RU2804008C1 - Method for making flour and fat from organic raw materials of animal origin - Google Patents

Abstract

FIELD: food industry.

SUBSTANCE: method for producing flour and fat from organic raw materials of animal origin, including the following operations: crushing frozen raw materials into pieces, grinding the pieces into minced meat, supplying minced meat to an electroplasmolyzer for preheating, squeezing the heated minced meat by a press or centrifuge method, where it is divided into a cake and water fat emulsion - broth; separating fat and residual solid particles from the water-fat emulsion; adding residual solids to the cake; feeding cake with added residual solids, as well as separately heated contact heat carrier – fat of animal or vegetable origin to the mixers of vacuum evaporators and mixing them there until a homogeneous mass – suspension; heat treatment, including drying, deodorization and disinfection of the suspension in vacuum evaporators until the cake moisture reaches 8-10%; separation of the suspension into greaves and contact heat carrier; adding an antioxidant to the greaves – producing flour; packaging flour in a container.

EFFECT: invention makes it possible to simplify the production of flour and fat, with high productivity and reduced energy consumption.

8 cl, 1 dwg

Description

The invention relates to the production of feed and food products and concentrates, in particular, fishmeal and veterinary fish oil. Production is carried out from biological raw materials of animal origin, incl. from food and other waste from fish farms, livestock and poultry farms, fish, meat and poultry processing enterprises, as well as other industries and agriculture.

At the moment, the following methods for producing fishmeal are known from the state of the art (see, for example, http://www.aquaristics.ru/pond/forage/sposoby-izgotovleniya-rybnoy-muki or information in the work: http://dspace. vniro.ru/handle/123456789/23221).

Direct drying method, based on simultaneous boiling and drying of raw materials, without intermediate reduction of water content in the raw material mass by pressing.

The disadvantages of the direct drying method include:

- it is not possible to process raw materials of medium and high fat content;

- low productivity, increased energy consumption;

- as a result of the slow evaporation of moisture, the formation of a caking solid mass is possible, which is difficult to dry;

- with prolonged treatment at a temperature of 95°C, gelatinization of more than 70% of collagen occurs.

Press-drying method for producing flour. The scheme involves grinding, boiling the raw materials and separating the broth from the boiled mass using a screw press. The solid residue (pulp) containing 50-55% moisture enters the dryer, is dried until the moisture content in the final product reaches 8-10%, the product is crushed, subjected to magnetic separation and packaged. At the same time, the broth obtained by pressing is processed, degreased, evaporated and then added to the pulp before drying.

The disadvantages of the press-drying method include:

- unsuitability for processing particularly fatty raw materials, as well as raw materials with a fine-fiber structure of muscle tissue;

- the need for mandatory processing of pre-pressed broth due to the large release of protein substances into the broth.

The centrifugal drying method, which is a modification of the press-drying method and differs from the latter in terms of the hardware design of the process, separates the fat-containing broth from the boiled mass. In this case, instead of a screw press, a precipitation centrifuge is used. The use of a centrifuge allows you to process raw materials with a high fat content. More efficient separation of fat during centrifugation makes it possible to obtain flour from fatty raw materials with a lipid content that is 25-30% lower compared to the press-drying method.

The disadvantages of the centrifugal drying method include:

the presence of complex units requiring highly qualified maintenance personnel;

- large dimensions of drying units, because a mass of high humidity is subjected to drying;

- the need to install additional equipment for processing the broth due to the large release of protein substances into the broth.

An extraction method is known, based on the extraction of fat from raw materials or from finished flour using organic solvents.

The disadvantages of this method include the following:

- duration of the process, its multi-stage nature and frequency;

- the need to install complex equipment;

- explosion hazard and toxicity of the solvents used;

- the need to completely remove solvents from the finished product.

There is a known method for thermal hydrolysis of fish waste to produce peptide, lipid and mineral-protein substances (RF patent No. 2727904). The method involves grinding raw materials, homogenization, degreasing, thermal hydrolysis, heat treatment, fractionation, cooling and drying. The disadvantages of this method include the following:

- duration of the process, its multi-stage nature and frequency;

- the need to install complex equipment;

- high energy consumption.

A known method and installation for producing fishmeal is described in RF patent No. 2454879. This solution is based on the production of fishmeal, which includes the following operations: squeezing the broth from pre-crushed raw materials, after which the pulp is transported with its simultaneous loosening and drying, then two-stage drying of the pulp is carried out by interaction with a gaseous coolant and separation of large and wet particles of the pulp, and After drying, the finished flour is separated from the coolant gas. At the same time, at each stage, the drying of the pulp is carried out simultaneously with its mixing with heated inert bodies made of heat-intensive material, loaded simultaneously with crushed feedstock in an amount of 10-20% of its weight, while the rate of supply of the gaseous coolant to the second stage of drying exceeds the speed supply of gaseous coolant to the first stage of drying, and gaseous coolants are supplied through each drying stage through separate closed circuits, while large and wet particles of pulp with inert bodies, separated at each drying stage, are returned for recycling.

