GR20150100550A - Treatment of plant co-products and olive tree sub-products for the production of functional products beneficial to livestock - Google Patents

Abstract

The preparation of functional products derived from the treatment of the olive tree’s residues and sub-products is based on the assembly of the proper mechanical equipment and the drying of the resulted basic plant products which are: a first product mainly composed of dried oil-cake and a second mainly composed of olive kernel wood. The final products have the beneficial properties of the olive fruit and olive oil and exhibit: antioxidant activity and heart-protective properties; enrichment of the livestock with oleic acid, linoleic acid and significant rates of natural antioxidant substances (polyphenols); improved taste and odor for meat and related products.

Description

PROCESSING OF PLANT BY-PRODUCTS AND OLIVE TREE BY-PRODUCTS TO PRODUCE FUNCTIONAL PRODUCTS AND THEIR EFFECT ON FARM ANIMALS

DESCRIPTION

Technical field of the invention

The present invention concerns the full utilization of plant products and olive tree by-products. It is carried out with a fixed processing device, in order to prepare complex complementary feeds without the addition of preservatives. These supplementary feeds can be given to farm animals, participating in a certain percentage in their diet. The animal products produced are enriched with oleic and linoleic acid as well as significant percentages of natural antioxidants (polyphenols). Animal meat, as well as all animal products, acquire an improved taste and smell.

Description of the existing technology

Today, olive oil is produced exclusively through the use of mechanical methods, which consist in pressing the fruit (pulp and pits) until a homogeneous viscous suspension is obtained, which is processed for phase separation.

During the phase separation stage, either hydraulic presses are used, or continuous centrifugation is applied. The continuous process is referred to as a three-phase process when the end products are olive oil, water and oil pomace, or as a two-phase process when the end products are olive oil and oil pomace.

In the three-phase system, water is added to the oily viscous suspension, and this mixture is then subjected to horizontal centrifuge treatment, where the solid phase is separated from the oily liquid. This liquid is then subjected to a vertical centrifuge, where the olive oil is separated from the water.

Today, the most common method is the two-phase method, as it involves less water consumption and therefore produces a smaller amount of residual water. This process uses two-phase centrifuges that separate the olive oil from the oil placenta. The placenta is a semi-solid residue with the characteristics of a thick pulp with moisture (45-75%).

Until now, the waste from olive oil production was either used for the preparation of pomace oil, or was discharged into the aquatic or terrestrial environment, polluting it. In addition, attempts have been made to date to incorporate various oil production by-products for the manufacture of animal feed, but with unsuccessful results.

The object of the present invention is the use of the solid residues of oil production as a raw material, with the aim of producing, after specific treatment, supplementary animal feed with a positive effect for farm animals and by extension for humans. In this way, olive tree residues are utilized and the final products produced acquire added value.

Brief presentation of the invention

Oil production waste has been of concern to state and private bodies for a number of years, due to its increased volume and polluting content.

With the present invention, we can utilize the solid waste of oil production by exploiting its properties. The utilization of olive mill waste does not only result in dealing with serious environmental pollution, as with appropriate processing we achieve the production of products that can be used as supplementary animal feed.

The placenta contains a significant percentage of oil with all its beneficial components. In addition, olive leaves contain more polyphenols than olive oil. Therefore, the final products produced gather all the beneficial properties of olive oil and plant products derived from the olive. In particular, the dried olive paste is characterized by a high percentage of oleic and linoleic acid, polyphenols, as well as an attractive smell. The heartwood produced after processing contains a very large amount of lignin and cellulose, as well as being characterized by beneficial fatty acids (oleic and linoleic acid) and polyphenols.

The raw materials are processed in a short period of time so that the raw material is not burdened. The process is detailed below.

The complementary feeds produced are characterized by high concentrations of antioxidants (a lot of phenols), as well as oleic and linoleic acids. Thus, the animal diet is enriched with bioactive ingredients, which can in fact give an improved taste to the meat produced, as well as enriching it with polyphenols, linoleic and oleic acid. In this way, we can introduce into the food chain new products derived from olive tree by-products, which improve the quality characteristics of animal products and, at a later stage, human health.

