RU2560634C1 - Method of processing mustard oil cake and device for its implementation - Google Patents

Abstract

FIELD: agriculture.

SUBSTANCE: method comprises moistening the oil cake with water when stirring, heating, keeping the moist oil cake to remove water vapour with volatile oil of mustard and subsequent drying under vacuum. The oil cake is preliminary crushed to 0.6-0.8 mm, moistening is carried out by spraying aqueous solution heated to a temperature of 65-70°C containing ascorbic acid and sodium chloride at a ratio of water:(ascorbic acid and sodium chloride) equal to 400:1. At that the ratio of ascorbic acid to sodium chloride is equal to 1:4, with the ratio by weight of the oil cake to water of 2.7:1. Keeping the moist oil cake is carried out for 30-35 minutes at the excess pressure of 1.2 atm and additionally ultrasonic treatment is carried out for 5-10 minutes simultaneously with moistening and drying under vacuum. The device for processing mustard oil cake comprises a housing with a jacket for heating, an agitator with paddle stirrers, a loading device for inputting the main component, and the loading device for output of the finished product, a supply system of moisturizing liquid, a vacuum system, a source of ultrasonic treatment. The housing is made in the form of two interconnected horizontally arranged half cylinders, each of which comprises a shaft with vanes for stirring mounted with the ability of adjustment of the speed of stirring, mounted with the ability to move the vanes of one shaft between the vanes of the other shaft during rotation of the shafts. The supply system of moisturizing liquid is made in the form of spraying nozzles mounted along the shafts. The feeding device for inputting the main component and the discharge device for output of the finished product are made in the form of hatches with the valve vacuum gate.

EFFECT: increase in the nutritional value of the feed additive obtained, increase in the degree of purity of the volatile oil of mustard, decrease in energy and time consumption.

2 cl, 3 dwg

Description

The group of inventions relates to the food industry and can be used in the disposal of waste mustard and oil production to obtain a high protein feed additive, neutralized and enriched with sodium ions and ascorbic acid.

A known method of disposing of waste mustard and oil production, including wetting waste water, mixing, heating, keeping moistened waste to remove water vapor with essential mustard oils, obtaining a dry product (see the description of the patent of the Russian Federation No. 2099972, A23L 1/225, publ. . 12/27/1997).

In the known method, an aqueous suspension is prepared at a ratio of waste and water 1: 6 + 1: 10 with heating to 45-50 ° C for at least 15 minutes. Subsequent treatment with hot steam is carried out for 40-45 minutes, the resulting product is fed to a spray dryer for drying at 105-120 ° C for 4 seconds.

The known method involves the preparation of an aqueous suspension using a large volume of water. Energy costs require heating the aqueous suspension to a temperature of 45-50 ° C and subsequent treatment with hot steam for 40 minutes. This treatment is necessary in order to remove dangerous anti-nutritional substances containing essential mustard oils. When purging with steam, the product must be heated through the wall of the apparatus to a temperature of 100 ° C or higher, since in this case the evaporation of water begins, with the vapor of which essential mustard oils are carried away. The duration of the treatment with hot steam indicates the duration of the whole process as a whole and also affects its costs. After capturing the resulting volatile anti-nutritional substances, the remaining volume must be dried to obtain a feed additive, which is uneconomical due to the use of a large amount of water in the preparation of an aqueous suspension. Spray drying of suspensions is highly energy intensive and is traditionally used in the drying of expensive food products.

In addition, the presence of nitriles and their derivatives in the final product is possible. The extraction and washing of the solid by-products of the mustard-oil mill production leads to the loss of the water-soluble part of the protein, the high temperature of the hot steam leads to the denaturation of the protein part, thereby depleting the feed value of the solid residue.

A known method of disposing waste mustard and oil production, adopted as a prototype, including wetting the waste water, mixing, heating, keeping moistened waste to remove water vapor with essential mustard oils (see the description of the patent of the Russian Federation No. 2360432, IPC A23K 1/00, published on July 10, 2009).

The disadvantages of this method include its energy intensity due to the use of two devices with very powerful electric motors. In addition, depending on the pH of the moistened waste, the process in the known method can go along the path of formation of nitriles and their derivatives having high toxicity, instead of allyl isothiocyanate (AITC).

