RU2538147C1 - Method for processing of sunflower or rape extraction cake (versions) - Google Patents

Abstract

FIELD: food industry.

SUBSTANCE: invention relates to food industry, fodder industry. The method involves protein and carbohydrates extraction from the extraction cake by way of introduction of alkali water solution with 5-20% concentration into a suspension prepared of a mixture of extraction cake and water at a ratio of 1:5-10 till the suspension acidity index (pH) is within the interval of 8.5-9.5. The suspension is maintained during 45-60 minutes at a temperature of 45-55°C. One performs preliminary purification of the extract where the suspension is supplied onto a decanter to produce an extract and a solid phase (cake, "НБВ") for subsequent stages of drying and granulation. One proceeds with final purification of the extract in a high-rate separator to produce the purified extract and a solid phase (residuum) for subsequent stages of drying and granulation, preliminary isolation of the purified extract protein by way of ultrafiltration and protein final concentration by way of moisture evaporation at low temperatures with protein subsequent delivery for drying to produce a sunflower or rape protein concentrate (SPC/RPC). One performs preliminary isolation of carbohydrates, passed through a UF membrane installation, in a reverse filtration osmosis installation to produce saccharide solution and carbohydrates final concentration by way of moisture evaporation to produce saccharide syrup (SS). Alternatively, the method version is implemented only at the stage of the extract preliminary purification; the extract passes through the second decanter to produce a solid phase and a purified extract; at the stage of the extract final purification, the solid phase (residuum) is mixed with the solid phase (cake, "НБВ") released from the second decanter for subsequent stages of granulation and drying.

EFFECT: inventions group allows to manufacture extraction cake processing products - SPC/RPC, "НБВ" and SS of high quality and expand the range of extraction cake products manufacture technologies.

22 cl

Description

The invention relates to the food industry, in particular to the production of sunflower or rapeseed meal from a method of extraction of a concentrate of sunflower or rapeseed protein (CBP and KBA), low protein fibers (CBF) and saccharide syrup (CC) used in the following areas of the economy:

- PBC and KBA - food industry (protein supplements), animal feed, poultry and fish;

- CBF - energy (incineration), agricultural (litter for livestock);

- SS - food industry (confectionery industry, beverage industry); animal feed, production of fodder yeast, production of amino acids.

As a raw material for the processing of meal according to the claimed technology, meal is used with a protein content of 35-40% (by weight) and with a residual fat content of not more than 2%. A higher fat content can result in a change in the quality of the protein concentrate (increase in fat content, the appearance of a “soapy” taste), and a decrease in the service life of some elements (membranes) of the equipment used. It is possible to use meal with a lower relative protein content, however, it must be borne in mind that the yield of PBC will be proportionally lower, and the output of CBF will be higher.

Known (patent RU No. 2340203, IPC A23J 3/14, A23J 1/14, published December 10, 2007) a method for producing a food protein isolate from sunflower meal, including extracting protein from meal (aqueous sodium chloride solution), separating insoluble sediment by filtration to obtain extract, protein extraction, separation by centrifugation of solid and liquid phases and drying of the solid residue.

There is a two-stage method for producing protein isolate from industrial sunflower meal (Shcherbakov V.G., Gorshkova L.M., Kovalenko N.P., Rubina L.V., Kuznichenko V.N., Rakovsky P.P. About food quality indicators sunflower protein. - Proceedings of the universities. Food technology. - 1976. - No. 1. - P.154).

In the known method, protein from sunflower meal is extracted in several stages (first with an aqueous solution of sodium chloride, and then with sodium hydroxide), which gives large losses of protein in the process of using several extractants due to the multi-stage process and requires the use of a large number of technological solutions. In addition, the resulting protein has a high content of phenolic compounds that obscure its color, and the increased chlorine content significantly limits the use of standard stainless steel industrial equipment due to the active corrosion of stainless steel at high concentrations of free chlorine.

