Low-Cost Protein from Cottonseed

AVA BUSH '

As a source of fiber, the cot ton trend has been downward -- in acres harvested and in value of the crop. In 1961, cot ton had a farm value of $ ~ b i l l i o n - not counting Government payments; in 1970, little more than a third of this (17).

"Acreage has fallen off by 60 percent in the past 20 years; production has de- clined by 30 percent .... Only the Mid- South states plus Alabama, Texas and Cal- ifornia planted more than % million acres to cot ton in 1971. The Mid-South and Texas alone accounted for 70 percent of the acreage and two-thirds of the produc- tion of cot ton in 1971" (4).

"And foreign mills can buy cot ton of comparable quality from our competi tors at a lower price than we can afford to offer" (3).

Even though the USDA's Agricultural Research Service is developing processes which give cot ton the properties of synthetics while retaining its own best features, such treatment adds to the cost.

However, cot ton has more than fiber to offer. With each 100 pounds of fiber, the cot ton plant yields approximately 170 pounds of cottonseed, 95 percent of which is available for processing. Such products as cooking oil, linters, and cot- tonseed meal and hulls (for livestock) have long been familiar to the public (6).

For some years extensive research has been conducted to determine the use of cot tonseed as a food source. Studies have been made to calculate the tolerance level of various animals for gossypol (the toxic polyphenolic compound present in the glands and a process has been developed for its removal.

Glandless, gossypol-free varieties of cot tonseed have come from the combined efforts of many agencies to add a new

' Instructor, Department of Home Economics, Stephen F. Austin State University, Nacog- doches, Texas.

Submitted for publication September 11, 1972.

source of protein for human consump- tion.

During the early Fall of 1968, experi- mental tests at the Texas A & M Univer- sity Oilseed Products Research Center dis- closed that a pleasant, nut-like product could be produced from undefat ted glandless cot tonseed kernels with a mini- mum of processing. The glandless kernels, edible as nuts after toasting, roasting or frying, were soon known as Tamunuts. They were tested successfully in spreads, candies, cookies, and other bakery items, and in direct consumption snack foods" (11).

These glandless cot tonseed kernels were even tested for fat ty acid composi- tion and storage characteristics after deep-fat frying in various mediums. Corn oil, cot tonseed oil, peanut oil, safflower oil, soybean oil, and sunflower oil were used, separately, to produce acceptable Tamunuts. They were organoleptecally evaluated by a laboratory taste panel. It was found that no rancidity was detect- able until the end of the third week. Dif- ferences in fat ty acid profiles observed were due to the contr ibution to the total fat content of the kernels by the various oils used in frying (10).

Three basic products, derived from the kernels following oil extraction, are named in accordance with their protein content -- flour if not more than 60 per- cent, concentrate if not less than 70 per- cent, and isolate when 90 percent or above.

Construction of a cot tonseed mill was begun in Lubbock, Texas, in January, 1972, and was scheduled for full opera- tion by October, 1972 (13).

Failure of building plans to arrive on schedule, plus three weeks of bad weath- er, resulted in the completion date being reset for March 1, 1973 (16).

At a cost of $1-~ million, this is the world's first commercial-scale plant for making food-grade cot tonseed protein

ECONOMIC BOTANY 27: 137-140. January-March 1973. 137

flour. It will employ the Liquid Cyclone Process developed by the United States Department of Agriculture's Southern Utilization Research and Development Division at New Orleans in conjunction with Dorr-Oliver, Inc., of Stamford, Conn. A semicommercial unit of this type at Hubli, in southern India, has been used successfully for the past two years to yield 2 to 3 tons of this flour daily (15).

One-sixth of the cotton production in the United States comes from the Lub- bock area. Plains Cooperative Oil Mill is composed of 120 gin associations repre- senting 12,000 farmers who share its profits. The mill had its beginning in 1937 with a crushing capacity of 70 tons per day, employing 20 men. Today the crush- ing capacity is 1200 tons with employ- ment of 250 persons. It has an annual payroll of $2 million and annual sales of $40 million. It is reported to be the world's largest single cottonseed crushing mill (8).

This new facility will employ 30 per- sons, receiving an annual payroll of $210,000. The flour mill will be com- prised of five buildings -- laboratory, a preparation center, the processing plant, and two storage houses. Largest among these is the processing plant which covers 5,000 square feet (9).

