CZ22445U1 - Barley treatment apparatus - Google Patents

Description

Technical field

The technical solution concerns the field of agriculture, food industry and feed industry, specifically equipment that is intended for barley processing, so-called barley biorefineries.

Background Art

Cereal β-glucans (from oat grain layers and whole barley grain endosperm) have been proven in the scientific literature many times to reduce blood sugar levels and reduce levels of harmful LDL (low density cholesterol). The source of β-glucans in human nutrition are the so-called functional foods with β-glucans, which are especially needed by people with diabetes and those suffering from hyperlipidemia, ie increased plasma cholesterol and triacylglycerols (fats), but these foods can also be used. preventive prevention of cardiovascular diseases, together with a large group of antioxidants from consumed vegetables and fruits (vitamin E, C, carotenoids, phenolic antioxidants), probiotics and prebiotics (acidophilic milk, fermented milk products, bifidobacterium-enriched products) with phytosterols (rapeseed oil and virgin - extra virgin oils), with phospholipids (soy products), with lignans (bread with flax seeds). Flavonoids from the group of antioxidants, the richest source of which are the red onion, also the cabbage, the fruit mainly of apple.

For each substance, if it is to be used in the prevention of cardiovascular disease, it is important to have the daily amount that an adult must consume. In cereal β-glucans, this is on average 3 g / day per person. Since up to 10% of β-glucans and up to 7% of β-glucans are present in cereals of some special barley varieties, it would appear that the production of functional β-glucans from these cereals is no problem. But the opposite is true. Special barley varieties, rich in β-glucans, are at risk for growers. They are so-called "vaxs" with waxy type of endosperm and hairless varieties, their yields are significantly lower than those of ordinary puffed varieties. The cultivation of such varieties is not effective; moreover, the content of β-glucans is highly dependent on the course of the weather, on the site, and on agrotechnics. According to the Czech utility model CZ 16072, there are known foods to which the barley-free barley is directly added, eg bread, pancakes, gingerbread, baby food, etc., but in terms of β-glucans, this is a negligible percentage of the daily dose. Concentrated formulations suitable for the production of functional foods are required to achieve the required daily dose.

A similar situation is in oats, where the cultivation of special varieties is also risky, and moreover, oats, unlike barley, contain β-glucans not in the whole dark, but only in its subaleuron (subsurface) layers. According to the Czech patent application PV 2008-24, there is known a method and apparatus for processing oats, the aim of which is to isolate β-glucans for the production of functional foods. The essence of this method and apparatus is that the oat bran, i.e. the grain wrapping part of the grain endosperm, is separated by coarse scrap and both parts are processed separately. Oat bran is isolated by extraction, filtration, centrifugation and other steps to isolate oat starch, oat protein and β-glucan as a highly viscous solution. A whole range of economically usable substances can also be produced from oat bran. Of the separated endosperms, oatmeal is formed from which oatmeal is subsequently flocculated with reduced β-glucans. However, this method and apparatus run into difficulties in grain processing technology, where conventional milling stands are not able to effectively separate the subaleuron layers of mp. In addition, this method is not at all useful in barley processing where β-glucans are present throughout the whole area.

The task of the technical solution is to create a device enabling efficient processing of mainly barley, ie. and the isolation of β-glucans from these barley, in a concentrated form suitable for the preparation of functional foods, while allowing the production of other usable substances and raw materials that would improve production economics and ensure substantially non-waste barley processing.

-1 CZ 22445 Ul

The essence of the technical solution

The task is completely solved by the barley processing equipment, in particular its hulled varieties according to the invention. It is based on the fact that it comprises an extraction vessel for the extraction of coarse barley pulp in an aqueous or alkaline extraction solution, followed by a filter for separating the solid and the filtrate from the extraction solution. The filtrate is collected in a process tank with a heater, where a process liquid is formed containing, in addition to the filtrate, an enzyme preparation based on α-amylase thermostable at a temperature of at least 90 ° C, an enzymatic activator and a neutralizing acid. The equipment also includes a cooled precipitation vessel with neutralizing acid inlet to precipitate proteins, pure β-glucans or a mixture of β-glucans with proteins in the process liquid, and a sail filter to separate pure β-glucans or a mixture of β-glucans with proteins from the process liquid.

