WO2011107760A2 - Produits comestibles de grandes valeurs fabriqués à partir de son, et procédé et appareil pour leur production - Google Patents

Produits comestibles de grandes valeurs fabriqués à partir de son, et procédé et appareil pour leur production Download PDF

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Publication number
WO2011107760A2
WO2011107760A2 PCT/GB2011/000324 GB2011000324W WO2011107760A2 WO 2011107760 A2 WO2011107760 A2 WO 2011107760A2 GB 2011000324 W GB2011000324 W GB 2011000324W WO 2011107760 A2 WO2011107760 A2 WO 2011107760A2
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Prior art keywords
fraction
protein
fiber
product
starch
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PCT/GB2011/000324
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English (en)
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WO2011107760A3 (fr
Inventor
Tomas Carlsson
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Gloway Properties Limited
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Publication of WO2011107760A2 publication Critical patent/WO2011107760A2/fr
Publication of WO2011107760A3 publication Critical patent/WO2011107760A3/fr

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    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
    • A23L7/00—Cereal-derived products; Malt products; Preparation or treatment thereof
    • A23L7/10—Cereal-derived products
    • A23L7/152—Cereal germ products
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
    • A23L7/00—Cereal-derived products; Malt products; Preparation or treatment thereof
    • A23L7/10—Cereal-derived products
    • A23L7/115—Cereal fibre products, e.g. bran, husk
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
    • A23L7/00—Cereal-derived products; Malt products; Preparation or treatment thereof
    • A23L7/10—Cereal-derived products
    • A23L7/198—Dry unshaped finely divided cereal products, not provided for in groups A23L7/117 - A23L7/196 and A23L29/00, e.g. meal, flour, powder, dried cereal creams or extracts

Definitions

  • the technology described herein generally relates to valuable food ingredients obtained from raw materials such as milling by-products, for example wheat bran and wheat middlings, and apparatuses and processes for producing the same.
  • the nutritional value of a food product is based on the ability of the consumer to assimilate the basic food value that the substance in question contains.
  • the nutritionally valuable components such as protein and starch can be encapsulated in fcellulose and lignin.
  • the connection between the various components often conditions the digestive value of a product on the binding properties of one product to another, and can result in greatly improved qualities.
  • a single alimentary substance can affect the digestive process in various ways.
  • grape seeds contain protein, starch and high quality fats, but without breaking the cellulose/lignin encapsulation grape seeds themselves are unsuitable for human consumption.
  • certain parts of many products in grape seeds, the fiber fraction
  • wheat bran is increasingly used as a food ingredient to provide fiber, but traditionally it is not particularly suitable for storage or human consumption without a high degree of processing (known as “stabilization"), and is otherwise classed as agricultural waste. Wheat bran in its natural state has a very short lifespan. Consequently, it is normally either thrown to waste or used to produce low value products such as animal feed.
  • Stabilized bran (i.e., one having an extended shelf life) has traditionally been produced using either an acid-based or a hydrothermal process followed by extensive drying. Processes used today often include several steps such as conditioning, wet cooking, drying and milling. The hydrothermal process is both expensive and slow, and its dependence on energy, water and chemicals, raises concerns about its environmental impact.
  • the disclosure comprises an apparatus, and a process for making a stabilized food stuff, such as bran, and a stabilized foodstuff, such as a stabilized bran produced by the process.
  • the disclosure further comprises an apparatus for performing a process of extracting edible foodstuffs from waste materials, as further described herein.
  • An apparatus as described herein comprises a homogenization system; and a density separation system. Additionally the apparatus further comprises a transport system. The apparatus still further comprises a grading system and an integrated packing system. The apparatus still further comprises an inline analysis system; and a computerized control system.
  • the apparatus is for converting milling byproducts into edible products, and comprises: a homogenizer configured to fragment the milling byproducts into particles, wherein the bindings between protein, starch, and fiber in the milling byproducts are broken apart in the particles; and a density-based separation system configured accept the particles from the homogenizer and to separate the particles into three fractions, wherein a first fraction is rich in fiber, wherein a second fraction is rich in protein, and wherein a third fraction is rich in starch.
  • the disclosure still further includes a homogenization unit, comprising: a first disc; a second disc; a first variably controlled motor configured to rotate the first disc; a second variably controlled motor configured to rotate the second disc; a first input channel configured to direct feed material and a flow of gas into a region between the first disc and the second disc; and an output channel configured to direct homogenized material out of the homogenizer, wherein the second disc comprises one or more angled channels that divert the raw material into a colliding zone between the first and second discs, and wherein the first disc comprises one or more pegs that travel through the colliding zone.
  • the first and second discs can be configured to counter-rotate with respect to one another.
  • the homogenization unit can optionally accept a second product stream for mixing with a first product stream during homogenization.
  • the apparatus and process of the present disclosure are particularly applicable to creation of edible bran products.
  • [0018J As disclosed herein is a process for producing a stabilized bran product from a raw material, the process comprising: storing the raw material in one or more containers, wherein one or more physical properties of the raw materials are measured; deducing one or more conditions of processing of the raw material, from the one or more physical properties; passing a gas through the raw material to create a fluidized raw material; homogenizing the raw material, thereby producing a homogenized raw material; and separating the homogenized raw material into two or more stabilized bran products, wherein the two or more stabilized bran products have different densities from one another.
  • the two or more stabilized bran products comprise: a first product rich in fiber; a second product rich in starch; and a third product rich in protein.
  • the process can be run as a closed system, and deploys either air or an inert gas as a transport gas.
  • compositions of products produced by the process(es) and apparatus(es) described herein include the following.
  • a stabilized bran product comprising, by weight: 8% - 30% protein; 30% - 70% starch; 4% - 15% fiber; 5% - 15% water; 1 % - 2% fat; and 0.5% - 5% minerals.