The product from this plant (estimated at 25 tons daily} will be 65-70 percent protein -- a flour which closely approxi- mates a concentrate. According to Dr. Charles J. Lewis, Executive Vice President of Research and Development for Grain Processing Corporation, in Muscatine, Iowa, an agreement has been signed for purchase of the entire first year's produc- tion. This large wet miller and chemical manufacturer plans to use this in their " food fortifier" plant, now under con- struction. Snack foods, breakfast foods, breads, pastries, waffles, doughnuts, breakfast rolls, candies, soft drinks and acidic juices such as orange and tomato are included. This information has been released by Dr. Lewis and Dr. R. C. Malzahn, head of the corporation's tech- nical depar tment (12).

Conversion of the flour into an isolate will not be done by the Lubbock mill;

however, this is the form necessary for analogs (or simulated meat}, for the iso- late is actually spun into the desired tex- ture. These items are available in bacon, chicken, fish and other flavors.

Much credit is due Mr. Henry L. E. Vix, Chief Engineer at the laboratory in New Orleans, and his staff of researchers and technologists who developed and refined this unique liquid cyclone process. It is the most workable method yet devised for preparation of degossypolized cottonseed flour.

"Gossypol is removed in pigment glands via liquid cyclones, thus giving the development its name. The process con- sists of several unique operations includ- ing adequate drying of the meats prior to flaking, fluidizing of the flakes using com- mercial hexane, comminuting the fluid- ized slurry for proper separation of the fine flour from the glands, hulls and coarse meal in the cyclones. Finally, the flour is defatted and washed with hexane on a rotary vacuum filter, dried and desolvetized under mild conditions to maintain protein quali ty" (18).

"Based on the weight of solids input, yields of 35-40 percent flour have been obtained. Yields can be increased by mul- tiple milling, remilling of the underflow, lowering the concentrat ion of solids in the feed to the cyclones or by the use of two or more cyclones in a series.

"Sanitary conditions should equal those maintained by a food processing plant. Cost is relatively low...estimated at about ten cents a pound.. .and would be competitive with soybean protein concen- t ra te" (21).

The New Orleans laboratory not only gave assistance to Plains Oil Mill but they have cooperated with all persons inter- ested in this new vegetable flour. They have supplied hundreds of pounds to indi- viduals and institutions desiring to investi- gate its composition or characteristics.

Dr. Aaron Altschul, well-known au- thori ty in the field of oilseed products, states that in the United States cottonseed already provides 15 percent of all protein concentrate that is used in balanced ra- tions for livestock (6).

It is estimated that approximately 20

138 ECONOMIC BOTANY

grams of protein from a cottonseed pro- duct would cost 10 cents, compared to $1.00 for the same amount of protein from beef" (19).

Why do we want another vegetable pro- tein when soybeans have been well accept- ed and provide a source of such excellent quality?

The soybean has disadvantages in some of its forms; however, discounting this, Americans ask for variety. And, further- more, in many areas of the world that suffer a shortage of protein, soybeans are not grown while cotton is a major crop (2O).

If there are glandless varieties of cotton now being grown, why aren't they planted exclusively? It is obvious that processing of flour would be simplified if degossy- polization (removal of gossypol) were not necessary.

Even though glandless varieties of cot- ton are being successfully grown, most cot ton producers are not yet ready to swap the old seed for the new. "There are indications that the glandless may be more susceptible to insect damage and require different cultural practices" (19).

All crops are, of course, susceptible to disease. However, generally, only certain strains of a given disease will at tack a susceptible plant. The danger arises when all plants over a widespread area have identical parentage, and are therefore all subject to the same mutant strain of dis- ease...an example is the 1970 corn blight which destroyed 15 percent of the United States corn crop. That variety of corn was Texas Male Sterile or T Cytoplasm (5).

It is now known that the "green revolu- t ion" may be backfiring. The "miracle seeds" of rice planted in Asia as a substi- tute for the local varieties are n o t more productive under usual conditions but show a decline unless teamed with irriga- tion water, chemical fertilizer and heavy application of insecticides and fungicides (due to a lack of resistance to pathogens and insects carrying them). "The seeds of hope may become the seeds of destruc- t ion" (7).

Even though glandless cottonseed yields a flour that many consider to be superior both in flavor and in color, the

cot ton people are not quite ready, now, to gamble on varieties so new.

Uses o f C o t t o n s e e d F l o u r Cottonseed flour is not a substitute for

grain flour and it does not serve the same purpose. It is used for enrichment of both vegetable and meat products. It fortifies both flavor and nutritive value. It provides no gluten for elasticity in yeast doughs; neither can it be used to thicken products for it is not a starchy material.

"Small quantities of protein additives generally improve qualities important to the consumer such as texture, fat dispersi- bility and the like" (18).

Staleness in baked products is retarded due to the cottonseed flour's ability to retain moisture. In appearance, the flour is off-white or creamy and has an aroma and flavor reminiscent of dried milk.

