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Cedar Rapids Food and Bioprocessors Manufacturing Report February 23, 2018 Authors CEDAR RAPIDS FOOD AND BIOPROCESSORS MANUFACTURING REPORT FEBRUARY 23, 2018 AUTHORS John P. Stanford Bioeconomy Institute Iowa State University Ames, Iowa, United States Kevin M. Keener Center for Crops Utilization Research Department of Food Science and Human Nutrition Iowa State University Ames, Iowa, United States Email: [email protected] Phone: (515) 294-4365 ACKNOWLEDGEMENTS This work was funded by the College of Agriculture and Life Sciences, Center for Crops Utilization Research, and Bioeconomy Institute at Iowa State University. Funding in part was also provided by the Gary and Donna Hoover Endowment in Mechanical Engineering at Iowa State University. Iowa State University does not discriminate on the basis of race, color, age, ethnicity, religion, national origin, pregnancy, sexual orientation, gender identity, genetic information, sex, marital status, disability, or status as a U.S. Veteran. Inquiries regarding non-discrimination policies may be directed to Office of Equal Opportunity, 3410 Beardshear Hall, 515 Morrill Road, Ames, Iowa 50011, Tel. 515 294-7612, Hotline 515-294-1222, email [email protected] EXECUTIVE SUMMARY Executive Summary Cedar Rapids, Iowa, has a long and notable history 38% higher than the citywide average. For the period as a center of bioprocessing activity in the United between 2007 and 2016, employment in the food and States. Consequently, many market leaders have bioprocessing cluster increased at a rate more than selected Cedar Rapids as a prime location in which double that found in other sectors, and it’s notable this to operate. The City of Cedar Rapids and Iowa State increase occurred as total manufacturing employment University (ISU) have established a partnership in decreased in the regional economy. In the past 10 years, efforts to understand and support further development the value of goods and services produced by the food of the bioprocessing and manufacturing industry in and bioprocessing cluster increased at a rate 1.5 times Cedar Rapids. ISU is a world leader in education and greater than general economic growth in the City of research for agriculture, bioprocessing, and engineering. Cedar Rapids. Therefore, this unique public-private partnership Included in this report are details of the major process combines excellence across industry, higher education, steps of each bioprocessing activity, descriptions of and the public sector to create a framework to sustain the major products and byproducts, and discussions unparalleled competitive advantage for bioprocessing of water, energy use, and waste generation from each companies in Cedar Rapids. area. Product volumes, economic trends, and current This work provides a foundational overview of the market values are included when available. Historical current practices of major bioprocessing activities economic data for major products is included in the in Cedar Rapids. Namely, corn, oats, and soybeans appendix. processing; yeast and fermentation products Areas for potential growth in the current processing manufacturing; and processed food manufacturing. and manufacturing practices of the major bioprocessing The value of corn and oats raw materials processed activities are identified through evaluation of current in Cedar Rapids exceeds $1.1 billion. For each job scientific literature and survey feedback from some of created in the food manufacturing and bioprocessing the major plants and facilities in Cedar Rapids. These industry serving Cedar Rapids, four additional jobs are areas will be explored in depth in future technical supported throughout the wider economy. Currently, publications in efforts to offer specific means to grow the bioprocessing industry in Cedar Rapids employs and improve current practices. approximately 5,000 individuals in manufacturing activities, and median income for cluster employment is Cedar Rapids Food and Bioprocessors Manufacturing Report / 3 TABLE OF CONTENTS Table of Contents Executive Summary ..................................................................................................... 3 Table of Contents. .4 1. List of Terms ............................................................................................................... 6 2. Introduction ................................................................................................................ 8 3. Cereal Grains and Oilseeds Processed in Cedar Rapids .................. 10 3.1 Corn. 10 3.2 Oats. 13 3.3 Soybeans ............................................................................................................... 15 4. Manufacturing Processes ................................................................................ 17 4.1 Corn Overview ...................................................................................................... 17 4.2 Dry Milling. 17 4.2.1 Process. 17 4.2.2 Products ....................................................................................................... 19 4.2.3 Water, Energy, and Waste ......................................................................... 20 4.3 Dry Grinding .......................................................................................................... 21 4.3.1 Process. 21 4.3.2 Products ....................................................................................................... 22 4.3.3 Water, Waste, and Energy. 25 4.4 Wet Milling ........................................................................................................... 26 4.4.1 Process ......................................................................................................... 26 4.4.2 Products. 28 4.4.3 Water, Waste, and Energy .......................................................................... 31 4.5 Oats. 33 4.5.1 Process. 33 4.5.2 Products ....................................................................................................... 34 4.5.3 Water, Waste, and Energy. 35 4.6 Soybeans ............................................................................................................... 36 4.6.1 Process. 36 4.6.2 Products ....................................................................................................... 40 4.6.3 Water, Waste, and Energy. 41 4 / Cedar Rapids Food and Bioprocessors Manufacturing Report TABLE OF CONTENTS 4.7 Yeast and Enzyme Manufacturing. 42 4.7.1 Yeast Production and Processing ............................................................ 42 4.7.2 Process. 42 4.7.3 Products ....................................................................................................... 42 4.7.4 Water, Waste, and Energy. 43 4.8 Processed Foods and Products ......................................................................... 44 4.8.1 Process. 44 4.8.2 Products ....................................................................................................... 45 4.8.3 Water, Waste, and Energy. 45 5. Conclusions ............................................................................................................. 46 References .................................................................................................................... 47 Appendix ........................................................................................................................ 52 A.1 Corn Products Historical Prices. 52 A.2 Soybean Products Historical Prices. 55 A.3 Cedar Rapids Wastewater Treatment Plant Data. 56 Cedar Rapids Food and Bioprocessors Manufacturing Report / 5 LIST OF TERMS 1. List of Terms Amylopectin Germ Highly branched polysaccharide composed of glucose Reproductive portion of seed that germinates to grow units with linearly connected α(1-4) bonds and into a plant. Seed embryo. branched α(1-6) bonds occurring approximately every Hexane 24–30 glucose units. Branching allows fast enzymatic Organic solvent used to extract oil from corn and degradation. soybeans. Amylose High fructose corn syrup (HFCS) Linear helical polysaccharide composed of α-D-glucose Sweetener made from corn starch that is produced from units bonded through α(1-4) glycosidic linkages. glucose using an enzyme called glucose isomerase. Degree of depolymerization (DP) Hominy Number of monomeric units in a macromolecule or Coarsely ground corn used to make grits. Also used as polymer. animal feed. Dextrose Hydroclone Fully hydrolyzed or depolymerized form of starch. Also Device that applies centrifugal force to a flowing liquid known as glucose. mixture that separates heavy and light components. Dextrose equivalent (DE) Lactic acid Measure of the amount of reducing sugars determined Organic compound produced by the bacteria by heating a syrup in a reducing solution of copper Lactobacillus during the steeping of corn as part of sulfate. The DE gives an indication of the degree of the first processing step in a corn wet milling facility. polymerization of starch sugars. Assists in the softening of the corn kernel during Distillers dried grains with solubles (DDGS) steeping. Nutrient rich coproduct of dry-grind ethanol production. Lecithin Used as a feed ingredient for energy and protein Mixture of phosphatides (phospholipids) derived from supplementation. vegetables. Lecithin has a variety of purposes including Endosperm acting as a wetting and dispersing agent, emulsifier, Part of the seed that acts as food storage for the stabilizer, and viscosity reducer. developing embryo (germ). Contains starch, protein, and Maltodextrin other nutrients. Polysaccharide composed of D-glucose units that
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