  • a stabilized bran product comprising, by weight: 40% - 70% fiber; 5% - 20% protein; 5% - 15% water; 0% - 15% starch; 1 % - 5% fat; and 1 % - 8% minerals.
  • a stabilized bran product comprising, by weight: 1 5% - 70% fiber; 10% - 40% protein; 5% - 15% water; 10% - 25% starch; 1 % - 5% fat; and 1 % - 8% minerals.
  • a stabilized germ product derived from wheat middlings comprising, by weight: 10% - 30% protein; 40% - 80% starch; 3% - 15% fiber; 5% - 15% water; 1% - 4% fat; and 0.2% - 2.5% minerals.
  • the types of product obtained utilizing the technology are unattainable with any other currently available technology, since all currently available methods interact with the raw materials to modify (in some cases drastically) the natural properties of the original raw materials.
  • FIG. 1A shows the internal and external structure and composition of a grain of wheat.
  • FIG. IB shows schematically the division of principal parts of a wheat kernel into various products as used in the food industry.
  • FIG. 2 shows a flow-chart of a process in overview as described herein.
  • FIGs. 3A and 3B show perspective views of two apparatus for performing processes as described herein, based on, respectively, inert gas, and air.
  • FIG. 4 shows a side view of the apparatus of FIGs. 3A and 3B, as described herein.
  • FIG. 5 shows a perspective view of a portion of the gas transport system of the apparatus of FIGs. 3 A and 3B, as described herein.
  • FIG. 6A shows a call-out of the glycerine scrubber
  • FIG. 6B shows a cross-section of the glycerine scrubber.
  • FIG. 7 feed system call-out.
  • FIGs. 8A - 8D show views of the homogenizer.
  • FIG. 9 shows a perspective view of a component of the unit of FIGs. 8A - 8D.
  • FIG. 10 shows exemplary components of an apparatus of FIGs. 8A-8D.
  • FIG. 1 1 shows a flow chart of a process of use of an apparatus as described herein.
  • FIG. 12 shows an overview of flow control through an apparatus as described herein.
  • FIG. 13 shows an expanded view of a portion of FIG. 13.
  • FIG. 14 shows aspects of computer control of an apparatus as described herein, and as shown in FIGs. 12 and 13.
  • Bran is the term given to the outer layer of a whole grain. It is typically a hard layer and is part of the grain itself, and is therefore distinguished from "chaff, a more coarse and scaly material that surrounds the grain but is not part of it.
  • FIG. 1 A shows a cutaway view of a grain of wheat, illustrating the wheat germ and endosperm in the interior, and the bran layer on the exterior.
  • FIG. IB shows schematically how the various parts of a kernel (individual components not shown to their exact proportions) end up in various products.
  • Germ embryo of the wheat plant
  • rudimentary primary root 501
  • rudimentary shoot 502
  • sheath of shoot 503
  • scutellum shield between germ and endosperm
  • Endosperm nutritive tissue for the embryo: cells filled with starch granules in protein matrix (505); cellulose cell walls (506); and aleurone layer (outer endosperm cells) (508).
  • Pericarp protection layer: hyaline membrane (nucellar tissue) (509); seed coat (testa) and tube cells (510); epidermis (outermost protective layer) (51 1 ); hypodermis (epicarp) (512); and endocarp (cross cells) (513). Also shown are the hairs of brush ('beard') (514).
  • a kernel of wheat can be seen as comprising three main parts.
  • the endosperm is about 82% by weight, and gives rise to flour.
  • the endosperm is the mass of the grain that ultimately forms white flour.
  • the germ is about 10% by weight and is generally part of wheat middlings, as described elsewhere herein.
  • the pericarp is about 8% by weight and forms part of bran.
  • About 65-70% of a wheat kernel can go to produce white flour; this means that about 12-15% of the endosperm is not released in a typical milling process. This portion is mostly encapsulated in the aleurone layer.
  • Bran includes pericarp and the aleurone layer as its principal ingredients, and is rich in a number of components that are important in nutrition: dietary fiber, essential fatty acids, starch, protein, vitamins, and some dietary minerals.
  • Aleurone is a layer of the grain rich in protein and in starch and sugar, and comprises an outer portion of the endosperm.
  • the aleurone and pericarp together is typically about 17 - 20% by weight of a wheat kernel. From wheat-based raw materials, about half of the aleurone layer goes into the bran, and the other half goes into the wheat feed fraction.
  • Bran is often discarded during milling and production of refined grains, which means that refined grains are actually less nutritious than the whole grain from which they are derived.
  • Bran is typically milled from cereal grains such as: wheat, oats, barley, rice, corn, maize, and millet.
  • Rice bran is typically obtained as a byproduct of converting brown rice to white rice (rice milling) and contains a number of antioxidants, as well as forms of vitamin E.
  • Wheat middlings is the term given to a product that a mill produces from whole wheat grain. Middlings contain germ plus some of the endosperm that is impossible to separate out in a standard milling process. Wheat middlings can be used as a feed product, and is sold at a price substantially lower than grain price. Wheat middlings are also called 'wheat feed'.
  • Separating the grain into its constituents involves the following processes: cleaning, storing, conditioning, gristing, and milling. This process can be exemplified for wheat as follows.
  • Cleaning begins with screening to remove coarse and fine materials. This is normally done by gravity separation. Grain is then separated by size, shape and specific weight. The finished product, whole, pure wheat is then passed into conditioning bins.
  • Milling is the process by which wheat is ground into flour. Milling is the separation of the bran and germ from the endosperm, and the reduction of the endosperm to uniform particle size (flour). This is done by a sequence of breaking, grinding, and separating operations.
  • Breaking involves passing the wheat through a series of grinding rolls, which break the wheat up into a bran fraction (which is removed), large mainly bran-free endosperm chunks, and a small amount of flour.
  • the endosperm chunks are then passed through a smooth set of rolls, which reduce the endosperm to finer and finer particles.
