
`then cooled to 90°F and sent to a fermentation vessel where a glucoamylase enzyme is
`added that converts the dextrin into the simple sugar dextrose. Yeast species,
`Saccharomyces cerevisiae, are used to metabolically convert the dextrose in to ethanol
`and carbon dioxide. The fermenting mash is referred to as a “beer”. The corn protein
`and recycled waters (stillage) provide a major source of nitrogen compounds absorbed by
`the yeast microbes. The fats and fiber in the fermenter remain untouched and concentrate
`as the starch is converted to ethanol. Fermentation is completed in 40- 60 hours. The
`beer is then sent to the distillation area to strip away the ethanol. The water and all solids
`(protein, fat and fiber) are collected from the distillation base and referred to as whole
`stillage. This whole stillage is then centrifuged to separate the coarse solids from the
`liquid. The liquid is referred to as thin stillage, which is recycled to the beginning of the
`process or concentrated in the evaporator to become Corn Condensed Distillers Solubles.
`The coarse solids collected from the centrifuge are called wetcake. Wetcake and
`condensed solubles are then combined and dried in a rotary dryer to form the feed co-
`product Corn Distillers Dried Grains with Solubles.
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`Average Yield Per Bushel
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`Ethanol 2.7 gallons
`DDGS 18 lbs.
`CO2 18 lbs.
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`• Corn Condensed Distillers Solubles (CDS) is a term generally used to refer to
`the evaporated co-products of the grain fermentation industry. Most of the CDS
`is added to the dried grains but some is available as a liquid feed ingredient. The
`quality and composition of CDS can be affected by a number of factors including
`the original substrate, the process used, and evaporation procedures. Nutritional
`properties of this product can vary greatly. On a dry matter basis CDS typically is
`29% protein, 9% fat and 4% fiber. The solubles are an excellent source of
`vitamins and minerals, including phosphorous and potassium. CDS can be dried
`to 5% moisture and marketed but generally the dry matter content is between 25 –
`50%. In addition to its nutritive qualities, it has also proven to be a highly
`palatable feedstuff, which can effectively be used to boost consumption of other
`feed ingredients. CDS is a brown, free flowing to semi-solid liquid similar in
`viscosity to molasses. Because of the fermentation of the sugars, it is less sweet
`than molasses, and the taste ranges from neutral too slightly sour. Because of its
`nutritive composition and high palatability, CDS can be a valuable addition to
`many livestock rations, especially those requiring high nutrient density or those
`diets which include ingredients which animals may find less acceptable such as
`
`Presented by
`Kelly S. Davis
`Quality Manager
`Chippewa Valley Ethanol Company
`
`Page 4 of 7
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`

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`Minnesota Nutrition Conference
`Minnesota Corn Growers Association
`Technical Symposium
`September 11, 2001
`poorer quality roughages. Like other feedstuffs, it performs best as a component
`of a properly balanced ration.
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`• Corn Distillers Dried Grains with Solubles (DDGS) are recovered in the
`distillery and contain all the nutrients from the incoming corn less the starch.
`Thus the DDGS has at least three fold as much nutrients as the incoming grain.
`Approximately 4% of the amino acid in corn is broken down and then reconverted
`to the more nutritionally valuable microbial types. Since the stillage is recycled,
`the ratio of these more valuable amino acid types continues to increase so that
`eventually they represent approximately 16% of the final DDGS’s amino acid
`content. No other feed ingredient (corn gluten feed or meal, soybean meal, etc)
`results from such a great percentage of microbial products and their back
`stocking. The yeast also provides increased vitamins, particularly the B-complex
`group. DDGS typically analyzes as 27% protein, 11% fat and 9% fiber. DDGS
`provides ruminants with an excellent source of bypass protein. This product is
`also available in a wet form. DDGS has been successfully included in rations for
`beef and dairy cattle, poultry, swine, aquaculture and pet foods.
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`The corn plant is an efficient factory for converting large amounts of radiant
`energy from the sun into a stable form of chemical energy stored as cellulose, oil and
`starch. It has proven to be a very versatile grain. The end products produced from corn
`are used in our everyday life. As we expand the processing of corn by investing in
`research that looks for more value added components or harvest the crop to produce
`expanded quantities of renewable liquid transportation fuels we will also generate more
`quantities of excellent co-products for the feed industry.
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`Acknowledgments: National Corn Growers Association and Corn Refiners Association
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`
`
`Presented by
`Kelly S. Davis
`Quality Manager
`Chippewa Valley Ethanol Company
`
`Page 5 of 7
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`Minnesota Nutrition Conference
`Minnesota Corn Growers Association
`Technical Symposium
`September 11, 2001
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`Corn Wet-Milling Process Overview
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`Presented by
`Kelly S. Davis
`Quality Manager
`Chippewa Valley Ethanol Company
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`Page 6 of 7
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`Minnesota Nutrition Conference
`Minnesota Corn Growers Association
`Technical Symposium
`September 11, 2001
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`Corn Dry-Milling Process Overview
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`Cond.
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`Presented by
`Kelly S. Davis
`Quality Manager
`Chippewa Valley Ethanol Company
`
`Page 7 of 7