Green Plains boosts high protein ingredient production capacity

The site leverages MSC technology from Fluid Quip Technologies.

The company says the completion of this MSC system increases the overall annual production capacity for its Ultra-High Protein ingredient to 430,000 tons. This capacity is bolstered by Green Plains' operations in Obion, Tennessee, Shenandoah, Iowa, Mount Vernon, Indiana, and its Wood River and Central City facilities in Nebraska.

That premium protein ingredient is targeted at the pet, aquaculture, and other animal feed markets and, due to the MSC system, it can be sustainably produced at scale without requiring additional land for feedstock production, according to the producer.

Louis Rens, SVP of global ingredient sales, at Green Plains, told FeedNavigator that the company is currently assessing the timing, location, and feasibility of installing additional MSC systems.

“The longer we operate these MSC systems, the more we learn and improve, leading to increased yields. Our initial goal was to produce 3.5 lbs of Ultra-High Protein per bushel, but we've already surpassed that, achieving over 4 lbs per bushel at some facilities. This progress allows us to meet growing demand and consider building additional systems at one or more of our sites." 

Transformation journey ​

The US firm has been evolving its business from traditional ethanol into a sustainable biorefinery platform producing value-add raw materials over the past few years. In 2018, it launched a strategic plan to enhance operational efficiency and develop high-protein ingredients. It started to divest non-aligned assets, reduce debt, and transform its business model, leveraging innovative technologies and strategic partnerships. Mid-2020 saw its Shenandoah, Iowa based biorefinery ship its first load of Ultra-High Protein, with Green Plains reporting protein levels of over 50%, high digestibility and nutritional value for that ingredient.

New product launch

In April this year, the company launched Sequence: “It's the world's first plant-based 60% protein ingredient made from a combination of corn and yeast. We are really excited about this brand and what it represents for the high-value aquaculture feed and pet food markets we serve as well as our ability to begin to custom tailor nutritional solutions for our customers,” Todd Becker, Green Plains CEO, told analysts during a conference call on the company’s financials in May.

It is now working to increase the production of that 60% protein product. "Our aim is to have 20% of our capacity dedicated to producing Sequence by the end of 2024, with a long-term goal of converting the entire platform to this higher-value product," explained Rens.

He told us customers have been highly impressed with the results when including Sequence in formulations. "Our product has seen significant uptake in the aquaculture sector, in a variety of aquatic species; aquaculture is one of our key target markets. This has already led to recurring business. Several customers are currently running feed trials to verify the results we've observed in our own tests. Notably, one customer is planning to publish [the findings of] a successful feed trial with shrimp using Sequence."

Carbon capture ​

Green Plains also recently announced the execution of construction management agreements and the ordering of major equipment to capture carbon from its Nebraska facilities. The company said this positions it to begin construction in the second half of 2024 and to start capturing the biogenic carbon dioxide from producing 287 million gallons of ethanol annually by the second half of 2025.

The carbon capture equipment, to be installed at Central City, Wood River, and York, Nebraska, is designed to manage up to 1.2 million tons of carbon capture capacity, accommodating post-combustion carbon capture and increased production.

Becker remarked: "By capturing our biogenic carbon dioxide from fermentation, we demonstrate our commitment to sustainable production practices... once operational, we believe we will reduce the carbon intensity of our biofuel by half, positioning us as one of the largest producers of low carbon-intensity feedstock for sustainable aviation fuel. This will also positively impact the high-quality ingredients such as Ultra-High Protein, Sequence, and renewable corn oil produced at our Nebraska biorefineries, further advantaging our entire portfolio."