  • the ground material is sieved, and free flour is removed, leaving only large particles to go forward into the next set of rollers, where these are further reduced to produce more flour.
  • a typical flour mill will have up to four break rolls and twelve reduction rolls, which leads to the production of some 16 flour streams, a nearly pure bran stream, a germ stream and a
  • bran/flour/germ wheat feed stream
  • the milling process is common to the production of all flours today.
  • the quality of the wheat going into the mill e.g. , as given by its protein content, will determine the types of flour being produced.
  • a miller can create further variations in features such as flour color and texture. Very white flours would come from the early streams only, while brown flours involve using most streams.
  • Wholemeal flour is produced when all the streams, bran, germ and flours are blended back together with nothing removed.
  • Examples of the types of flours produced are: white bread flours; brown bread flours; wholemeal flours; patent flours (high quality specialty flours); cake flours; biscuit flours; pastry flours; household flours; brewery flours; and flours for starch/gluten separation.
  • the production of bread requires products with high, medium and low fermentation properties. It is necessary to analyze several types of grain before constructing a finished product that will consistently meet the specific requirements of an end user.
  • the integrity of the semole and/or semolina must be maintained with regards to the goodness of the gluten, with the right relationship of tenacity and elasticity, low acidic degree, high degree of vitreous property and a low degree of mineral and/or fibrous residue, etc. This forces the grain industry to keep a great number of grains with differentiated natural properties, whose mixture allows the creation of the various types of finished product.
  • the instant technology is directed to methods and apparatus for the manufacture of specialty food ingredients.
  • the methods and apparatus are able to separate the key components of raw materials, mainly byproducts of processing food staples, such as wheat bran and wheat middlings, to create valuable food products, including bran and flour.
  • the instant disclosure includes an innovative process and apparatus for converting milling byproducts, such as cereal waste, to a new range of high value functional ingredients, such as bran products, that are suitable for human consumption.
  • the products have characteristics of excellent taste, appealing texture and appearance, and have an extended shelf life. Certain of the products combine high dietary fiber, and mineral content.
  • the products can be produced with a variable, e.g., very low, starch and fat content, or with the available starch and fat included, according to a buyer's requirements.
  • the products can replace commonly used ingredients in various food sectors (such as breakfast cereals, baked foods, diet/sugar free foods, and meat products, e.g. , sausages), but are produced at much lower cost than currently available alternatives, and hence offer the potential to capture an even larger market share than existing products.
  • the UK market for bran is the largest in Europe and is rapidly growing due to current trends towards the purchase of 'healthy' foods such as cereals and brown breads.
  • Such markets would be positively impacted by the introduction of bran products that have qualities of the products described herein.
  • the range of products that can be produced by the process(es) and apparatus(es) herein represents a range of high quality food ingredients. The origin of all of them is 100% natural, and they are all fit for human consumption.
  • a typical raw material used in the processes described herein are milling byproducts, in particular bran (part of the outer casing, as described herein), from cereal crops such as, wheat, barley, oats and rice, as well as to other non-cereal crops.
  • Other raw materials suitable for use include wheat middlings.
  • Two principal raw materials that may be used, as described herein, are wheat bran and rice bran.
  • the wheat bran comprises the outer layers of the wheat grain that cover the endosperm (the part of the wheat used for flour).
  • Principal products that result from the processes herein therefore include, respectively, stabilized wheat bran and stabilized rice bran.
  • Stabilized rice bran produced as described herein can be further processed to preserve the high fat content available. Rice bran fat can then be preserved for oil extraction and for the feed market (e.g. , for horses). There is also a potential market for stabilized rice bran for human consumption though this has not matured to date, in part because it contains high levels of silicon. Rice bran deteriorates rapidly so the process described herein is most effective immediately after the rice grain is milled and the bran is separated.
  • the raw material is wheat bran and is separated from the starch portion (flour) of the wheat in the initial processing steps in conventional mills, and consists of four key components: fiber (36 - 44%), starch ( 14 - 18%), proteins (10 - 15%), and minerals (4 - 6%).
  • Exemplary minerals include compounds containing the elements: zinc, iron, copper, selenium, cobalt, potassium, phosphorus, magnesium, and calcium, normally in biologically active forms as found within the natural substances.
  • Some raw materials also contain trace amounts of elemental silicon or sulfur, which arise from, e.g. , pollution such as incorporation of particulates in regions where the crop is growing.
  • the germ also containing portions of aleurone
  • wheat feed is separated from flour.
  • the four key components of germ (wheat feed) are: starch (30 - 45%), protein (14 - 18%), fiber (4 - 10%), and minerals (2.5 - 5%).
  • Both wheat feed and wheat bran can be processed according to processes and apparatus as described herein.
  • the stabilized bran and wheat feed products can be customized to fit specific demands from the food industry such as adjusting for: high fiber content, high protein content, or high starch content.
  • the stabilized bran products can be further separated into three principal fractions, each of which has a preferred utility.
  • the three principal fractions are designated (arbitrarily) herein as A, B, and C.
  • C fraction high starch and protein (e.g., from wheat bran and wheat feed).
  • the fiber-rich fraction (A) normally also comprises additional minerals, and antioxidants. It can therefore be used in many products and thereby enhances healthy functions.
  • the protein fraction (B) is a high quality product that contains a plant protein contribution that is much better utilized as human food than as a feed product. In the case of a wheat-based material, the protein fraction is also relatively rich in the fat that holds much of the valuable vitamins in wheat.
  • the starch fraction (C) is a product that has properties that make it a possible additive to standard flour in order to obtain a harder flour for pasta and pastry production without the need for a specialty flour. When used in higher concentrations it can be used similarly to a whole grain flour for production of brown bread.