A common disadvantage of the above known methods is the change in the structure of the protein as a result of its extraction from the extract by precipitation during treatment with an acid type reagent (aqueous succinic acid solution). In addition, it should be noted that for both sunflower and rapeseed, the method of obtaining the protein isolate by precipitating the protein by changing the pH by adding acid works only at the laboratory level - the particles of precipitated sunflower protein are so small that they are precipitated using an industrial decanter centrifuge impossible.

The objective of the present invention is to expand the range of economical (optimal) technologies for the production of KPB / KBB, NBV, SS high quality from by-products of oil extraction production.

A single technical result of the invention is the implementation of the specified method for processing sunflower and rapeseed meal to produce sunflower or rapeseed protein (PBC and KBA), low protein fibers (CBF) and saccharide syrup (CC).

The specified technical result for the first variant of the claimed method is achieved due to the fact that the processing method of sunflower or rapeseed meal is characterized by:

the allocation of protein and carbohydrates from meal by introducing into a suspension prepared from a mixture of meal with water in a ratio of 1: 5-10, an aqueous alkali solution of 5-20% concentration until the acidity of the suspension is established in the range of 8.5-9.5 pH, followed by holding the suspension for 45-60 minutes at a temperature of 45-55 ° C;

preliminary purification of the extract, where the suspension is fed to a decander to obtain an extract and a solid phase (cake, CBF) for subsequent drying and granulation;

final purification of the extract in a high-speed separator to obtain a purified extract and solid phase (sludge) for subsequent drying and granulation;

preliminary protein extraction by ultrafiltration of the purified extract and the final concentration of the protein by evaporation of moisture from it at low temperatures, followed by feeding the protein for drying to obtain a sunflower or rapeseed protein concentrate (PBC / CRP);

preliminary extraction of the carbohydrates passed through the UV membrane unit in the reverse osmosis filtration unit with the formation of a saccharide solution and the final concentration of carbohydrates by evaporation of moisture to obtain a saccharide syrup (CC).

The specified technical result for the second variant of the claimed method is achieved due to the fact that the processing method of sunflower or rapeseed meal is characterized by:

the allocation of protein and carbohydrates from meal by introducing into a suspension prepared from a mixture of meal with water in a ratio of 1: 5-10, an aqueous alkali solution of 5-20% concentration until the acidity of the suspension is established in the range of 8.5-9.5 pH, followed by holding the suspension for 45-60 minutes at a temperature of 45-55 ° C;

preliminary purification of the extract, where the suspension is fed to the first decander to obtain a solid phase (cake, CBF), and the extract, which is mixed with water and fed to the second decander to obtain a solid phase and extract;

final purification of the extract, which is obtained by mixing the extract after passing through the first decanter and the extract obtained after the second decanter, in a high-speed separator to obtain a solid phase (sludge) and a purified extract, while the resulting slurry is mixed with a solid phase (cake, CBF) after the second decanter for subsequent drying and granulation;

preliminary protein extraction by ultrafiltration of the purified extract and the final concentration of the protein by evaporation of moisture from it at low temperatures, followed by feeding the protein for drying to obtain a sunflower or rapeseed protein concentrate (PBC / CRP);

preliminary extraction of the carbohydrates passed through the UV membrane unit in the reverse osmosis filtration unit with the formation of a saccharide solution and the final concentration of carbohydrates by evaporation of moisture to obtain a saccharide syrup (CC).

Before extraction, to intensify the process, the meal is cleaned by removing impurities from it using a metal detector and / or vibration sieves.

The increase in the amount of water per part of the meal during the preparation of the suspension is determined by the increase, on the one hand, of the yield of protein and sugars, and on the other, the costs of operation and investment in equipment. Therefore, in practice, the optimum ratio of meal to water is 1: 5-10.

As an aqueous solution of alkali, it is possible to use, for example, NaOH (caustic, sodium hydroxide) or KOH. The preferred choice of NaOH or KOH is due to the fact that these alkalis a) are strong (with a lesser amount of alkali required, the product is cleaner), b) are industrially produced, c) are relatively inexpensive. A quantitative indicator of the upper boundary of the indicated range of the concentration of the extractant allows avoiding damage (denaturation) of the protein when adjusting the pH (acidity) of the suspension, while at low concentrations, a large capacity is required to prepare the solution. The optimal solution is an extractant concentration of 10-15%.