Advantages of the invention

The raw materials are processed in such a way as to preserve the bioactive substances as well as the aromatic compounds of the raw materials and the finished products.

Functional products can be used for food, animal feed, raw materials for the pharmaceutical industry, cosmetics and perfume industry, solid fuel and fertilizer industry.

The final products, the supplementary feed, contain significant percentages of antioxidants - a lot of phenols -, oleic, linoleic and palmitic acids, which give antioxidant character and reduce the chances of cardiovascular problems, respectively.

Full description of the invention

The entire production line consists of stainless steel mechanisms, which are suitable for food. Listed below is the mechanical equipment for the preparation of functional products from residues and by-products of olive trees.

A. Mechanical equipment

1. Tank (reception) of raw material

2. Conveyor belt

3. Cutting machine

4. Dryer

A) Hearth

B) Heat exchanger

5. Air transportation

6. Phase separation device - Air separation

7. Second phase separation device

8. Processing and separation device depending on the particle size composition.

9. Mixer

10. Weighing machine

11. Packaging

More specifically:

1. The raw material is collected in a stainless tank. It is kept for a short time, to avoid the growth of microorganisms and oxidation of its components.

2.        Transport of a certain amount of raw material (90-60% olive oil and 10-40% leaves and vegetable parts of olive trees). Continuous conveyor line so that the correct production process is maintained.

3.        The device is used to break up aggregates and plant products. This device is adjusted according to the size of the raw material (revolutions, power). A 20 hp electric motor and an inverter speed reducer are used.

4.       The hot air dryer is multi-path variable speed of the raw material and has a constant feed. There are temperature and humidity sensors on all dryer runs so that performance is controlled by an electronic system.

A) Heartwood or pellet fuel is used in the hearth. The burner starts and stops automatically based on the command given by three thermocouples (thermostats) that are placed one at the outlet of the dryer, the second at the inlet of the dryer and the third at the pipe connecting the stove to the exchanger. The hot and humid air that leaves the dryer is recycled in the hearth and all the solid suspended particles of the raw material, which have been carried away by the air current, are burned. In this way we achieve in addition to protecting the environment and saving energy. Part of the flue gas after the heat exchanger is recycled to the hearth. The flue gases of the stove, since they are finally at a lower temperature due to the heat exchanger than the original, are led to a cyclone and then to a microparticle removal filter. In other words, we have an operationally 'green unit', not only in terms of waste disposal, but also in terms of the operation of the stove.

B) This exchanger should have a large exchange surface. The construction material is stainless steel, material suitable for food. The exchanger is powered by a controlled air flow turbine (37,000m<3>/h); At the outlet there is a temperature sensor based on which we adjust the speed of air entering the exchanger. The device for processing vegetable products and oil pulp has the necessary central control and automation panel, where depending on the handling needs of each product, its operation and processing process is programmed. In addition, depending on the type of products to be processed, the appropriate bypasses of the arrangement devices are automatically activated, for shredding the sheets. Alternatively, the bypass settings may be controlled as desired by the device operator.

5.       Transportation of the dried raw material is done by closed pipelines in which a current of air is passed at a suitable speed, so that the material flies and drifts, with the proper pressure, and can reach the required distance. Blowers of this type are the most suitable as they maintain a constant flow, regardless of pressure changes.

6. In the first-phase separator, air separation is carried out, which is achieved by the vertical drop of the dried raw material. During the fall, an air current of controlled speed carries away the olive chips and olive leaves resulting in the collection of 1) olive chips by 45% and 2) heartwood by 55%. The air separation system consists of the following:

A) Conveyor screw

B) Waterfall

C) Wind turbine

D) Cyclonic system to deal with the emission of dust into the atmosphere during the production process.