  • the C fraction derives principally from the aleurone layer. It is valuable to get a high level of gluten (-30%) - into the flour fraction. This can be accomplished with the apparatus described herein, but cannot be done with other equipment. [0081] If all three product fractions (A, B, and C) are used, up to 25% more of the starting grain material can be turned into high value food products, which can therefore provide a significant improvement in human nutrition.
  • Stabilized wheat bran in any form is a recognized commodity, and therefore commands prices which reflect the traditionally high cost of the stabilization process.
  • Two principal wheat bran products that can be produced by the process include stabilized low-starch wheat bran (A), and stabilized high protein wheat bran (B).
  • Raw wheat bran can be processed by the apparatus described herein to produce stabilized low starch wheat bran (A), a fiber rich product, which is low in fat and starch, and is stabilized.
  • Stabilized low starch wheat bran can be used in breakfast cereals, baked foods, and as an additive to meat products such as sausages.
  • Stabilized low starch wheat bran made by the process and apparatus herein has a shelf life of 12 months. This is in line with acceptable shelf life limits in the industry, which typically are expressed conservatively and do not exceed 12 months due to the slightly hygroscopic properties of the products and the accompanying risk of mould development. On the other hand, products having a shelf life that are practically and significantly less than 12 months are not attractive.
  • Stabilized high protein wheat bran is similar to stabilized low starch wheat bran, but with a higher protein content. It has optimum use as a fiber boosting additive in breakfast cereals, bakery and pasta. While it is fit for human consumption, it also has use as a high quality animal feed.
  • the optimum use and largest market for the products is in fiber and/or mineral enrichment for food.
  • the largest sector of the food industry that can benefit is the breakfast cereal industry.
  • stabilized bran products are in the enhancement of texture for biscuits and pastries, and as a bulk filler for processed meats and sausages.
  • Additional product refinement means that stabilized bran products as described herein can be added to liquefied foods and beverages such as soups and drinks, without changing any aspects of the product.
  • a specialty high protein flour can be produced from wheat bran by the process described herein.
  • This is a specialty flour with high protein, fiber and mineral content, and also gluten.
  • Gluten is a natural substance formed from the proteins in flour when it is mixed with water. Gluten is essential for the production of normal and high quality bakery products. Without it, those products would not rise and the end result would be flat bread (pita bread, chapatti). Gluten is also essential for pasta production; the sticky nature of gluten holds the pasta together throughout the production process and prevents it from wilting when it is cooked.
  • Fraction C can be used as a high quality blending agent for other, low protein, flours. This enables its use in a wide range of foods, including bread, pasta, and in particular a wide range of high quality baked foods.
  • the key advantages of this product are as follows:
  • a high fiber white flour is a much sought after ingredient that provides an alternative to the high fiber brown flour that is used to make wholemeal bread.
  • the appearance of the product is light, so it can be used for production of fiber enriched white bread. This is particularly appealing in regions where there is not a high consumption of brown or wholemeal bread (e.g., Italy and France).
  • the product is rich in minerals that have potential valuable health benefits without any detriment to the product taste, smell, or its mouth-feel.
  • Wheat bran itself is the primary cost of goods sold; its price varies between €65- 130/ton throughout the year, though it can be obtained for only the cost of transport from certain mills.
  • stabilized low starch wheat bran and high protein wheat bran produced by the methods herein can compete at well below the production cost price of competitor products.
  • Strong American and Australian wheat types (containing, for example, 15% - 17% protein) are imported and milled throughout Europe. These flour types sell at approximately €500/ton and are regarded as the best quality flours.
  • the specialty flour product created by the process and apparatus as described herein can compete with these flour types and be produced and sold at similar prices.
  • the process described herein involves converting a raw material, such as wheat bran - or germ (wheat feed) - into high value human foods, within a controlled, high technology environment.
  • the process creates food products that are: highly nutritious; have very low fat content; have long shelf life; and have high fiber content.
  • the process can be optimized to: reduce the energy necessary to carry it out; increase the nutritional value and lifespan of the products; and widen the range of end products typically understood to be obtainable from, e.g., bran.
  • bran Hitherto, wheat bran, for example, has had limited use because it is high in fiber, but by processing it with the apparatus herein, it is possible to obtain the 3 separately useful fractions: an A-fraction that has beneficial uses in cereals; a B- fraction that can be used by the baking industry; and a C fraction that can be used by the pasta/pastry industry.
  • the process herein can extract parts of milling byproducts such as bran and middling from wheat, corn, barley, oat, rice, and the like.
  • the extracted parts typically comprise three fractions: a fiber rich fraction, a protein rich fraction, and a flour-like fraction high in protein and starch.
  • Benefits to the milling and bakery industries of the process include: increase of yield of useable products from raw materials; improved quality consistency in the finished products; reduced use of higher priced grains; substantial energy savings; and an ability to modify the proportions of ingredients such as gluten accurately in the finished products, by varying certain parameters of the process.
  • the process described herein makes it possible to derive useful products from 100% of the grain, thereby leading to a significant reduction in waste and loss of potentially useful materials from a given harvest.
  • the high impact and separation system described herein can recover virtually all of the endosperm from raw materials such as wheat, in contrast to normal milling processes, which waste a portion of the endosperm.
  • the process addresses increasing demands for healthy food products that do not contain artificial additives.
  • the reduced C0 2 footprint arises in two ways from this technology. First by the increased yield of products from a given harvest, which means that the total carbon dioxide released per ton harvested decreases. Carbon dioxide is released during production of fertilizers and energy use on fields and by transport of materials. Second, the C0 2 footprint is reduced by the lower energy consumption of the process compared to other processes in the industry, for example wet processing of milling by-products to extract fiber fractions. In addition, the wet or acid extraction methods of fiber used elsewhere in the industry lead to a waste of protein and starch which, themselves, are key components that could form the basis of valuable food quality products.
