Selected Accomplishments for Fiscal Year 1998 (listed by Component)

Malting quality improvement in barley. Scientists purified two protein-degrading enzymes from malt that had never been analyzed before. They also used biochemical methods to ascertain which enzymes are most important in degrading proteins during the brewing process. This knowledge, combined with related information compiled by ARS, makes it possible to regulate how proteins are degraded during the malting and brewing processes and thus to improve an important determinant of quality of the final product.

Improving flavor of corn products. Research by ARS scientists provided a much better understanding of the factors responsible for the flavor of a number of corn products including popcorn and corn tortilla-type products. The research required developing improved methods to measure the volatile compounds responsible for the flavor of these products. The knowledge derived from this research gives the producers and processors of corn products a better basis for the design of new cultivars and new processing methods to produce products of high flavor quality.

Bittersweet citrus limonoids. ARS scientists, with collaborators, have been developing knowledge to eliminate citrus bitterness that arises after juicing. They identified and isolated a gene that can eliminate delayed bitterness caused by synthesis of a class of limonoid compounds and are working to create a transgenic nonbitter citrus. Limonoid compounds in both bitter and nonbitter forms have demonstrated anticancer properties and insect antifeeding properties and may have substantial value.

Better prediction of dough mixing strength. ARS researchers developed a quick method to predict dough mixing strength (important to breadmaking quality) by measuring the amount of insoluble polymeric proteins in wheat flour. This technique enables a single technician to analyze up to 100 samples per day, differentiating stronger doughs (larger amounts of polymeric proteins) which produce better breads, from weaker doughs, which produce poor-quality breads. This improved method of evaluating flour quality will be of value to millers and bakers, who need better methods to predict baking properties.

Modifying durum wheat for breadmaking. Research showed that bread made with durum flour (traditionally used in pasta manufacture) had improved antistaling properties when compared with bread made with 100 percent spring wheat flour (the more traditional base for breadmaking). New durum wheat experimental lines were developed with high-molecular-weight glutenins transferred from spring wheat, thus improving the breadmaking properties of the durum wheat. A new use of durum wheat for commercial breadmaking is the goal of this research.

Roasting affects peanut allergenicity. ARS researchers produced direct evidence that roasting may enhance peanut allergenicity. The research shows that a better method of processing is needed to reduce or eliminate the allergenicity of peanut proteins.

Control of Fusarium dry rot in potatoes. ARS scientists have discovered and developed safe and efficient biological agents to control Fusarium dry rot in potatoes, potentially replacing or reducing the use of chemical control agents and reducing the $100-500 million/year in economic losses suffered by the potato industry.

Model for aflatoxin sampling plans for peanuts. ARS scientists developed a peanut market system model to show the effects of industry processing methods and aflatoxin regulations on the reduction of aflatoxin in peanuts. The model provides USDA and the peanut industry a method to predict the effects of proposed new aflatoxin regulations and new processing methods, allowing their evaluation before implementation (which is very costly, and can be disruptive if the new procedures are not fully effective).

Functional, healthful food ingredients from oats and barley. A natural extraction process was used to remove the coarse fiber components from oat and barley to produce soluble food fiber ingredients with functional and healthful qualities. The products, called Nu-TrimX, were used as dairy cream, coconut cream, or milk substitutes in foods such as frozen desserts, milk, cheese, and non-dairy creamers. A patent was filed on the technology.

Low oil-uptake rice batter. A rice batter that was developed is inexpensive, has the desirable characteristics of traditional batters (e.g., fries crispy), and possesses the unique property of retaining significantly less oil during frying than wheat batters. The rice batter is composed mainly of flour prepared from low-cost broken rice and small quantities of specially modified rice starch.

Margarines free of trans fatty acids. Trans fatty acids, produced during the partial hydrogenation of vegetable oils, have been associated with elevated serum cholesterol, possibly increasing the risk of coronary heart disease. Margarine and shortening oils were prepared essentially free of trans fatty acids by blending soybean oils, genetically bred for special properties, with harder vegetable oils, or through high-pressure hydrogenation.

Improved extraction of corn fiber oil. Corn fiber oil, derived from corn bran, is an important new product recovered from the waste fiber fraction of the corn wet-milling process. In cooperation with a CRADA partner, ARS developed two processes to extract corn fiber oil. Research by ARS scientists and collaborators found that the oil has serum-cholesterol-lowering properties. Patent applications are pending on both processes, and the oil is being developed for commercialization by a CRADA partner.

Preservation of raw cattle hides by irradiation. ARS demonstrated that gamma and electron beam irradiation can successfully preserve raw cattle hides until they can be tanned. The process has potential for replacing traditional salt curing, which produces environmentally damaging brine wastes and requires expensive environmental treatment. Adoption of this process could help improve the global competitiveness of the domestic tanning industry.

New biodegradable plastics. ARS research sponsored by the Biotechnology Research and Development Corporation resulted in the granting of several patents in the U.S. for the use of starches and flours in blends with proprietary polyhydroxyl ester ethers to make a variety of biodegradable materials including films, foams, and both compression- and injection-molded articles. This technology is anticipated to provide a significant new use of corn starch. Technologies were also developed for plastic blends that contain low-value polymers from crop residues. Selected formulations were tailored for use in commercial graphic signs. Tests demonstrated that the blends had excellent print and weather properties.