The disadvantages of this solution are complexity and insufficient performance.

The closest source of information is RF patent No. 2295878 dated March 27, 2007. This patent discloses a fishmeal production line. This line contains, installed in a technological sequence, connected by interoperational conveyors, a receiving hopper, a fish grinder, a heat treatment device with boiling, a press for separating a dense mass of raw materials from the liquid phase, which are accumulated in a drying extruder and a settling separation tank, respectively, a food additive dispenser for dried pulp and grinder of the finished product before packaging.

The disadvantage of this solution is the unsuitability of processing particularly fatty raw materials, as well as raw materials with a fine-fiber structure of muscle tissue.

The proposed method is aimed at eliminating the above-mentioned disadvantages, namely, it makes it possible to create a simple technology for processing any intended raw material into flour.

The technical result is simplification of the production of flour and fat, while at the same time high productivity and energy efficiency.

The technical result is achieved by the fact that the method for producing flour from organic raw materials of animal origin includes the following operations:

- crushing frozen raw materials into pieces,

- grinding pieces into minced meat,

- feeding minced meat with high humidity into the electroplasmolyzer for preheating,

- dividing the heated minced meat into cake and water-fat emulsion - broth;

- separation of fat and residual solid particles from the water-fat emulsion;

- adding residual solid particles to the cake;

- feeding the cake with added residual solid particles, as well as a separately heated contact coolant - fat (fat of animal or vegetable origin) to the mixing devices of vacuum evaporation units and mixing them there until a homogeneous mass - suspension;

- heat treatment, including drying, deodorization and disinfection of the suspension in vacuum evaporation units until the cake moisture content reaches 8-10%;

- separation of the suspension into greaves and contact coolant;

- adding an antioxidant to greaves - obtaining flour;

- packaging flour into containers.

The raw materials are crushed into pieces and ground into minced meat. Water is introduced into the minced meat, after which the minced meat with high humidity is fed into an electroplasmolyzer for electrical activation and heating.

The minced meat, after heating, is pressed or centrifuged, where it is separated into cake and water-fat emulsion. The water-fat emulsion is centrifuged and separated into fat, water and residual solids (trace).

After centrifugation, the fat is sent to packaging.

The cake enters a vacuum evaporation unit with a mixing device, where it is mixed with a contact coolant (fat of animal or vegetable origin).

The cake with the contact coolant forms a homogeneous mass (suspension) due to the VVU mixing device. In the VVU, during heat treatment, the cake undergoes evaporation, disinfection and deodorization in one stage.

From the VVU, the suspension is sent for separation by pressing or centrifuge. After separation, we get crackling and contact coolant.

Next, an antioxidant is added to the greave and we get the final product - flour.

The contact coolant is returned for reuse in the production process.

The claimed solution is illustrated in Fig., which shows a general diagram of the method for producing flour and fat from organic raw materials of animal origin.

In fig. The following positions are indicated.

1 - organic raw materials of animal origin, in particular frozen fish waste;

2 - crushing frozen raw materials into pieces and grinding them into minced meat;

3 - adding water to the minced meat if necessary, depending on the initial moisture content in the raw material and feeding the minced meat with high humidity into the electroplasmolyzer;

4 - electrical activation and preheating of minced meat in a plasmalizer;

5 - separation of heated minced meat into cake and water-fat emulsion - broth (centrifugation);

6 - separation of fat and residual solid particles from the water-fat emulsion (broth);

7 - supply of cake and contact coolant to the explosive device, mixing until a homogeneous mass - suspension;

8 - drying, deodorization and disinfection of cake in suspension in a VVU;

9 - separation of the suspension into greaves and contact coolant;

10 - adding an antioxidant to the greave, obtaining flour;

11 - packaging flour and fat into containers;

12 - fat;

13 - cake;

14 - residual solid particles;

15 - water;

16 - water discharge;

17 - contact coolant - fat (fat of animal or vegetable origin);

18 - non-contact coolant - synthetic oils with operating temperatures above 200°C;

19 - external heat source (heater).

Next, a more detailed description of the operations of the proposed method and technological process is disclosed.

The initial frozen raw material 1 is crushed into pieces 2 and then ground 2 into minced meat. Unfrozen raw materials can be immediately ground into minced meat. Before feeding it into the electroplasmolyzer 4, water 15 is introduced into the minced meat 3 (water is added if necessary, depending on the initial moisture in the raw material and can be supplied separately from outside) in small quantities for better operation of the electroplasmolyzer 4 (passage of currents through the minced meat), after which minced meat with high humidity is fed into the electroplasmolyzer 4 for electrical activation and heated to temperatures at which the cell does not boil and the protein does not coagulate. At the same time, fat and moisture are separated more efficiently from the minced meat cells and there is no loss of protein substances in the starting raw material, as happens with press and centrifugal drying methods, in which the raw material is boiled, which leads to the destruction of cells and the release of protein substances during the separation process. substances from the product along with water.