  • the process described herein also removes the need for wet cooking of materials and an ensuing energy intensive drying step. Due to the use of a dry heated gas stream, with extensive and well defined contact time and temperature, enzymes are deactivated (coagulated) without destroying the nutritional value of the product. Enzyme coagulation stops the enzymatic break down of fat to free fatty acids.
  • An operating temperature can be chosen that enhances coagulation of enzymes, and, in combination with high impact processing, it is possible to specifically stimulate coagulation of the large enzyme proteins (> 60 kD).
  • the temperature of the process in a narrow and well-defined band in order to reach coagulation temperatures in the product, without reaching a gelatinization temperature for the remaining low level of starch that is present.
  • the temperature varies according to the raw material, but for wheat it is ⁇ 61 °C, the temperature at which coagulation of lipase enzyme occurs.
  • the A fraction and also the B fraction which has higher levels of protein and starch, are stabilized.
  • the dry nature of the process also keeps available water soluble substances intact in the product; this is especially important because the antioxidants found in wheat germ, when not washed away by wet processing, enhance the stability of the product without the need for artificial additives.
  • Another advantageous aspect is that the process does not use harsh acidic treatments or chemical processes to treat raw materials, as with existing techniques used in the baking nd milling industries.
  • the homogenization (sometimes referred to as disaggregation), as further described herein, of the components of the raw material (grain or flour) without breaching their constituent molecular structures, thereby preserving their natural properties, allows the creation of the desired products with safety and expediency. It also insures a uniform finished product with a narrow range of dimensions of granules and therefore a saving of time in subsequent processing steps.
  • the C-fraction product produced by the technology herein derives from portions of the kernel that are closer to the bran portion of the grain. This can be mixed in with a weaker flour to produce a specialty flour of the desired consistency. Since the C-fraction can be produced from the wheat bran itself by the process herein, this obviates the need for purchase and storage of a separate hard flour such as Manitoba flour.
  • the processes herein are a highly technical solution to deriving valuable products from raw materials that, due in part to the computer control and design, are still easy to operate and maintain.
  • the computer control not only permits creation of products having a high level of purity and an even consistency, but also permits control over composition and physical properties.
  • FIG. 2 shows, in overview, a process as described herein for preparing stabilized bran products from wheat milling byproducts.
  • the wheat byproducts are subjected to three stages: a humidity control process (Stage 1 ), a homogenization (Stage 2), and a separation stage (Stage 3).
  • the product fractions A, B, and C (exemplified in FIG. 2), that are obtained from the separation stage (Stage 3) are further subjected to grading (Stages 4 - 6, respectively), and each divided into two further fractions (coarse and fine, in each case), typically controlled by inline analysis.
  • Exemplary proportions for fractions A - C are as follows: stabilized low starch wheat bran (60%); stabilized high protein wheat bran (20%); and specialty high protein flour (20%).
  • Isolation of the various (up to 6) product fractions can be considered to comprise 2 stages: a first stage is a density-based separation, to give the principal different fractions A - C; a second stage, referred to as grading, separates the particles in a given fraction by particulate size.
  • the second stage is mainly to ensure that stray flakes of bran don't come through to a given fraction (the flakes will be diverted away from the sifter), and may also be used to organize a given fraction into subdivided quantities having more uniform ranges of particle sizes.
  • FIG. 1 1 shows, in overview, steps in a process for creating stabilized bran products from raw materials, generally.
  • raw materials 1 1 1 are diverted to storage 1 10, wherein basic properties can be assessed in order that parameters for the process of creating stabilized products can be selected.
  • the raw materials are then fluidized 120, for example by passing air or an inert gas 1 13 through them, so that they can flow to other parts of the processing apparatus more easily, and also so that the bulk composition can be made more even.
  • the fluidized raw materials are then subject to homogenization 130, for example in a specially designed homogenizer as described elsewhere herein.
  • the homogenized raw materials are then subjected to a density-based separation 140, and the contents of three principal fractions A, B, and C, are diverted to respectively separate storage areas 1 1 5, 1 17, and 1 19.
  • FIGs. 12 - 14 illustrate the process overview in conjunction with particular apparatus features, and are described as follows.
  • air or an inert gas such as N2 or C0 2 as a transport gas is largely dictated by the composition of the raw materials, as described elsewhere herein. Where a similar role is performed by either gas, the gas can be referred to herein as the transport gas, which is taken to mean a gas appropriate to the raw materials in question.
  • raw materials 1 1 1 are accepted from, e.g., a milling process, and are placed into storage silos 1 , 2. Once the raw materials have been assessed for content and various physical parameters, they can be moved into the apparatus for processing, for example, via screw transporters 48, 49.
  • Fluidization of the raw materials 1 1 1 can take place in a wind box 47.
  • the wind box accepts air or inert gas from a low pressure gas tank 3.
  • the low pressure gas tank 3 is in fluid communication with a high pressure gas tank 26, which provides a source of transport gas that can be drawn upon as needed.
  • Low pressure gas tank 3 is also equipped with an air bleed 27 so that excess pressure build-up if at all can be regulated.
  • Transport gas from low pressure gas tank 3 is directed to use throughout the apparatus and process, for example in material feed control 15, and density separation system 12.
  • Fluidized materials from the wind box are carried through material feed control 15, using a stream of low pressure gas, and directed to homogenizer 13.
  • the materials are broken apart in a manner that disrupts binding of dissimilar components (e.g., starch and proteins) without breaking down the underlying molecular structure of the individual components themselves.
  • the homogenizer is further described elsewhere herein.
  • Homogenized material is carried via the low pressure gas stream from homogenizer 13 to density separation system 12, which achieves a separation of the homogenized material into three fractions, based on respective densities.
  • Material is diverted from the density separator via a sifting system (not shown in FIG. 13), to an area for bagging of products 19, 30.
  • Separation system 12 and bagging system 13 is shown in expanded form in FIG. 14.
  • Transport gas from the separator passes through a system of compressors and valves, and is diverted through various heat exchangers to the bagging system and the low pressure gas tank.