Soy inks. Soy oil has great potential to replace petroleum-based oils in formulation of printer's inks, which would reduce dependence upon imported petroleum, increase biodegradability, and reduce volatile organic emissions. This market for soy oils is estimated at 1 billion pounds, or 8 percent of domestic production. Sheetfed and heatset inks consisting of pigments and 100 percent soybean oil were formulated and tested and found to be functionally comparable to mineral-oil-based vehicles. A patent was awarded to ARS for the sheetfed and heatset ink technologies.

Development of an effective phytase feed additive. Most seeds contain large amounts of phytic acid, a compound rich in phosphorus but indigestible by monogastric animals such as pigs and chickens. ARS scientists are developing stable, cost-effective phytase (an enzyme that breaks down phytic acid) as a feed additive to convert phytic acid in soybean and other seed meals into compounds that monogastric animals can easily digest. Successful application of this technology will lower phosphorus content of animal manure and thus of runoff as well. Phytase is expected to contribute significantly to a reduction in the movement of agriculture-derived nutrients into rivers. It could also end the need to supplement animal feed with phosphate, because more of the phosphorus in the meal will be available. Recently, a specific phytase inhibitor was developed and several factors were identified that correlate with increased thermal tolerance. The inhibitor provides animal nutritionists with the means to block contaminating microbial phytase available in the animal gut. Feeding studies with poultry and swine, using phytase produced in transgenic alfalfa, indicate much promise for this technology to improve both the nutritional quality of animal feed and the purity of our nation's rivers.

Antifungal peptides. Potent antifungal peptides (small proteins) and genes encoding these peptides were discovered and are being used to transform/genetically engineer plants to prevent fungal diseases, which can cause very large economic losses through spoilage and formation of mycotoxins.

Use of gin process control systems increasing. Overcleaning and overdrying cotton during gin operations damages cotton fibers, reducing their value to the textile mill, and also generates considerable waste that adds to the cost of the textile. ARS has developed computerized gin process control technology to optimize gin performance and minimize fiber damage. The technology, which has been patented and licensed to the private sector, includes new hardware to capture and analyze cotton samples and to automatically route them, sensors to measure moisture and other important fiber characteristics, computer models of ginning systems and an optimization model, and systems to control the gin operation accordingly. During 1998, eight ARS-developed gin process control systems were installed in private industry. These new systems, marketed as 'IntelliGin,' increased value to the farmer by about $15 per bale.

Fuzzy cottonseed utilized as nutrient-dense animal feed. In cooperative work with Cotton Incorporated and the private sector, ARS has been solving problems related to utilizing cottonseed directly as feed. Fuzzy (non-delinted) seed must be coated with starchy materials to allow it to flow smoothly. Residual long fibers must be removed, and drying must be cost-efficient. A pilot plant to perform these operations has enjoyed considerable success, resulting in the first commercial plant to produce fuzzy seed coming online in Virginia in 1998. This process produces a new, nutrient-dense, high-energy feed for dairy cattle that was not previously available.

Improved fabric processing technology. Treatment of cotton with hydrolytic enzymes alters its properties, including appearance, softness, and feel. The process is relatively slow. ARS in 1998 demonstrated that treatment of fabric with ultrasonic energy improves the efficiency of cellulase treatment of fabric up to 100%. ARS is currently cooperating with private companies to evaluate and advance this technology to the commercial stage.

Flame-resistant 100 percent cotton fabric. Cotton fabric must be treated to reduce its flammability to meet standards for carpeting, upholstery, and protective clothing. The cost and durability of treatment need to be improved. ARS has developed new polyphosphate-urea flame-retardant finishing processes for different cotton fabric types that are both durable and lower cost than the process they might replace. The technology is currently being evaluated in the private sector.

New films to replace polyethylene for agricultural mulches. Composites of fiber (paper) impregnated with polymerized vegetable oils were found to have sufficient wet strength and sufficiently slow rate of breakdown to function as biodegradable agricultural mulch films. They are cost competitive with polyethylene, which is currently used for mulching. Where polyethylene is used in agriculture, it is a significant problem, because it is non-biodegradable and expensive to dispose for the farmer. Biodegradable mulches suitable for use in agriculture will benefit the environment and will also significantly lower the costs of crop production.

Biodegradable heavy metals adsorbents from agricultural plant residues. ARS scientists chemically modified low-value crop byproducts with citric acid through reactive extrusion to form biodegradable ion exchange resins that can remove heavy metals and textile dyes from wastewaters. Methods were also developed to regenerate these resins many times, making the entire process more economic. Other ARS scientists developed technology to chemically activate carbon derived from almond shells. The new activated carbon can sequester 2-4 times as much metal ion as commercial carbons that were evaluated. In addition, the scientists produced granular activated carbons from black walnut and macadamia nutshells that are particularly good at removing a wide range of organic compounds from both air and water resources. Soybean hulls were also converted to adsorbent material which was able to remove more than 95 percent of toxic and potentially toxic metals, such as cadmium, copper, lead, nickel and zinc from contaminated water and wastewater.