For grain producers, few sights are as disheartening as pre-harvest sprouting (PHS). Triggered by untimely rains, PHS causes grains to germinate in the head, degrading quality and often leading to contamination with mycotoxins. This renders the grain unfit for food, feed, and even many industrial uses, resulting in significant financial losses. However, researchers at South Ural State University (SUSU) have developed an innovative technological solution that not only addresses this spoilage but creates a high-value product from it.
The SUSU team’s integrated approach tackles both the safety and efficiency challenges of converting spoiled wheat into bioethanol. The process begins with a crucial decontamination step: treating the damaged grain in a field of low-ionized gas (cold plasma). This plasma treatment effectively neutralizes toxic mould fungi and other pathogens, making the biologically hazardous material safe for further processing.
The true innovation, however, lies in the fermentation stage. The scientists compared two methods: traditional yeast fermentation and fermentation using specialized enzymes, with both processes enhanced by ultrasound treatment. The results were striking. The method combining enzymatic fermentation with ultrasound proved superior, producing a higher-quality ethanol suitable for technical, medical, and even food-grade applications. Most significantly, this combination slashed the required fermentation time from 7 days down to just 3.
This acceleration is a game-changer for economic viability. Faster processing means lower energy costs, higher throughput for biorefineries, and a more responsive supply chain. This aligns with global trends in the biofuel sector, where the International Energy Agency (IEA) has highlighted the need for more efficient and cost-effective advanced biofuels to meet decarbonization goals. By providing a rapid, reliable method to upscale agricultural waste, the SUSU technology directly contributes to this objective.
The technology developed at South Ural State University represents a powerful shift in how the agricultural sector can manage crop loss. It transforms a catastrophic event—the spoilage of a grain harvest—from a total write-off into a viable feedstock for the burgeoning bioeconomy. For farmers, agronomists, and agricultural engineers, this offers a promising risk mitigation tool. By creating a reliable market for spoiled grain, it enhances farm-level resilience, reduces waste, and contributes to the production of sustainable biofuels. This innovation is a clear example of how scientific advancement can close loops in the agricultural value chain, turning problems into profits.
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