  • Surplus transport gas from the wind box and material feed control can be diverted via a fan filter 5 and fan 97 back to the low pressure gas tank.
  • raw materials come from the homogenizator and are subject to 3 consecutive separation stages.
  • Each separation stage accepts additional transport gas as needed, and is equipped with a heat exchanger and a separate bagging station.
  • the main costs of operation which include electricity, heating and cooling, are less than €5/ton.
  • Labor costs include the costs of employing unskilled workers who can be trained easily, and simple maintenance and regulation work. The overall process can therefore be practiced very cost effectively.
  • the disclosure further comprises an apparatus for performing a process of extracting food products from milling waste or low value products which are normally used as animal feed.
  • the system described herein can be installed as a stand-alone system or incorporated into existing milling processes for grains. It is possible to integrate it in the milling cycle without upsetting the processing. It can also be incorporated in a bakery production line (instead of the milling process), and be placed at the beginning of the working processes, modifying the natural property of the bases upon arrival. This would allow a bakery to use a lesser quality flour and still achieve the same if not superior results.
  • the technology can eliminate, or limit, the search for specific grains to construct a material with the characteristics that are necessary to distinguish flour for bread, from one that would be acceptable for cakes or sweet products.
  • a manufacturer is able to increase the commercial yield, while maintaining the quality of the finished product. By integrating the technology described herein in the milling process, it is possible to adjust the various
  • a negative color is a grayish color, which deviates from the more attractive and appealing pure white.
  • a gray color can be imparted to the flour by bran. However, such a color effect can be obviated at least in part by the process herein, which separates fiber away from high quality components such as protein and gluten.
  • the apparatus and process of the present disclosure are particularly applicable to extraction of edible fiber (A fraction) and additional flour products (C-fraction) fractions from bran and middlings.
  • the fraction C can be used in combination with standard white flours in order to obtain specific characteristics such as high protein content, or additional nutritional value from increased content of minerals and vitamins.
  • the C fraction can be mixed directly by either addition of mixing compound in front of C-fraction cyclone or just after the rotating valve by introduction of a vortex mixing device inline.
  • the main advantage is that no further process equipment is needed and products can be packed direct without further processing, since the inline automatic NIR analysis system can be programmed to automatically adjust mixing proportions to congregate specifications and/or customer demand.
  • the apparatus described herein can be constructed as one or more small modular units, that can be located close to the sources of raw material (e.g., flour mills), and/or sales channels (e.g., bakers and cereal producers), thus minimizing transportation costs. Carbon emissions are small as the process consumes very little energy. Running costs are also low as the machine is fully automated and computer controlled, unskilled labourers can be trained to operate the machinery, and it can be set up to provide remote access control for the managers.
  • raw material e.g., flour mills
  • sales channels e.g., bakers and cereal producers
  • the apparatus is built in a scale that fits comfortably within the A-frame construction of warehouses, as found in Europe and Russia, for example. It is found to be convenient, as well as in compliance with many local regulations regarding industrial facilities, if the apparatus is set up as two modules, each of which is approximately 5m x 5m x 7m in dimension.
  • a first module includes the homogenizor, compressor, and separator(s);
  • a second module includes the bagging unit and sifters.
  • Such an arrangement is not the only arrangement of components of the apparatus as further described herein, but is a typical arrangement because it is consistent with regulatory requirements which dictate that the feed material is separated from the product output.
  • a plant with one unit can process 5-7 tons of bran an hour depending on the type of bran and logistics of the operation. This can lead to production cycles of 80-1 12 tons of bran per day, for example in a two-shift day.
  • the units are modular it is easy to scale the plant up by adding additional units, and thereby scale up production.
  • FIG. 3B There are two principal categories of apparatus for carrying out processes as described herein: an air system, of which an exemplary form is shown in FIG. 3B, and an inert gas system, as exemplified in FIG. 3A. It would be understood by one of skill in the art that the
  • FIGs. 3A and 3B configurations of the apparatuses in FIGs. 3A and 3B are exemplary and that many variations in implementation are possible while maintaining a function and product production that is consistent with the description herein.
  • a particular component is described as performing a particular role, for example a compressor, or a sifter, it can be assumed that another component performing the same overall function could replace the described component in another implementation of the apparatus.
  • FIGs. 3A and 3B are relatively compact and typically have dimensions of approximately 14 m long by 10 m wide.
  • FIGs. 3A and 3B are labeled consistently with one another.
  • the following description of the inert gas system includes description of various components common to both systems. Where inert gas is referred to in the context of a component that is common to both versions of the system, it can be assumed that air is intended for the corresponding air-based system. Components found in one system and not the other are described separately.
  • FIGs. 3A and 3B Portions of the apparatus in FIGs. 3A and 3B are excerpted into separate figures for clarity.
  • FIGs. 4 and 5 show portions of the apparatus.
  • FIGs. 6A and 6B show the glycerine scrubber in overview and cross-section.
  • FIG. 7 shows the feed system.
  • Two key parts of the apparatus are the homogenizer (which is not milling the bran, but beating it up so that it falls apart into different fractions.), and the density separation unit to separate the bran into different fractions (A, B, and C).
  • the glycerine drier is also important. This functions by pumping glycerine through a heat exchanger. The glycerine is also heated up in flash-tank 25 to boil off water.
  • Typical feeds that require the inert gas based process are rice bran and other materials that contain high levels of fat that quickly oxidize if exposed to air. Also, products that have increased risk of ignition, such as those containing fine particulates, can be processed in the machine in an inert gas atmosphere.
  • FIG. 3B An exemplary closed inert gas system for carrying out processes as described herein is shown in FIGs. 3A, 4, 5, 6A, 6B and 7.
  • FIG. 3B A corresponding air-based system is shown in FIG. 3B.