The objective and technical result of the proposed method is to increase the degree of purification of the feed product from essential mustard oils, increase the nutritional value of the resulting feed additive and reduce energy and time costs.

The technical result is achieved by the fact that in the method of processing mustard cake, including moistening the cake with water while stirring, heating, keeping the moist cake for removing water vapor with essential mustard oils and subsequent drying under vacuum, there are differences, namely, the cake is pre-ground to size 0, 6-0.8 mm, humidification is carried out by spraying with an aqueous solution heated to a temperature of 65-70 ° C, an aqueous solution containing ascorbic acid and sodium chloride, in a ratio of water: (ascorbic to sugar and table salt), equal to 400: 1, while the ratio of ascorbic acid to table salt is 1: 4, with a weight ratio of cake to water equal to 2.7: 1, the moistened cake is kept for 30-35 minutes with excess a pressure of 1.2 atm and additionally carry out sonication for 5-10 minutes simultaneously with moisturizing and drying under vacuum.

The proposed method allows to obtain a bulk product enriched with sodium ions and ascorbic acid, remove isothiocyanates harmful to animals from mustard cake, and maintain the amino acid composition of the cake in its native state without denaturation, as well as prevent the formation of nitriles and their derivatives with high toxicity, by moisturizing with an aqueous solution containing sodium chloride and ascorbic acid, providing a pH shift towards an alkaline environment;

- intensify the processes of humidification and drying by supplying water in a finely dispersed state and using ultrasound with a power of at least 600 VA at the stage of humidification and drying, which facilitates greater penetration of water during the wetting process and more complete hydrolysis with less water and less time;

- reduce energy and time costs during drying by reducing the amount of water to 25%;

- reduce costs by using instead of two one apparatus-hydrolyzer.

The method is implemented as follows.

Heated to 50 ° C, crushed cake to 0.6-0.8 mm moisten heated to a temperature of 65-70 ° C aqueous solution.

The pre-prepared aqueous solution contains ascorbic acid and sodium chloride, taken in the ratio of water: (ascorbic acid and sodium chloride), equal to 400: 1, with a weight ratio of cake to water, equal to 2.7: 1, and with a ratio of ascorbic acid to sodium salt equal to 1: 4.

Simultaneously with the water supply, mixing and sonication are performed with a power of 600 VA (vibration intensity of at least 140 dB) for 10-15 minutes.

Then the sonication is stopped and within 30-35 minutes there is hydrolysis at a pressure of 1.2 atm.

After hydrolysis is complete, the pressure is released, the vacuum is turned on, and ultrasound is simultaneously turned on.

The drying process under vacuum lasts 15 minutes. At the end of drying, the vacuum is turned off and the dried neutralized cake is discharged for further packaging in consumer packaging.

To implement the method, a device is proposed associated with the method of a single inventive concept.

A device for processing mustard cake, adopted as a prototype, comprising a housing with a jacket for heating, a mixing device with paddle mixers, a loading device for introducing the main component and an unloading device for outputting the finished product, a humidifier supply system in the form of a single nozzle, a vacuum system (see the description of the patent of the Russian Federation for utility model No. 111026, IPC B01J 8/10, published on December 10, 2011), while the device has a vertical layout.

The presence of one nozzle for spraying liquid in the known device does not provide wetting at atmospheric pressure of a thick layer of hydrolyzable oil cake, which is a disadvantage of the known device.

After hydrolysis, the moistened mass (suspension) must be transferred to the next apparatus for stripping, which leads to the loss of volatile and harmful AITC into the atmosphere, and also increases the cost.

In a vertical apparatus, a mixing device with a very viscous moistened mass is ineffective. The hydrolysis process may not go completely, which will lead to a large residual amount of nitriles in the final product.

The reactor heating system using a coil is ineffective.

The technical task of the proposed device is to increase the degree of purification from essential mustard oils, increase the nutritional value of the resulting feed additive and reduce energy and time costs.