In a preferred embodiment of the invention for the production of alcohol, the apparatus further comprises a fermentation vessel for fermenting the filtrate of the process fluid from the sail filter, a centrifuge for yeast protein centrifugation from the ferment, and a distillation column for distilling the alcohol from the residual yeast without yeast protein.

Furthermore, the device according to the invention preferably comprises a dryer for drying the solids from the filter for dried barley pulp or dried precipitated proteins, drying the pure β-glucans or a mixture of β-glucans with proteins into dried pure β-glucans or a dried mixture of β-glucans with proteins , and drying the filtrate of the process liquid from the sail filter to a mixture of glucose and fructose. The individual products are dried in the oven successively on the basis of ongoing technological processes, stored or packaged and sold as feed for livestock.

In a preferred embodiment of the apparatus provided with the fermentation vessel and the distillation column, the apparatus further comprises also a dryer for drying the yeast protein from the centrifuge and the stillage from the distillation column, also for livestock feed. It is further advantageous for this embodiment to connect an alcohol tank connected to the distillation column connected to the cooled precipitation vessel and provided with an alcohol withdrawal valve and an alcohol supply valve. So it is possible to take and sell the alcohol from the system, in case of insufficient production it is possible to add alcohol to the system.

The advantage of the barley processing equipment is that it enables the efficient and basically non-waste processing of common varieties of hulled barley varieties for the isolation of β-glucans usable especially for the production of so-called functional foods. Also, isolation and preparation of a mixture of β-glucans with proteins is beneficial because the weight loss diet in humans is based on reduced intake of fats and carbohydrates and increased protein intake. Barley vegetable proteins are particularly well suited for this purpose because they compensate for the imbalance between animal and plant proteins in the obese who use these diets. Excess animal protein could cause kidney complications and is clearly negative in terms of intestinal hygiene. The biological value of barley proteins is higher for both wheat and maize because they contain a lower proportion of prolamins and a higher proportion of essential, accessible amino acids.

Last but not least, the device according to the invention enables to produce simultaneously a number of products which are economically usable especially as feed for livestock.

Drawing overview

The technical solution will be explained in more detail by means of a drawing, in which FIG. 1 shows a technological block diagram of a device according to the invention.

Exemplary embodiments

It is to be understood that the following examples of embodiments of the invention are presented to illustrate but not to limit the possible embodiments of the invention to the examples. Those skilled in the art will find or will be able to ascertain, using routine experimentation, a greater or lesser number of equivalents to the specific embodiments of the invention specifically described. These equivalents will also be included in the scope of the following protection claims.

Example 1 - Barley biorefinery

Barley, the food barley, is the best raw material for biorefineries because it has a higher fiber and β-glucans content. Less suitable are barley varieties, which are classified as industrial barley (for whiskey, starch, ethanol) and malting barley. The worst raw material is feed barley, which is high in protein and low in β-glucans.

io The composition of the sample of used barley in the exemplary embodiment (variety: BLANÍK) in the dry matter:

% 3

starch 60.0 proteins 13.0 N-substances soluble 2.0 cellulose 5.0 pentosans 9.0 β-glucans 3.5 low molecular weight carbohydrates (sucrose, maltose, glucose, fructose) 2.5 fats 3.0 mineral substances 2.0 100

13.4% of the original dry barley contains 81.1% protein and 18.9% β-glucans. The daily dose of this product is 15.9g / day for 1 adult.

The barley processing apparatus, also referred to as biorefinery, is shown in Fig. 1.