7.       At this stage, the separated oil pulp (pulp - sheet) is received as mentioned above and is driven to a rotary machine with a brush for better cleaning of the oil pulp from the heartwood. Then, with a vertical drop, it is received in a vibrating sieve of centrifugal operation, which consists of four rows of sieves of different cross-section, starting from the smallest cross-section - diameter to the largest. During the cross-section, a separation is made according to the specific weight of the material.

8.       In this device, the pure processed oilseed meal is processed and separated, based on the particle size composition. In the roller mill, the raw material is ground and transferred to a sieve for separation or returned to the roller mill for grinding, so that we receive the appropriate particle size. The development of high temperatures is avoided during processing.

9. The mixer is used to homogenize the added products.

10. Closed-type weighing machine. The device is used after the mixer.

11.     The packaging of the product is done with suitable packaging materials in paper bags and mega bags.

B. Products

According to the above process, two final products are received:

1st product: The first produced product consists mainly of separated dried olive pomace which shows the following characteristics: Table 1: Chemical Characteristics

The final product has a low moisture content, which is one of the main characteristics of animal feed, so that microorganisms do not grow. The drying method, as mentioned above, is such that the bioactive components (such as e.g. polyphenols, etc.) are not destroyed in the final product produced. Crude fibers based on the production process are kept at low levels of 15-40%. Thus, farmed animals benefit from the existence of vegetable fibers as in this way the functioning of their gastrointestinal tract is improved. The high percentage of polyphenols enhances its antioxidant action, blocking the action of free radicals, offering an additional natural antimicrobial action. The product is also characterized by a high percentage of oleic acid, as shown in Table 2.

According to research in recent years, more and more efforts are being made to use by-products/by-products from plant processing industries, such as for example oil production, oil mills, in the breeding of productive animals and in farmed fish. According to studies, the olive kernel as well as the products that can be obtained from its processing can confer beneficial properties on farmed animals and fish. For example, raising fish with fish feed that includes some percentage of olive oil enriches the flesh of the fish with anti-inflammatory polar lipids. Nasopoulou C. et al. (2011). Effects of Olive pomace and olive pomace oil on growth performance, fatty acid composition and cardioprotective properties of gilthead seabream (Sparus a u rata) and seabass (Dicentrarchus labrax).

Table 2: Fatty Acid Profile

2nd product: The second produced product consists mainly of heartwood, which exhibits the following characteristics:

Table 3: Chemical Characteristics

The final product has a low moisture content, which prevents the growth of pathogenic microorganisms. The drying method as mentioned above is such that the produced final product retains its bioactive components (such as polyphenols, etc.). Crude fibers are the main component of the product and are found at a rate of 47-70%. In this way, farmed animals benefit from the existence of vegetable fibers as the function of their gastrointestinal tract improves. The high percentage of vegetable fiber brings rapid satiety to the animal. The high percentage of polyphenols enhances its antioxidant activity, thus enhancing its antimicrobial activity. In addition, the product shows a high percentage of oleic acid, which occurs in large concentrations in olive oil.

Table 4: Fatty Acid Profile

C. Effect of products on farm animals

These two produced products can be used as compound supplementary feeds, which are added in a certain percentage to the total ration of farm animals.

From studies that have been carried out, the final product A can be used to enrich the diet of broiler chickens, egg-producing chickens, fattening piglets, while the final product B is used in dry season sows. The two produced products are completely safe for all farm animals.

Broiler chickens

More specifically, from research carried out by broiler breeding units, it was observed that the enrichment of the ration with supplementary feed from olive tree residues at a rate of 2-10% from the 11th day until slaughter, results in:

•        To improve the digestibility of food, due to the presence of crude fibers.

•       The increase in carcass yield.

·        Decreasing the humidity of the litter.

•       The increase in the preservation time of the fresh carcass up to three days more, due to the existence of the natural antioxidant substances.

•       The reduction of mortality in poultry farming.

•       The increase in the percentage of polyphenols and oleic acid in the meat produced.

•       To improve the taste, smell and aftertaste of the broiled chicken, due to rearing with a diet enriched with dried oilseed meal.

•       The produced meat should show intense biological activity, and therefore be able to act against atherogenesis and high blood pressure, having anti-inflammatory properties with a cardioprotective effect. This fact is due to total polar lipids and their activity.