The technical problem is solved in that the device for processing mustard cake containing a housing with a jacket for heating, a mixing device with paddle mixers, a loading device for introducing the main component and an unloading device for outputting the finished product, a humidifier supply system, a vacuum system, have differences, namely, it additionally contains a source for ultrasonic processing, the casing is made in the form of two horizontally placed half-cylinders interconnected, in each of which is installed with the possibility of controlling the mixing speed, the shaft with mixing blades installed with the ability to move the blades of one shaft between the blades of the other shaft during rotation of the shafts, the humidifier supply system is made in the form of nozzles for spraying installed along the shafts, and a loading device for introducing the main the component and the unloading device for the exit of the finished product are made in the form of hatches with a valve vacuum valve. The proposed device allows you to:

- provide the ability to control the speed of mixing;

- eliminate stagnant "dead zones";

- to ensure uniform spraying of an aqueous solution for effective wetting of the cake;

- provide ultrasonic treatment of the reaction mass to accelerate the rate of enzymatic hydrolysis;

- to provide the possibility of increasing the pressure to 1.2 atm to increase the rate of enzymatic hydrolysis, which together leads to an increase in the degree of purification from essential mustard oils, increase the nutritional value of the resulting feed additive and reduce energy and time costs.

A device for processing mustard cake is illustrated by drawings, where: in FIG. 1 schematically shows a main view of the device; in FIG. 2 - section aa in FIG. 1; in FIG. 3 is a section BB in FIG. 2.

A device for processing mustard cake consists of a horizontally mounted housing 1 with a water jacket 2 for heating, equipped with a loading hatch 3 at one end of the housing 1, an unloading hatch 4 at the other end, an aqueous solution supply system into the housing 1, and a vacuum system with shutoff valves ( a vacuum system with shutoff valves is not conventionally shown in the drawing). The loading hatch 3 and the unloading hatch 4 are equipped with valve vacuum valves (vacuum valve valves are not shown conventionally in the drawing).

The water solution supply system inside the housing 1 is located in two hatches 5 and 6. The water solution supply system inside the case 1 is made in the form of four nozzles 8, two on each door 5 and 6 for uniform spraying of moisture over the surface of the mixed mass.

Source 7 for ultrasonic treatment is installed in the middle part of the housing 1 in the hatch 5.

The housing 1 is made in the form of two interconnected half-cylinders with an inner diameter of 1000 mm.

Inside each half cylinder, shafts 9 and 10 are installed parallel to each other with mixing blades 11 and 12, mounted with the possibility of rotation of the shafts 9 and 10 towards each other.

The blades 11 are made flat and mounted on the shaft 9 in two mutually perpendicular planes and rotated relative to the plane at an angle of 45 °.

The blades 12 are made of triangular section and are mounted on the shaft 10 in two mutually perpendicular planes.

The blades 11 and 12 are placed on the shafts 9 and 10 so that when the shafts 9 and 10 rotate towards each other, they form a “comb” with the ability to move the blades 11 of the shaft 9 between the blades 12 of the shaft 10, and the shaft 9 with flat blades 11 with the right rotation moves the mass from the hatch 3 to the hatch 4, and with a left rotation in the opposite direction, the shaft 10, with the right and left rotation, moves the mass in only one direction from the hatch 3 to the hatch 4, ensuring the movement of mass at the bottom of the device in a circle.

The housing 1, the shafts 9 and 10 and the blades 11, 12 are made of stainless steel.

To enable rotation of the shaft 9 and 10 towards each other, one of the ends of the shaft 10 is equipped with a gear 13, and the shaft 9 has a gear 14 engaged, the shaft 10 is connected through a gear reducer 15 to a drive 16 made in the form of an electric motor with a frequency converter, which allows you to adjust the number of revolutions from 60 to 120 rpm.

A device for processing mustard cake is as follows.

Heated crushed cake through the loading hatch 3 is fed into the housing 1 preheated with a water jacket 2 with the drive 16 turned on, which rotates the shafts 9 and 10 with the blades 11, 12, respectively. After loading the meal, the loading hatch 3 is closed and an aqueous solution heated to a temperature of 70 ° C, taken in the ratio of meal to water, equal to 2.7: 1, is fed through nozzles.

An aqueous solution is preliminarily prepared by adding ascorbic acid and sodium chloride to the water in the ratio water: (ascorbic acid and sodium chloride) 400: 1, with a ratio of ascorbic acid to sodium chloride equal to 1: 4.

Simultaneously with the water supply through the nozzles 8, the contents are mixed with blades 11 and 12 and the device 7 is sonicated with 600 VA (vibration intensity not less than 140 dB) for 5-10 minutes while the cake is wetted.