In the container 2, the coarse ground barley is stored, which is fed into the extraction vessel 3 with the stirrer 5 and the extraction solution 4. The more alkaline the extraction solution 4, the higher the yield of β-glucans from the extraction, but their quality deteriorates. Extraction solution 4 can also be water, resulting in the extraction of high quality β-glucans but with low yield, so that the extraction must be repeated several times. In the case of the alkaline extraction solution 4, the extraction must be carried out at least twice in succession. The barley pulp 1 used is filtered on a sieve filter 6 as a solids 14 from filtration, washed with a wash solution consisting of water with vinegar, which is fed to a sieve filter 6 through a conduit 7 and discharged by a drain 9, passed to a dryer 13 and dried after drying for example as feed for farm animals (poultry).

The filtrate 8 from the sieve filter 6 is collected in a process tank 10, mixed with a stirrer and neutralized with neutralizing acid 18, most often with dilute hydrochloric acid, to a pH of 6.5.

Enzymatic activator 23 consisting of anhydrous CaCl ₂ and enzymatic preparation 17 based on α-amylase of thermo-resistant type with guaranteed function at temperature are added to process tank W.

95 ° C. The process liquid 15, which thus forms in the process tank 10, is heated to a temperature

-3C 22445 U1C using a heater 12 to destroy β-glucans decomposing enzymes and maintain at 95 ° C for a total of 60 minutes, after which process liquid 15 is allowed to cool freely to room temperature.

After cooling, the process liquid 15 is neutralized with the neutralizing acid 18 formed by the dilute

HCl (1: 2 - 1: 3) until exactly pH = 4.5 was reached and allowed to stand until protein precipitation. In one embodiment, the process liquid 15 can be pumped through a sieve filter 6 where the solids 14 (protein) are filtered off and discharged to a drier 13 from which the dried protein 26 is distributed as a feed for the livestock, wherein the process protein 15 without protein returns to process tank J0. In a second variant of the embodiment, cesium liquid 15 is therefore left in the process tank 10 even with the precipitated proteins.

Protein 15 with or without protein is pumped into a chilled coagulation vessel 19. Add 20 alcohol at least 50% by volume, mix and cool to 4 ° C for 24 hours.

A rubbery mass consisting of gummy β-glucans and arabínoxylans precipitates in the cooled precipitation vessel 19, which cannot be effectively separated from β-glucans, but their properties are similarly favorable to those of β-glucans, so there is no need to separate them. The rubbery mass, together with the already precipitated proteins, is separated by a filter cloth on a sail filter 25.

The wet mass of β-glucans 16 or a mixture of 16 β-glucans and proteins is weighed, the dry matter content determined. Dry in an oven 13 at 105 ° C, then dry the grind to form dried β-glucans 24 or a dried mixture of 24 β-glucans and proteins. This product can be sold separately as a raw material resp. addition to functional foods.

In a variant of the embodiment, the filtered process liquid 15 from the sail filter 25 is centrifuged and subsequently dried on an evaporator or dryer 13 to a dry mixture of 27 glucose and fructose, which is used as feed for farm animals, or as a sweetener for preparing energy beverages. animals, eg for cattle.

In a second variant of the embodiment, the process liquid 15 from the sail filter 25 is fed to a fermentation vessel 28 where the sugar solutions are processed to the yeast 29 in a customary fermentation process, which is centrifuged in a centrifuge 30. The yeast protein 31 obtained by centrifugation is dried in an oven 13 and recovered. is also a feed for livestock. The residual yeast 32 devoid of yeast protein 31 goes from the centrifuge 30 to the distillation column 33 where the alcohol 20 is distilled therefrom. The stillage 34 from the distillation column 33 is used as feed for the livestock, preferably after drying in the oven 13. it can be produced as a stand-alone product for sale, or stored in a collecting tank from which it is fed to the cooled precipitation vessel 19 via the alcohol replenishment valve 22 to process the β-glucans. Through the alcohol withdrawal valve 21, alcohol 20 can be removed into containers and subsequently stored elsewhere or sold.

The above-described devices can also successfully produce β-glucans from feed barley, if further filtration by a sail filter 25 is added to the cooled precipitation vessel 19 prior to the addition of alcohol 20 and completely precipitated barley proteins are separated. This results in the end product losing the protein portion of the protein β-glucan concentrate, which is a pity, but the β-glucan concentration in the final product increases sharply to 80-90%. Of course, the yield of β-glucans will be less, about 20% of the usual amount. On the other hand, the daily dose required for a person and day is substantially reduced and will be in the range of 3 to 5 g / day for 1 adult, as it will essentially be a concentrate.

