Lexington, KY - Distilleries have been a part of the Kentucky landscape for almost as long as there has been a Kentucky, but spirits aren't the only thing the facilities make.
For generations, farmers have used the residual material left over after the distilling process, sometimes referred to as distiller's grain.
The mixture can come in a wet form affectionately known as "slop," or it can be an almost dry matter, depending on the methods used at respective distilleries. In either case, it has proven to be a cost-effective, nutritious way for cattle farmers to supplement their feeding needs.
Dr. Jeff Lehmkuhler, an extension beef specialist at the University of Kentucky (UK) College of Agriculture, said his research of the use of distiller's grain found the by-product has been in use as far back as the 1800s and is still a smart idea today.
"Utilization of spent grains and thin stillage, or slop, is not a new concept. In fact, the potential of distillery byproduct feeds to reduce production costs was widely recognized by the fermentation industry," he said. "According to articles published in the early 1900s, many of the distilleries had built feeding facilities and/or dairies near their plants."
Research over the years has shown that many types of byproducts, whether wet or dry, contain valuable proteins essential for good diets, but it wasn't always thought of in such a positive light.
Lehmkuhler noted that, at one time, a lack of knowledge on how to properly utilize those feeds resulted in distillery co-products getting a bad reputation by association with poor animal husbandry.
"In the mid-1800s, the New York Times reported the health departments were seeking to ban the use of slop from the diets of dairy cows and accomplished this in New York in the late 1800s. Cincinnati followed with a ban in the early 1900s. However, in some instances this ban was short-lived, as the milk quality issues were pointed out to be more related to sanitary conditions rather than the feed," he said. "When you get a new feed like this, it's about learning how to feed it properly. At that time, there wasn't enough roughage being fed, and once they learned that they needed to include a minimum amount of roughage in the diet, the feed was allowed back in."
Despite its longtime use, the utilization of such feed products is still reviewed today to make sure nutrient levels are proper, and use of the feedstock should be researched by farmers.
"It is important to note that in most of the recent research, stillage is not the primary ingredient offered to growing and finishing cattle. Rather, stillage was a portion of the daily dry matter consumed," he said. "Producers are cautioned when using these feedstuffs, and it is suggested that they contact a nutritionist or their extension agent for more information for feeding these products."
It is also important to note that the feed matter coming from the distilleries is alcohol free, so there are no drunken cows running around the countryside, said Lehmkuhler. He pointed out that the only way that could possibly happen is if the matter is mixed with another material that has the potential to ferment.
All in all, Lehmkuhler said, distiller's grain is a great feed resource that works well in ruminant diets and when compared to soybean meal, for example, it's very cost- competitive from a protein standpoint.
But before all cattle producers in the state line up to get a share of the feed supplement, there are some limitations to its use - one being the volume that's produced by a specific plant on a daily or weekly basis. Some plants slow or shut down production for periods of time, and it becomes a challenge.
Another thought, as more facilities dry the matter as opposed to leaving it in a thin stillage form, is that it becomes more mobile.
"The dry matter is certainly more workable and it's quite a valuable commodity, but one of the risks, in my opinion, is that if it gets wheels under it, it's a potential feed resource that might leave the state," said Lehmkuhler.
Making it a business
A couple of things that have spiked the interest in using distiller's grain are the increased price of corn due to extensive use in the production of ethanol and an up-and-down cattle market, leaving producers looking for ways to trim the budget.
Chris Sea, a cattle producer from Anderson County, has used the byproduct for his own herd and has now turned that into a business, delivering the feedstock to other farmers. Sea contracts with Four Roses Distillery to pick up all of the facility's distiller's grain and then sells it to producers who might not otherwise be able to get the product. The feedstock produced there is about 25 to 30 percent dry matter and has a consistency similar to peanut butter, said Sea.
"It is a good feed, high in protein, and its longevity, as far as spoilage, is good," he said. "In balancing rations, you need a little protein, especially this time of year. If you don't have that in high-quality hay, then this protein source is good."
Sea also said that because the product must be removed from the distillery as soon as possible, he is on call 24-7. Coupled with the fact that once he picks up at the facility, he immediately takes it to a customer, some as far as 150 miles away, and the business venture keeps him quite busy.
"I get a load out every eight-and-a-half to nine-and-a-half hours. I've tried to line it up so it doesn't hit the ground. When I get a truck loaded, I've got a place to go with it, and so far it's worked pretty good that way," he said.
Sea added that it has been a good business to be in, and there are a lot of good people with whom he does business.
"I hope this has helped some people, and I hope I treat them fairly. I want them to make it," he said.
Sea knows well the needs of the cattle farmer because, as he puts it, "I live it."
The relationship between two flagship industries in the state has proven to be beneficial for both over the years, and as long as there is bourbon and cattle production in Kentucky, hopefully that relationship will continue.