The recommended exposure time of the suspension in the indicated temperature range after adding the extractant to it is 45-60 minutes (extraction steadily increases until the exposure time 30-40 minutes, then grows very slowly). Under these conditions, most proteins and carbohydrates are released into the solution. Above the indicated right values of the acidity and temperature ranges, protein denaturation begins.

To increase the yield of the extract at the stage of cleaning it from suspended particles, an additional decanter centrifuge can be used, where the solid phase mixed with water is sent after the first decanter centrifuge. The solid phase after the second decanter centrifuge, as well as after the first, is sent to drying and granulation, and a mixture of extracts after the first and second decanter centrifuges is fed to the high-speed separator. Before feeding the solid phase after the second decanter centrifuge for drying and granulation, the solid phase is mixed with a high-speed separator.

The drying of the solid phase is carried out, as a rule, on a disk dryer, and an extruder is used for granulation.

At the stage of purification of the extract from suspended particles, it is possible to use other than decanter centrifuge centrifugal equipment, for example, self-unloading high-speed separators. However, decanters are cheaper and more reliable. The number of decanters used depends on their performance and type.

The proposed two-stage sequential purification of the extract using a decanter centrifuge, and then a high-speed separator is the most technologically advanced and economical, as it provides:

- processing a large number of suspensions at the entrance to the decanter,

- high purity of the extract at the outlet of the separator,

- relatively low investment.

The pores used to extract the UV membrane dissolved in the protein extract must be selected so that water and dissolved hydrocarbons are passed and protein molecules are not passed. As a result, the protein is concentrated over the surface of the membrane, and water and dissolved carbohydrates pass through the membrane. Possible types of UV membranes used: GR01-99PP or GR01-99PE series manufactured by Alfa Laval Nakskov A / S.

The concentration of protein and saccharides is produced, as a rule, in a vacuum evaporation unit. It is advisable to use a semi-automatic packaging line for packaging dry KPB after spray drying. To increase particle size, the dry protein concentrate after spray drying can be agglomerated with a "fluidized bed".

At the same time as the carbohydrates dissolved in the extract are extracted in the OO filtration unit (membrane), water is regenerated. The pores of the OO of the filtration unit are selected in such a way that only water is passed, and dissolved carbohydrates and other dry substances are concentrated over the membrane surface, forming a saccharide solution. Saccharides pre-concentrated on the OO filtration unit are subjected to enzymatic treatment. Purified water passing through the OO membrane is returned to production. The volume of regenerated water can be up to 80% of the total water consumption for technological purposes.

As evidence of the implementation of the claimed method, a phased description of the claimed method is provided, indicating the optimal performance of the raw materials used, components and modes, as well as equipment that can be used.

FEEDING AND CLEANING

The meal is loaded with automatic loaders into the receiving hopper, from where it is fed by REM STC500 screw conveyors to the extraction tanks. Before the meal is fed into the extraction containers, foreign impurities (stones, wood, metals) are removed from it. Metal removal is performed using the automatic Cassel Shark BD model, and non-metallic impurities are removed using vibration sieves of the FMC Link-Belt CS model.

PROTEIN AND CARBOHYDRATE EXTRACTION

In extraction vessels of type ALEV25, meal is mixed with warm water in the proportion: one share of meal to 6 parts of water to form a suspension. The suspension is maintained in suspension with paddle mixers installed in the extraction tanks. A 10% aqueous solution of NaOH is added to the suspension until the acidity of the suspension is 9.5 pH, while the extraction temperature is maintained in the range of 45-55 ° C. Used 10% NaOH solution is obtained by diluting the original widespread industrial product - 45% NaOH.