Then the ultrasonic treatment is stopped and the contents of the housing 1 are incubated for 30-35 minutes, where hydrolysis occurs at an overpressure of 1.2 atm.

After hydrolysis is complete, the pressure is released, the vacuum is turned on, and at the same time, the ultrasonic treatment source 7 is turned on.

The drying process under vacuum lasts 15 minutes. The vapor-ester mixture containing essential mustard oils that are hazardous to the health and life of animals is sent to a capture system that includes a mechanical filter and a refrigerator (the capture system is not shown conventionally in the drawing).

At the end of drying, the vacuum is turned off, the reverse of the shaft 10 is turned on, the discharge hatch 4 is opened, and the dried neutralized cake is unloaded by the blades 11 into the intermediate hopper for further packaging in consumer packaging (the intermediate hopper is not shown conventionally in the drawing).

Example

Heated to 50 ° C crushed cake to 0.6-0.8 mm in the amount of 800 kg is fed into the housing 1, preheated with a water jacket 2 to a temperature of 50 ° C.

The loading of the housing 1 cake is carried out for 1-3 minutes.

After loading the cake, the loading hatch 3 is closed and 300 liters of water are heated up to 65-70 ° C for 10 minutes through nozzles 5 of a droplet size of 100 microns.

An aqueous solution containing 150 g ascorbic acid and NaCl sodium chloride in the amount of 600 g per 800 kg of oilcake is preliminarily prepared.

Simultaneously with the water supply, mixing is carried out by the blades 10 of the contents and processing by the device 7 with ultrasound with a power of 600 VA (vibration intensity of at least 140 dB).

Ultrasonic treatment is carried out for 10-15 minutes during the wetting of the meal. Then the sonication is stopped and within 30-35 minutes there is hydrolysis at a pressure of 1.2 atm.

After hydrolysis is complete, the pressure is released, the vacuum is turned on, and ultrasound is simultaneously turned on.

The drying process under vacuum lasts 15 minutes. The vapor-ester mixture containing essential mustard oils that are hazardous to the health and life of animals is sent to a capture system including a mechanical filter and a refrigerator.

At the end of drying, the vacuum is turned off, the discharge hatch 4 is opened, and the dried neutralized cake is discharged into the intermediate hopper for further packaging in consumer packaging.

Claims (6)

1. A method of processing mustard oilcake, including moistening the oilcake with water while stirring, heating, maintaining a moistened oilcake to remove water vapor with essential mustard oils and subsequent drying under vacuum, characterized in that the oilcake is pre-ground to 0.6-0.8 mm, humidification is carried out by spraying with an aqueous solution heated to a temperature of 65-70 ° C, an aqueous solution containing ascorbic acid and sodium chloride, with a ratio of water: (ascorbic acid and sodium chloride) equal to 400: 1, while the ratio e ascorbic acid to sodium chloride is 1: 4, with a weight ratio of oilcake to water equal to 2.7: 1, the moistened cake is aged for 30-35 minutes at an overpressure of 1.2 atm and an additional ultrasonic treatment is carried out for 5 -10 minutes while moisturizing and drying under vacuum. 2. A device for processing mustard cake containing a housing with a heating jacket, a mixing device with paddle mixers, a loading device for entering the main component and a loading device for outputting the finished product, a humidifier supply system, a vacuum system, characterized in that it further comprises source for ultrasonic treatment, the casing is made in the form of two horizontally placed half-cylinders interconnected, each of which is installed with the ability to control the mixing speed of the shaft with mixing blades installed with the ability to move the blades of one shaft between the blades of the other shaft during rotation of the shafts, the humidifier supply system is made in the form of nozzles for spraying installed along the shafts, and the loading device for introducing the main component and the unloading device for the output of the finished product is made in the form of hatches with a valve vacuum valve. 3. A device for processing mustard cake according to claim 2, characterized in that the blades are mounted on shafts in two mutually perpendicular planes. 4. A device for processing mustard cake according to claim 2, characterized in that the blades of one shaft are made of triangular section. 5. A device for processing mustard cake according to claim 2, characterized in that the blades of the other shaft are made flat. 6. A device for processing mustard cake according to claim 5, characterized in that the flat blades are fixed with rotation relative to the plane at an angle of 45 °.

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