  • a wind box is a unit where inert gas flow or air flow fluidizes a solid product, thereby facilitating its transport.
  • a cyclone is a standard piece of equipment to extract what is transported by gas in a fluidized flow.
  • the gas and particulates are introduced tangentially into the cyclone and subjected to rotation. This lets the particulates travel to the surface of the interior wall of the cyclone; the gas leaves from the center of the cyclone, free of particulate material; the particulate material falls to the bottom of the cyclone by gravitation.
  • FIGs. 3A, 3B, 4, 5, 6A, 6B and 7 are identified as follows, in Table 1 .
  • Inert gas tank compressed or liquid C0 2 or N 2
  • Wall representing border between inside building and outside
  • the system can be operated as a totally closed system with re-circulated inert gas such as carbon dioxide or nitrogen in order to totally eliminate oxidization of un-stabilized bran products.
  • Products that are generated that are particularly hazardous due to dust, explosion risk, allergic reactions, or are toxic, can therefore be processed in this system without any difficulty. Toxicity rarely arises but can be associated with very small particulates such as nano particles, which could be dangerous if inhaled, or airborne mould or spores.
  • a closed system makes it safe and practical to process materials that contain such elements. Products can be stabilized by heat during the process and packed directly in a bag without contact with air. The bags can also be filled with inert gas during packing if it is necessary to obtain an extended shelf life. By having a direct connection between the separation unit and a specially built bagging system, all contact with air is avoided. As a result, a very high level of product safety and long shelf life is obtained on the products.
  • the raw material such as a wheat bran
  • the raw material is delivered in bulk, or may be transported directly from a milling process, such as by pneumatic or screw conveyer, and is stored in a silo system before it is processed by the apparatus.
  • a silo system is exemplified as two raw material silos 1 and 2 in FIG. 3A.
  • Two or more silos make blending materials from silo 1 and silo 2 possible: for example bran can be stored in silo 1 , and wheat feed in silo 2, thereby enabling different ratios of blend to be fed into the apparatus in order to meet a particular customer's specifications for the end products.
  • Silos 1 and 2 are fitted with conveyors 41 , for example bottom screw conveyers, that transport material from each silo to a wind box 47 (FIG. 7) where a transport system 33, for example a pneumatic transport system, diverts the raw material(s) to feed hopper 15. If flaky wheat bran material is the raw material, pure oil free compressed air is used to fluidize material in the silos 1 , 2. This can be accomplished by blowing air in at the silo's conical shaped lower parts 28 and 29.
  • conveyors 41 for example bottom screw conveyers
  • a transport system 33 for example a pneumatic transport system
  • the conical parts of the silos are lined with a perforated plate, typically having a perforation diameter of 0.05 - 0.1 mm, and pressurized air is blown in between the silo wall and the perforation plate with the result that the raw material in the silo is effectively fluidized. This effectively avoids build up of "bridges" of the raw material in the conic part of the silo.
  • the silo system can be excluded, and the raw material can be directly pneumatically fed to a feed hopper cyclone 31.
  • raw materials are delivered to the processing plant in bags (a term of art in the industry, usually referring to a bag containing up to 50 kg content), or big bags (a term of art in the industry, usually referring to a bag containing 500 - 1 ,000 kg content that is equipped with a lifting device and must be manipulated with e.g. , a fork-lift truck), an optional bag empting unit 30 can be installed online on the screw conveyer 41 to wind box 47, see FIG. 7.
  • the apparatus further comprises a feed hopper system 15.
  • Raw material is transported from wind box 47 to feed hopper cyclone 31 on top of feed hopper 15.
  • raw material is pneumatically transported using an inert gas supply from gas tank 3.
  • the pneumatic transport system 33 is a closed loop, and dry filtrated inert gas from low pressure tank 3 is used and supplied by pipe system 50 (FIG. 7).
  • Raw material is
  • feed hopper 15 gravitationally fed into feed hopper 15, via a rotation valve 32 located on top of feed hopper 15.
  • Feed hopper 15 can be equipped with a sensor, such as an inline NIR (near infra-red) instrument 46, that intermittently, for example, at a frequency of 10 - 30 times per minute, monitors various content parameters of the raw material, including: moisture, protein, fat, crude fiber, starch, and ash.
  • the NIR instrument provides output to a main analysis unit 45, which is in communication with a computer control system 44 that can be set to adjust machine settings according to raw material quality, and according to fluctuations in the raw material content. This ability to make continuous adjustments is important because the bran material is not a uniform product. In particular, the fine fractions tend to fall to the bottom during transport, and the moisture content varies widely with the part of the grain being processed.
  • the total grain overall contains proportionately more moisture than does the endosperm.
  • the endosperm is totally enclosed in the outer layers of the pericarp; there is normally more humidity in the outer layer than in the endosperm, where the starch is protected by proteins. Accordingly, it is important to be able to adjust the machine to take account of variations of humidity / moisture content in the raw materials as they are being processed.
  • the NIR instrument can also generate a raw material report, for example in graphic and/or table form, that can be included in documentation for a processed batch, and can also be used in pricing raw material according to the values of the recorded parameters. If any critical parameters, such as moisture, ash, or fat and fiber content, is in excess of pre-defined limits, an alarm can be triggered. In some instances, machine control can be set to automatically stop the raw material feed, or optionally automatically direct the material on a bypass system (not shown in the figures) to a storage for non processed or waste material. If an automatic bypass is installed, normal processing will restart as soon as the raw material parameter(s) is/are within the predefined range(s) again. A log of the amount of bypassed material can be kept. If an automatic bypass is not installed, a manual raw material deviation procedure must be followed until raw material parameters are back in the programmed range. Typically the NIR has 8 sensors, in communication with a single central processing unit (see items 43, 45).
  • a transport screw 48 driven by a motor 49, such as a frequency controlled motor, that feeds the raw material to the pneumatic transport system for homogenization unit 13.
