Compositions and Methods for Producing Fermentation Products and Residuals

Abstract

The present invention provides compositions and methods designed to increase value output of a fermentation reaction. In particular, the present invention provides a business method of increasing value output of a fermentation plant. The present invention also provides a modified fermentation residual of higher commercial value. Also provided in the present invention are complete animal feeds, nutritional supplements comprising the subject ferment residuals. Further provided by the present invention is a method of performing fermentation, a modified fermentative microorganism and a genetic vehicle for modifying such microorganism.

1 . A method of fermentation using carbon-containing material, comprising:
 (a) mixing a carbon-containing material with a culture comprising genetically modified microorganisms that, in a fermentation reaction, produce an alcohol and a fermentation residual comprising a nutrient selected from the group consisting of amino acids, cofactors, hormones, proteins, vitamins and lipids, wherein the content of the nutrient in the fermentation residual is greater than that of an unmodified corresponding microorganism when used in the fermentation reaction;   (b) fermenting the culture under conditions suitable for production of the alcohol and under conditions suitable for production the nutrient;   (c) separating the alcohol from the culture; and   (d) producing the fermentation residual comprising the nutrient.   
     
     
         2 . The method of  claim 1 , wherein the microorganisms comprise a recombinant expression vector comprising an exogenous nucleotide sequence encoding a polypeptide and a regulatory sequence that controls the expression of the exogenous polypeptide, wherein expression of the exogenous polypeptide results in increased nutritional content of the fermentation residual compared with that of the unmodified microorganism. 
     
     
         3 . The method of  claim 2 , wherein the nutrient is an essential amino acid to at least one domesticated animal and the exogenous polypeptide comprises the essential amino acid. 
     
     
         4 . The method of  claim 3 , wherein the essential amino acid is selected from the group consisting of lysine, methionine, phenylalanine, threonine, isoleucine, tryptophan, valine, leucine, arginine, taurine and histidine. 
     
     
         5 . The method of  claim 2 , wherein the expression of the exogenous sequence is under the control of a regulatory sequence selected from the group consisting of a regulatory sequence of a heat shock gene, a regulatory sequence of a toxicity gene and a regulatory sequence of a spore formation gene. 
     
     
         6 . The method of  claim 1 , wherein the genetic modification modifies at least one of the structural genes in the nutrient's synthetic pathway. 
     
     
         7 . The method of  claim 1 , wherein the genetic modification modifies a regulatory control of the nutrient's synthetic pathway. 
     
     
         8 . The method of  claim 7 , wherein the synthetic pathway is for an essential amino acid for a domesticated animal. 
     
     
         9 . The method of  claim 1 , wherein the genetic modification modifies a structural gene that regulates synthesis of a peptide containing at least one essential amino acid for a domesticated animal. 
     
     
         10 . The method of  claim 1 , wherein the genetic modification modifies the nutrient's transport processes out of or into the microorganism. 
     
     
         11 . The method of  claim 2 , wherein expression of the exogenous sequence is induced when the fermentation reaction has achieved at least about 50% completion. 
     
     
         12 . The method of  claim 11 , wherein the at least about 50% completion is evidenced by a decrease in glucose content to less than about 50% of an initial content of glucose present in a fermentation reaction mixture prior to beginning the fermentation reaction. 
     
     
         13 . The method of  claim 2 , wherein expression of the exogenous nucleotide sequence depends on glucose concentration. 
     
     
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         21 . The method of  claim 1 , wherein the carbon-containing material is selected from the group consisting of cellulose, wood chips, vegetables, biomass, excreta, animal wastes, oat, wheat, corn, barley, milo, millet, rice, rye, sorghum, potato, sugar beets, taro, cassaya, fruits, fruit juices, and sugar cane. 
     
     
         22 . The method of  claim 1 , wherein the fermentation residual comprises distillers dried grains. 
     
     
         23 . The method of  claim 1 , wherein the fermentation residual comprises distillers dried grains with solubles. 
     
     
         24 . The method of  claim 1 , wherein comprising incorporating the fermentation residual into animal feed. 
     
     
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         31 . The method of  claim 1 , wherein the microorganism is selected from the group consisting of  Zymomonas  sp.,  E. coli, Corynebacterium, Brevibacterium, Saccharomyces, Clostridium  and  Bacillus  ssp. 
     
     
         32 . A genetically modified microorganism that, in a fermentation reaction, produces an alcohol and a fermentation residual comprising a nutrient selected from the group consisting of amino acids, cofactors, hormones, proteins, vitamins, and lipids, wherein the content of the nutrient in the fermentation residual is greater than that of an unmodified corresponding microorganism when used in the fermentation reaction. 
     
     
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         56 . A fermentation culture comprising:
 (e) a genetically modified microorganism that, in a fermentation reaction, produces an alcohol and a fermentation residual comprising a nutrient selected from the group consisting of an amino acid, a cofactor, a hormone, a protein, a vitamin, and a lipid, wherein the content of the nutrient in the fermentation residual is greater than that of an unmodified corresponding microorganism when used in the fermentation reaction and   (f) a fermentation medium for production of nutrients comprising a carbon source.   
     
     
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