Effect of process variables on the quality characteristics of pelleted wheat distiller's dried grains with solubles

The rapid expansion of ethanol processing plants in Canada has resulted in a significant increase in the production of wheat-based distiller's dried grains with solubles (DDGS). Transportation and flowability problems associated with DDGS necessitate investigations on pelleting. In the present study, the effect of process variables like die temperature (T) and feed moisture content (Mw) on the pellet properties like pellet moisture content, durability and pellet density was explored using a single pelleting machine; further studies on pelleting DDGS using a pilot-scale pellet mill were also conducted to understand the effect of die diameter and steam conditioning on durability and bulk density of pellets. Proximate analysis of DDGS indicated that crude protein and dry matter were in the range of 37.37–40.33% and 91.27–92.60%, respectively. Linear regression models developed for pellet quality attributes like pellet moisture content, pellet density and durability adequately described the single pelleting process with R2 value of 0.97, 0.99 and 0.7, respectively. ANOVA results have indicated that linear terms T and Mw and the interaction term T × Mw were statistically significant at P < 0.01 and P < 0.1 for pellet moisture content and pellet density. Based on the trends of the surface plots, a medium T of about 50–80 °C and a low Mw of about 5.1% resulted in maximum pellet density and durability and minimum pellet moisture content. Results from pilot-scale studies indicated that bulk density, durability and throughput values were 436.8–528.9 kg m−3, 60.3–92.7% and 45.52–68.77 kg h−1, respectively. It was observed that both die diameter and steam addition had a significant effect on the bulk density and the durability values. The highest bulk density and durability were achieved with 6.4 mm die diameter with steam addition compared to 7.9 mm die with or without steam addition.