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Local farmers will have another market for corn in 2024.

October 6, 2022

4 Min Read
The former Central MN Renewables ethanol plant in Little Falls is being revamped to produce cultured protein by Superbrewed F
MAJOR RENOVATION: The former Central MN Renewables ethanol plant in Little Falls, Minn., is being revamped by Superbrewed Food to produce cultured protein. Photos courtesy of Superbrewed Food

A former Minnesota ethanol plant is on track to produce the world’s first anaerobically cultured protein.

Though Superbrewed Food’s process of “biomass fermentation in an anaerobic environment using sugars from a variety of feedstocks” sounds complicated, farmers near the Little Falls plant just need to know it will provide a high value and local market for the corn they grow. For consumers, the whole-food protein offers a plant-based alternative, rich in protein and nutrients, that offers many advantages and can be used in a variety of foods.

“We take corn, convert it to sugar and ferment it to 85% protein,” says plant manager Ryan Carruth, who is overseeing the ethanol plant revamp, and developing and designing the processing system to be in place by 2024.

Process advantages

Superbrewed Food is different from other alternative proteins, such as those made by precision fermentation (a genetically modified process), because it is an anaerobically (without oxygen) fermented whole-food protein made from microflora found in nature that converts plant starches into a nutrient-rich protein ingredient. The process of fermentation — similar to making beer, yogurt and kimchi — makes it a non-GMO process. The result is a whole food that retains natural nutrition, including a full day’s supply of B-12; four other B vitamins; all nine essential amino acids; and a good source of minerals, such as iron, phosphorus and magnesium.

bowl of Superbrewed Food protein powder and glass bottle of white liquid

With 85% protein by weight, it surpasses other microbe products. It has a 60% weight conversion of sugar to the final product, so it’s a highly efficient process, says Bryan Tracy, Superbrewed Food CEO and co-founder. It’s also affordable, due to its scalability and the stable supply of corn.

“We combine our proprietary microflora with starch plus two salts — at which point it is then anaerobically fermented in less than a day,” Tracy says. “After fermentation, it is simply washed and dried, leaving a whole-food protein powder that is minimally processed to preserve the extra nutrition beyond protein.”

“Our product tastes neutral; we don’t have to mask the flavor. Products can get the nutrition without affecting function or taste,” Carruth adds, noting that the protein is white and has a smooth texture.

Besides having high nutrition, it is allergen-free, made with non-GMO, No. 2 yellow corn, and it’s affordable and versatile to use in vegan and all types of protein products.

Diverse market opportunities

One of Superbrewed Food’s first collaborations is with Bel Group (makers of Babybel and Laughing Cow cheeses, etc.), to develop a line of cheeses. The protein is being made at the Superbrewed Food demo-scale facility in Delaware.

Potential markets are endless. With a full day supply of B-12, it’s ideal for vegans who don’t eat eggs. It can be added to protein bars and shakes.

“There’s lots of interest in things that are allergen-free. And with its high amino acids, there’s lots of interest in the performance market for weightlifting,” Carruth adds.

Compared to animal protein, the Superbrewed Food protein has a 75% lower footprint and uses 50% less water.

“Several companies are already working with Superbrewed Cultured Postbiotic Protein in their innovation pipelines, in categories ranging from alternative dairy to baked goods,” Tracy says. “It has excellent pH and temperature stability, so it does not clump in hot foods or beverages or when cooking. Additionally, it can serve as an emulsifier, so it lends a creamy and smooth texture to foods, and has low water activity that extends shelf-life stability.”

Sustainable opportunity

Though the fermentation process to create ethanol and postbiotic protein is similar, it will take work and time to refine the former ethanol plant and develop the process. Carruth estimates it may be 2024 before the first corn goes through the plant.

For farmers in the Little Falls area, Superbrewed Food will provide an opportunity when production begins.

“The nice thing about this plant site is that it has a lot of history [formerly Central MN Ethanol]. It was an important facility in the past for taking local corn. It will give farmers an option to have a local delivery point for high-value crops,” Carruth says. “And food markets are more stable than commodity feeds.”

Growers in the non-GMO soy program can take advantage of the practices and storage they have in place to add non-GMO corn to their rotation.

There is also zero waste because the fermentation process produces short-chain fatty acid butyrate, which promotes gut health and reduces the need for antibiotics. Superbrewed Food plans to produce butyrate as a human food additive and flavoring, as well as a crude version for livestock producers.

“We look forward to rekindling farmer relationships at this facility to create a new product,” Carruth says.

Goerge is a freelance writer based in Parkers Prairie, Minn.

 

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