It is important to realize that the β-glucan extraction conditions and the presence of arabic 45 noxyllanes as sticky viscous solutions require considerable dilution and therefore handling of large volumes of liquids. When 100 kg of barley "BLANÍK" is processed, about 1,200 necessary daily doses are produced. However, to isolate these 1200 daily doses, it would be necessary to manipulate 72,000 l of extraction solution 4, that is, an extraction vessel 3 having a volume of at least 50 m ³ and a process vessel 10 of even volume would be required to process this amount of barley at once

-4CZ 22445 Ul

100 m ³ . It is therefore clear that the manufacturing process must be organized as periodically continuous and based on the manufacturer's capabilities. In any case, it is a large-scale production.

Also, the regeneration and actual production of alcohol 20 from sugar solutions that have been formed by the digestion of barley starch by an enzymatic route is high throughput. When processing 100 kg of barley at a time, there is about 50 m ^{3 of} alcohol 20 in the process liquid 15, which is still recovered on the distillation column 33. Since the alcoholic starch yield at the average quality of work is 60%, it is expected that when processing 100 kg of barley in a given 60 χ 0.6 = 36 dm ^{3 of} 100% ethanol, ie 37.5 1 96% alcohol 20, can be obtained from this quantity. About 50% of this amount will supplement the technological losses of alcohol 20 during the precipitation of β-glucans. 15 to 18 dm ^{3 of} 96% alcohol per 100 kg of processed barley.

Industrial usability

The device according to the invention can be used for the effective isolation of β-glucans and / or a mixture of β-glucans and proteins from barley, for their subsequent use in the preparation of functional foods, and for the production of a number of feeds for livestock as by-products. Last but not least, the device is usable for the production of alcohol.

Claims (5)

PROTECTION REQUIREMENTS Apparatus for processing barley, in particular of its stinking varieties, characterized in that it comprises an extraction vessel (3) for extracting coarse pulp (1) in an aqueous or alkaline extraction solution (4), a filter (6) for separating the solids ( 14) and a filtrate (8) from the extraction solution (4), a process tank (10) with a heater (12) for the process liquid (15) comprising the filtrate (8), an enzyme preparation (17) based on thermostable α-amylase a temperature of at least 90 ° C, an enzymatic activator (23) and a neutralizing acid (18), and further comprising a refrigerated precipitation vessel (19) with a supply of neutralizing acid (18) to precipitate proteins (26), pure β-glucans (16) or a mixture of β-glucans with proteins (16) in the process liquid (15), and a cloth 25 filter (25) for separating pure β-glucans (16) or a mixture of β-glucans with proteins (16) from the process liquid (15). The apparatus of claim 1, further comprising a fermentation vessel (28) for fermentation of the process liquid filtrate (15) from the sheet filter (25), a centrifuge (30) for centrifuging the yeast protein (31) from the ferment (29). , and a distillation column (33) for distilling alcohol (20) 30 from residual ferment (32) without yeast protein (31). The apparatus of claim 1, further comprising an oven (13) for drying the solid (14) from the filter (6) to dried barley pulp (1) or dried precipitated protein (26), drying pure β-glucans. (16) or mixtures of β-glucans with proteins (16) to dried pure β-glucans (24) or dried mixture (24) β-glucans with proteins, and drying the filtrate process 35 liquid (15) from the sliding filter (25) to a mixture (27) of glucose and fructose. The apparatus of claim 2, further comprising an oven (13) for drying the yeast protein (31) from the centrifuge (30) and the stillage (34) from the distillation column (33). Apparatus according to claim 2, characterized in that an alcohol tank (20) is connected to the distillation column (33) and communicates with a cooled precipitation vessel (19) and is provided with a valve (21). 40 and the valve (22) of the alcohol supply (20).