The results are listed, through diagrams 1-8, which are found in the designs section and described below and through table 5:

Diagram 1: Development of Total Microbial Flora, at various time intervals. Where:

, CONVENTIONAL

ENRICHED

Table 5: Percentage of polyphenols and oleic acid in broilers

Chart 2: Differences in taste between conventionally roasted breast

and enriched chicken. Where:

— ♦ BAKED BREAST

CONVENTIONAL CHICKEN

— ♦ BAKED BREAST

ENRICHED CHICKEN

and A - baked chicken, B - fatty, C - sweet, D - salty, E - rich, Z -

delicious.

Figure 3: Differences in aftertaste between roast breast

conventional and enriched chicken. Where:

— ♦ ■ BAKED BREAST

CONVENTIONAL CHICKEN

— ♦ BAKED BREAST

ENRICHED CHICKEN

and A - baked chicken, B - metallic, C - fatty, D - sweet, E - salty, Z -

astringent, H - rich, Θ - oily.

Figure 4: Differences in odor between conventional roast breast

and enriched chicken. Where:

— ♦ ROAST WITHOUT BREAST

CONVENTIONAL CHICKEN

— ♦ BAKED BREAST

ENRICHED CHICKEN

and A - fried chicken, B - fried chicken fat, C - chicken fat, D - fragrant, E - oily, Z - thick smell, H - spicy.

Figure 5: Differences in taste between conventional and fortified chicken leg roasts. Where:

BAKED LEG OF CONVENTIONAL CHICKEN

— ♦ BAKED LEG

ENRICHED WITH CHICKEN

and A - baked chicken, B - baked chicken fat, C - fatty, D - sweet, E - salty, Z - rich, H - tasty.

Figure 6: Differences in aftertaste between conventional and fortified chicken leg roasts. Where:

— ♦ BAKED LEG

CONVENTIONAL CHICKEN

— ♦ - BAKED LEG

ENRICHED WITH CHICKEN

and A - baked chicken, B - fatty, C - sweet, D - salty, E - astringent, Z - rich, H - oily, T - long.

Figure 7: Odor differences between conventional and enriched chicken leg roasts. Where:

— ♦ BAKED LEG

CONVENTIONAL CHICKEN

— ♦ - BAKED LEG

ENRICHED WITH CHICKEN

and A - fried chicken, B - fried chicken fat, C - chicken fat, D - fragrant, E - oily, Z - animal fat, H - thick smell.

Chart 8: Biological activity of the total polar lipids of the samples. Where:

□CONVENTIONAL

□ ENRICHED

Egg-producing hens

Similar results were presented by the research in egg-producing hens with ration enrichment with supplementary feed from olive tree residues at a rate of 2-10% from the genetic maturation of the hen until its removal. The results are listed below:

• An increase in egg production was observed.

• Polyphenols in eggs produced by laying hens that consumed enriched rations were twice as high as in conventional eggs.

· An increase in the percentage of fat was observed, as well as an increase in monounsaturated fatty acids, due to the increase in oleic acid. High concentrations of monounsaturated fatty acids, and more specifically oleic acid, have been proven to have beneficial properties in terms of human cardiovascular disease.

Table 6: Profile of fatty acids in egg samples (mg/100g fresh

sample)

tr*: Traces

Fattening piglets

Supplemental feed from olive tree residues was applied at a rate of 2-10% to fattening piglets after weaning until slaughter. Here are the results:

·        Feed conversion ratio (FCR) improves significantly.

• Livestock losses are reduced.

• Carcasses of piglets fed with enriched ration have been proven to have a longer shelf life than those of conventional rearing.

·        The percentages of polyphenols showed a significant increase.

•       The percentage of oleic acid in the carcass meat was significantly increased.