PRELIMINARY CLEANING OF THE EXTRACT

From the extraction containers, the suspension is pumped to the Alfa Laval NX438B-31G decanter centrifuge (decanter). In a decanter centrifuge, dissolved proteins and carbohydrates are separated from undissolved substances (fiber, ash, undissolved proteins and carbohydrates) due to the action of centrifugal forces. The solid phase (cake, CBF) after a decanter centrifuge is mixed with water and fed to a second decanter centrifuge to maximize the release of dissolved substances. The cake after the second decanter centrifuge is sent to drying and granulation. The extract after the first decanter centrifuge is mixed with the extract after the second decanter centrifuge and is fed by a centrifugal pump to the stage of final purification of the extract.

FINAL EXTRACT CLEANING

The final separation of undissolved substances from the extract is carried out on a self-discharging high-speed separator Alfa Laval Clara601S due to the action of centrifugal forces. The solid phase from the separator (sludge) is mixed to the cake after the second decanter centrifuge before being fed to the dryer, and the purified extract is fed by an Alfa Laval LKH-25 centrifugal pump to the preliminary protein concentration stage.

PRELIMINARY PROTEIN CONCENTRATION

Preliminary concentration (extraction) of the protein dissolved in the extract is performed on an ultrafiltration (UV) membrane unit Alfa Laval UF system 10SEQ.

FINAL PROTEIN CONCENTRATION

The final protein concentration is carried out on a ConVap2000 vacuum evaporation unit, where moisture is evaporated from the product at low temperatures (to prevent protein coagulation).

DRYING AND PACKING PBC

The concentrated protein is fed to a spray dryer to produce a dry PBC, which is then packaged in 50-kg bags on a semi-automatic packaging line.

DRYING, GRANULATION AND PACKING OF CBF

The cake mixture after the second decanter with sludge is fed to a BSM3000 rotary dryer for drying in a stream of hot air, after which it is fed to an OGM 90 extruder to obtain granules and then packaged.

PRELIMINARY CONCENTRATION OF SUGARIDES AND REGENERATION OF WATER

Dissolved carbohydrates (saccharides) passed through the UV membrane unit (saccharides) are fed to the Alfa Laval RO system 20SEQ reverse osmosis (OO) filtration unit, where preliminary concentration of dissolved carbohydrates and water regeneration are performed.

ENZYME PROCESSING OF SUGARIDS

When used in animal feed, saccharides pre-concentrated on an OO filtration unit are enzymatically processed for conversion to monosaccharides.

FINAL CONCENTRATION AND PACKAGING OF SUGARIDS

The final concentration of saccharides is performed on an Alfa Laval AlfaVap3000 vacuum evaporator, where moisture from the product (saccharides) is evaporated at low temperatures (to avoid caramelization). The sugar syrup obtained after concentration is packed in semi-septic bags.

CIP washing of basic equipment should be carried out twice a day after 10 hours of operation. The total duration of each SIW process is 1.0-1.5 hours when washing different objects with parallel SIW lines. For better cleaning of the membrane surface, it is recommended to use additives of chemically active substances (enzymes).

The optimum extraction temperature is 45-55 ° C. To heat the process water to the indicated temperature, a water heating station is provided. Equipment is also provided for supplying water to the extraction tanks. The buyer should provide a water treatment station to bring the chemical composition of water to the level of drinking water in accordance with GOST 2874-82.

Claims (22)