Not only can cottonseed flour aid the family financially but it offers great prom- ise in the field of dietetics.

A study done over a period of several weeks with young children attending the Stephen F. Austin State University Nur- sery School showed foods protein-forti- fied with cottonseed flour to be an accept- able mid-morning snack, appealing to youth and adults as well (1).

Persons having diabetes or hypogly- cemia can utilize this product, which is rich in protein yet low in carbohydrates and calories. In developing recipes for this group it was found that glanded cotton- seed flour teamed with sugarless sweeten- ers turned out desserts with a rich satisfy- ing flavor; provided low-caloried salad dressings with some substance for the bland-flavored greens, and gave hidden value to pureed succulent vegetables (2).

In conclusion, a new source of protein for human consumption has been en- dorsed. Protein, referred to by some nutri- tionists as the "vital ingredient" in our diet, can be "low cost" -- when it comes from cottonseed.

1. R e f e r e n c e s

Bush, Ava. Spring, 1971. Developing meth- ods for preparing food containing cotton- seed flour so that it is acceptable to various age levels. A report on research (done with

B U S H : P R O T E I N F R O M C O T T O N S E E D 139

funds provided by Stephen F. Austin State University). Unpublished.

2. Bush, Ava. Spring, 1972. Developing reci- pes containing cottonseed flour that are acceptable for persons with diabetes or hypoglycemia. A report on research (done under the direction of Dr. Wilma A. Brown, Texas Woman's University at Denton). Unpublished.

3. Butler, Eugene. January, 1972. Cotton export costs must come down. The Progres- sive Farmer. Birmingham, Alabama. 87(1): 20a-21 a.

4. Deterling, Del. January, 1972. A look at cotton production 10 years down the road. The Progressive Farmer. Birmingham, Alabama. 87(1): 12a, 17 a.

5. Gentry, Jerry. June, 1972. Can we learn to feed the world in time? The Plain Truth. Ambassador College. Pasadena, California. pp. 23-26.

6. Harden, Margarette. Sept. 4, 1971. Baking with cottonseed flour may become reality in near future. The Cotton Gin and Oil Mill Press.

7. Harris, Marvin. June-July, 1972. How green the revolution. Natural History. The Ameri- can Museum of Natural History. New York. LXXXI(6): 28-30.

8. Herger, John F. 1972. The world's first commercial cottonseed flour mill. Brochure prepared for Plains Cooperative Oil Mill of Lubbock, Texas.

9. Howell, Duane. 1972.Mill ground-breaking held. Avalanche Journal. Farm Editor. (Reprint from Lubbock newspaper: Thurs- day, January 13, 1972).

10. Lawhon, J. T., C. M. Cater & Karl F. Mattil. July, 1970. Influence of the deep-fat frying medium on the acceptability and stability of glandless cottonseed kernels for use as a high-protein, low-cost edible nut. Food Technology. 24(817): 93-5.

11. Lawhon, J. T., C. M. Cater & Karl F. Mattil. June, 1970. Preparation of a high-protein low-cost nut-like food product from gland- less cottonseed kernels. Food Technology. 24(701): 77-80.

12. Lewis, Charles J. April 25, 1972. Personal correspondence (with enclosure of trade papers news release). Executive Vice-Presi- dent Research and Development. Grain Pro- cessing Corporation. Muscatine, Iowa.

13. Martin, Wayne. January 6, 1972. Personal interview, Production Manager of Plains Cooperative Oil Mill. Lubbock, Texas.

14. Mercer, Marilyn. July, 1972. The vital ingre- dient in your diet. McCall's. The McCall Publishing Co. New York. 99(12): 48-9.

15. Olivo, Walt. May 1, 1972. Personal corre- spondence (with enclosures). Director of Information and Promotion. Plains Cooper- ative Oil Mill. Lubbock, Texas.

16. Ibid. Personal correspondence. November 10, 1972.

17. Scruggs, C. G. November, 1971. Texas cotton a big industry in trouble. The Pro- gressive Farmer. Birmingham, Alabama. 86(11): 19.

18. Vix, H. L. E., P. H. Eaves, H. K. Gardener, Jr. & M. G. Lambou. October, 1971. Degos- sypolized cottonseed flour -- the liquid cyclone process. The Journal o f the Ameri- can Chemists Society. 48(10): 611-5.

19. . January 17, 1972. Cottonseed flour plant. Commodity News Ticker.

20. . June 15, 1970. Cottonseed to join soybean as human protein source. Chemical Engineering. pp. 96-8.

21. . Spring, 1971. High protein foods from cottonseed. Foods of Tomor- row. (A 4 page reprint).

140 ECONOMIC BOTANY