Next, the minced meat, after heating, goes to centrifugation 5, where it is divided into cake 13 with a moisture content of no more than 55-60% and a water-fat emulsion.

The water-fat emulsion is centrifuged 6 and separated into fat 12, water 15 and residual solids (trace) 14.

Part of the separated water 15 is reused in the technological process, the rest is drained 16 into the sewer system in accordance with all technological standards.

The isolated fat 12 from the minced meat due to the electrical activation does not require additional cleaning and disinfection, therefore, after centrifugation, it is sent to packaging for further sale 11.

Solid particles 14 are sent to cake 13 for subsequent drying.

The cake enters vacuum evaporation units (VUU) 7 with a mixing device, where it is mixed with contact coolant 17 (fat of animal or vegetable origin), which is supplied separately in a heated state to 160-180°C. The ratio of the supply of cake and coolant with a given temperature to the VVU depends on the initial characteristics of the processed raw materials. Loading of cake and contact coolant into each explosive device is carried out alternately (cyclically), due to this the production process runs continuously. This is necessary for effective heating of the total volume of cake involved in the production process, obtained from the feedstock. The volume and quantity of explosives depends on the amount of processed raw materials.

The cake with the coolant forms a homogeneous mass (suspension) due to the mixing device VVU 7. In a cake suspension, with a given heat treatment 8, the following processes occur in one stage: drying, disinfection and deodorization. At the same time, due to the high thermal conductivity of the liquid contact coolant 17, a uniform thermal field is created, which is difficult to achieve with any other drying methods. As a result, the drying process is greatly accelerated and the use of energy-intensive auxiliary equipment in the production process is not required.

Heating of the suspension in the VVU is carried out by passing through the VVU jacket a non-contact coolant 18 heated from an external heat source 19 (synthetic oils with an operating temperature above 200°C).

Once the cake moisture content in the suspension reaches 8-10%, the suspension is automatically sent from VVU 7-8 for separation. Separation 9 is carried out using a press or centrifuge method. After separation, we obtain greaves and contact coolant 17.

The compressed greak is crushed and mixed with antioxidant 10, resulting in the final product, fish meal, which is packaged in container 11.

Contact coolant - fat is returned for reuse in the production process.

The use of the proposed method for producing flour and fat from organic raw materials of animal origin provides, in comparison with existing methods, the following advantages:

- primary heating of raw materials by electroplasmolysis does not lead to destruction of the cell structure, but activates it, due to this, moisture and fat are better released from the raw materials, and the protein fraction remains in the cell;

- the process is significantly accelerated and the use of energy-intensive auxiliary equipment is not required;

- drying, deodorization and disinfection occur in one process;

- the ability to process all types of raw materials, including infected ones;

- reduction of energy costs due to the use of intensive heat exchange and intensive removal of generated moisture by vacuum pumps.

Claims (19)

1. A method for producing flour and fat from organic raw materials of animal origin, including the following operations: - crushing frozen raw materials into pieces, - grinding pieces into minced meat, - feeding minced meat into the electroplasmolyzer for preheating, - pressing heated minced meat using a press or centrifuge method, where it is divided into cake and water-fat emulsion - broth; - separation of fat and residual solid particles from the water-fat emulsion; - adding residual solid particles to the cake; - supplying cake with added residual solid particles, as well as a separately heated contact coolant - fat of animal or vegetable origin to the mixing devices of vacuum evaporation units and mixing them there until a homogeneous mass - suspension; - heat treatment, including drying, deodorization and disinfection of the suspension in vacuum evaporation units until the cake moisture content reaches 8-10%; - separation of the suspension into greaves and contact coolant; - adding an antioxidant to greaves - obtaining flour; - packaging flour into containers. 2. The method according to claim 1, characterized in that, depending on the initial moisture content of the raw material, additional water is added to the minced meat before being fed into the electroplasmolyzer, for better operation of the electroplasmolyzer. 3. The method according to claim 1, characterized in that the minced meat in the electroplasmolyzer is heated to temperatures at which the cell does not boil and the protein does not coagulate. 4. The method according to claim 1, characterized in that the minced meat, after heating in an electroplasmolyzer, is sent for pressing or centrifugation, where it is separated into a cake with a moisture content of no more than 55-60% and a water-fat emulsion. 5. The method according to claim 4, characterized in that the separated fat from minced meat due to electrical activation in an electroplasmolyzer does not require additional cleaning and disinfection, therefore, after centrifugation it is sent to packaging. 6. The method according to claim 1, characterized in that the heated fat supplied to vacuum evaporation units (VU) is a contact coolant - fat of animal or vegetable origin, which is separately supplied in a heated state to 160-180 ° C. 7. The method according to claim 1, characterized in that the cake and contact coolant are loaded into each explosive device alternately, due to this the production process runs continuously and at the same time the total volume of the cake is effectively heated. 8. The method according to claim 1, characterized in that the heating of the suspension in the explosive device is carried out by passing through the jacket of the explosive device a non-contact coolant heated from an external heat source with an operating temperature of over 200°C.

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