1. The method of processing sunflower or rapeseed meal, characterized
the allocation of protein and carbohydrates from the meal by introducing into a suspension prepared from a mixture of meal with water in a ratio of 1: 5-10, an aqueous alkali solution of 5-20% concentration until the acidity of the suspension is established in the range of 8.5-9.5 pH, followed by holding the suspension for 45-60 minutes at a temperature of 45-55 ° C;
preliminary purification of the extract, where the suspension is fed to the decanter to obtain the extract and solid phase (cake, low protein fibers (CBF)) for subsequent drying and granulation;
final purification of the extract in a high-speed separator to obtain a purified extract and solid phase (sludge) for subsequent drying and granulation;
preliminary protein extraction by ultrafiltration of the purified extract and the final concentration of the protein by evaporation of moisture from it at low temperatures, followed by feeding the protein for drying to obtain a sunflower or rapeseed protein concentrate (PBC / CRP);
preliminary extraction of the carbohydrates passed through the UV membrane unit in the reverse osmosis filtration unit with the formation of a saccharide solution and the final concentration of carbohydrates by evaporation of moisture to obtain a saccharide syrup (CC). 2. The method according to claim 1, characterized in that prior to the extraction, the meal is purified by removing impurities from it. 3. The method according to claim 2, characterized in that the cleaning of the meal is carried out using a metal detector and / or vibration screens. 4. The method according to claim 1, characterized in that the ratio of meal to water for the preparation of the suspension is 1: 6, and the concentration of the aqueous alkali solution introduced into the suspension is 10%. 5. The method according to claim 1, characterized in that the drying of the solid phase (cake, CBF) is carried out on a disk dryer, and an extruder is used for granulation. 6. The method according to claim 1, characterized in that spray drying is used to dry the concentrated protein. 7. The method according to claim 6, characterized in that the dry protein concentrate after spray drying is subjected to agglomeration. 8. The method according to claim 6, characterized in that for the packaging of dry protein concentrate after spray drying, use a semi-automatic packaging line. 9. The method according to claim 1, characterized in that the final concentration of protein and saccharides is produced in a vacuum evaporation unit. 10. The method according to claim 1, characterized in that at the same time as the extraction of carbohydrates dissolved in the extract on the reverse osmosis filtration unit, water is regenerated. 11. The method according to claim 1, characterized in that the saccharides previously concentrated on the reverse osmosis filtration unit are subjected to enzymatic treatment. 12. A method of processing sunflower or rapeseed meal, characterized
the allocation of protein and carbohydrates from the meal by introducing into a suspension prepared from a mixture of meal with water in a ratio of 1: 5-10, an aqueous alkali solution of 5-20% concentration until the acidity of the suspension is established in the range of 8.5-9.5 pH, followed by holding the suspension for 45-60 minutes at a temperature of 45-55 ° C;
preliminary purification of the extract, where the suspension is fed to the first decanter to obtain a solid phase (cake, CBF), and the extract, which is mixed with water and fed to the second decanter to obtain a solid phase and extract;
final purification of the extract, which is obtained by mixing the extract after passing through the first decanter and the extract obtained after the second decanter, in a high-speed separator to obtain a solid phase (sludge) and a purified extract, while the resulting slurry is mixed with a solid phase (cake, CBF) after the second decanter for subsequent drying and granulation;
preliminary protein extraction by ultrafiltration of the purified extract and the final concentration of the protein by evaporation of moisture from it at low temperatures, followed by feeding the protein for drying to obtain a sunflower or rapeseed protein concentrate (PBC / CRP);
preliminary extraction of the carbohydrates passed through the UV membrane unit in the reverse osmosis filtration unit with the formation of a saccharide solution and the final concentration of carbohydrates by evaporation of moisture to obtain a saccharide syrup (CC). 13. The method according to p. 12, characterized in that prior to the extraction, the meal is cleaned by removing impurities from it. 14. The method according to item 13, wherein the cleaning of the meal is carried out using a metal detector and / or vibration screens. 15. The method according to p. 12, characterized in that the ratio of meal to water for the preparation of the suspension is 1: 6, and the concentration of the aqueous alkali solution introduced into the suspension is 10%. 16. The method according to p. 12, characterized in that the drying of the solid phase (cake, CBF) is carried out on a disk dryer, and an extruder is used for granulation. 17. The method according to p. 12, characterized in that for drying the concentrated protein using spray drying. 18. The method according to 17, characterized in that the dry protein concentrate after spray drying is subjected to agglomeration. 19. The method according to 17, characterized in that for the packaging of dry protein concentrate after spray drying, use a semi-automatic packaging line. 20. The method according to p. 12, characterized in that the final concentration of protein and saccharides is produced in a vacuum evaporation unit. 21. The method according to p. 12, characterized in that at the same time as the extraction of carbohydrates dissolved in the extract on the reverse osmosis filtration unit, water is regenerated. 22. The method according to p. 12, characterized in that the saccharides, previously concentrated on a reverse osmosis filtration unit, are subjected to enzymatic treatment.