Diagram 9: Development of Total Microbial Flora, at various time intervals. Where:

— ♦ CONVENTIONAL

— ♦ ENRICHED

Table 7: Determination of Polyphenols in piglet samples (mg/Kg)

Table 8: Fatty acid profile in piglet samples (mg/100g fresh meat)

Claims (5)

1. Method of processing vegetable by-products and by-products of olive trees and any plant product for the production of innovative and functional products, which is carried out through the dehydration method (food grade) and the raw material separation method, where solid residues of oil production in tanks are received as raw material and then through a conveyor belt this raw material is transferred to the cutting machine for a specific cross-section of material, the dehydration of the raw material to produce the final plant product is done with the hot air dryer fully automated, the burner starts and stops automatically based on the command that they give thermocouples (thermostats), which method is characterized by the fact that after the raw material has been dehydrated, it is transferred to the first and second phase separation devices where: A) a vertical air separation of the first whole is carried out in percentage, where we receive 45% crumb oil and 55% heartwood. B) next, the oil pulp is transferred to the second-phase separation device (rotary machine with a brush) for the best cleaning of the oil pulp from the heartwood, then, with a vertical drop, it is led to the vibrating sieve of centrifugal operation, which consists of four rows of sieves of different cross-section ( starting from the smallest cross-section - diameter to the largest), while then it is transferred to the roller mill, where the raw material is ground and transferred to a sieve for separation or returned to the roller mill for grinding, so that we receive the appropriate granulometry of the final product. 2.     Functional product that can be used as supplementary animal feed for the production of enriched animal products based on the method of claim 1, characterized in that it consists of dried olive oil rich in oleic, linoleic and palmitic acids as well as high phenols, as a result of which it is characterized as an antioxidant precursor with antimicrobial activity and as a precursor of gaseous ammonia scavenger from the rearing chamber. Specifically, it consists of moisture by 3.0-8.0 g/100g, total fiber by 15.0-40.0 g/100g, total fat by 15.0-20.0 g/100g, polyphenols by 9000-15000 mg/kg, total carbohydrates by 35.0-40.0 g/100g, total sugars by 0.5-1.0 g/100g, proteins by 8.0-20.0 g/100g, salt by 0.3 -1.0 g/100g and total ash by 5.0-6.0 g/100g. The total fat of the product consists of myristic acid by 0-0.1%, myristelic acid by 0-0.1%, palmitic acid by 11.0-13.0%, palmitoleic acid by 0.5-1.0% , stearic acid by 2.5-3.0%, oleic acid by 68.0-73.0%, α-linoleic acid by 10.0-12.0%, linolenic acid by 1.0-2.0% , cis-11,14,17-eicosatrienoic acid by 0-0.5%, cis-8, 11,14-eicosatrienoic acid by 0-1.0%, cis-7,10,13,16,19-docisapentenoate acid by 0-1.0%, cis -4,7,10,13,16,19-docodihexenoic acid by 0-1.0%. 3. Use of the functional product of claim 2 as supplementary feed for the production of enriched animal products, characterized in that it is used in broiler chickens at a rate of 2.0 - 10.0% from the 11th day to slaughter, resulting in animal meat to be enriched with oleic and linoleic acid, as well as with significant percentages of natural antioxidants (polyphenols). Animal meat acquires an improved taste and smell, an antioxidant character and the chances of cardiovascular problems are reduced. 4.     Use of the functional product of claim 2 as supplementary feed for the production of enriched animal products, characterized in that it is used in egg-laying hens at a rate of 2.0 - 10.0% from the genetic maturation of the hen until its removal, resulting in animal products to be enriched with oleic and linoleic acid, as well as with significant percentages of natural antioxidants (polyphenols). In this way, they acquire an improved taste and smell, an antioxidant character and the chances of cardiovascular problems are reduced. 5.     Use of the functional product of claim 2 as supplementary feed for the production of enriched animal products, characterized in that it is used at a rate of 2.0 - 10.0% in fattening pigs after weaning until slaughter, with the result that the animal meat enriched with oleic and linoleic acid, as well as significant percentages of natural antioxidants (polyphenols). Animal meat acquires an improved taste and smell, an antioxidant character and the chances of cardiovascular problems are reduced.