  • the transport screw 48 controls the material feed speed, e.g., from 0 - 6 tons per hour. Limits to the feed speed can be set manually in the computer control system 44. Alternatively, the feed speed between the hopper and the homogenization unit can be
  • Homogenization unit 13 is further shown in FIGs. 8A, 8B, 8C, and 8D.
  • Raw material is transported by a closed loop inert gas pneumatic transport from feed hopper 15 to a cyclone 52 on top of homogenization unit 13, FIG. 3A.
  • the cyclone 52 is directly connected to the material intake in the homogenizer unit 13 without a rotation valve. This is important due to the option to control pressure in other parts of the machine.
  • a computer controlled valve on top of cyclone 52 is controlling the pressure in homogenizer unit 13, and in the density separation system 12.
  • Inert gas flows from the pneumatic transport system 51 to the homogenizer unit 13.
  • the pressure in homogenizer unit 13 is normally lower than the pressure in the pneumatic transport system 51 that feeds material into the homogenizer.
  • the pressure in the transport system is 0.7 - 0.9 bar absolute
  • the pressure in homogenizer is typically 0.4 - 0.8 bar absolute.
  • absolute signifies the actual value of the pressure; typically when the term absolute is omitted, it is implied that the pressure is above atmospheric pressure.
  • the lower pressure in the homogenizer unit reduces friction, with reduced energy consumption as a result. Additionally, the reduced pressure and gas flow keep material temperatures below a level at which damage to the materials would occur.
  • raw material is exposed to high accelerating and impact de-accelerating forces that break the protein-starch bonds in the aleurone cell layer, and separate aleurone and pericarp, as well as epidermis and hypodermis, from one another.
  • This high energy agitation and separation can also be termed disaggregation of the structures. If germ (wheat feed) is the raw material, binding between the parts in germs is broken up and parts remaining of endosperm are separated.
  • the high protein and fat concentration in germ is made available for separation, and the rudimentary primary root (also known as the embryonic axis) and scutellum are separated.
  • the enzymes in the aleurone cell layer of scutellum are partly or totally coagulated by the high forces, and this enhances the stabilization process.
  • the material is not grinded but broken apart in the process into its principal fractions.
  • the rudimentary primary root is hard to separate by other processes currently available in the art, but it is important to be able to separate it because it contains a specific protein that is not appealing to eat because of its bitter taste
  • the homogenizer unit has two disks which are driven by two separate frequency controlled electric motors. This makes it possible to run the two disks at different speeds or to counter rotate the discs at different speeds according to what products are being processed.
  • Homogenizer unit settings can be part of a recipe optimized for each raw material type, and can be stored in the computer control unit.
  • the recipes can be made easily accessible for an operator from, e.g. , a start up screen, and machine based settings are then automatically made according to recipes for the actual raw material being processed.
  • Empirical settings for actual or new raw materials can easily be stored in the computer system by an operator as new recipes. This function enhances rapid build up of know how regarding processing of specific raw materials.
  • the particles are then separated as a function of their specific weight. Homogenized material is fed into a density separation system 12 where the product is separated into three fractions according to density. The A fraction is the most dense, and the C fraction has the lowest particle density.
  • Computer controlled valves adjust the system according to demands on the specification of final products, with help of feedback from an inline NIR (near infra-red) instrument 20 that controls the final products on an intermittent basis, for example every 2 - 6 seconds in each output silo.
  • the computer system adjusts the density separation system to meet product specifications.
  • the level of materials in the silos is linked to the product speed, and steps taken to avoid over adjustment.
  • the processed material comes out of density separators in 3 fractions, and ends up in the silos 19, where the protein, starch, concentrations, etc., are monitored by NIR. It should be noted that, in the specific embodiment described herein, there is a lag in time from processing time till the time that the material reaches the NIR.
  • the computer processing unit takes into account the levels in the silos and the time it takes for new product to come through.
  • Density based separation can be achieved by a number of different methods, the resulting efficiency of separation being dependent on a particular technology type.
  • the most efficient method utilizes a high speed rotating unit inside a cyclone.
  • a down-tube is located in the center of a chamber, and is perforated; around the down- tube are a number of high-speed rotating paddles with a specific angle. As the paddles rotate, they create a vortex around the down-tube.
  • the high density particles are separated efficiently into different fractions, independent of the particle size.
  • Product purity that can typically be obtained with this method is, e.g., 90% starch in C fraction.
  • cooler/heater units 9, 10, 1 1 for each of the three product fractions that emerge during separation.
  • the units 1 1, 10, 9, permit some individual temperature adjustments.
  • the A fraction can be set to 220 °C
  • the B fraction can be set to 48 °C
  • the C fraction can be set to 42 °C.
  • Temperatures can also be varied according to starting material and desired product quality.
  • the A fraction can be set to 50 °C for stabilization not toasting.
  • An over pressure at a level of 1 .5 bar absolute is generated by the combined vacuum pump/compressor 7, and pneumatic transport gas is preheated by the compression. Adjustment to the required temperature for a given fraction is made by a separate heat exchanger that uses the glycerine from gas drying loop (3; 22; 23; 24; 25) as cooling or heating media. As shown in FIG. 3A, the heat exchangers (transport gas cooler/heaters) for the A fraction, B fraction, and C fraction are 1 1 , 10, 9, respectively. Computer control adjusts the transport gas temperature to a value specific to a particular recipe. Roasting, drying and stabilization are made during transport to the product processing station 14 and 18.
  • Inline NIR instruments keep track of moisture levels, and adjust the temperature according to required moisture content and level of roasting or enzyme coagulation/stabilization. High moisture present in the product needs a higher temperature to achieve the required roasting level (stabilization), due to energy consumption used to evaporate water.
  • a fraction from bran is relatively robust and can be treated with high temperature without any negative effects on product quality, and in fact a high level of stabilization is achieved with a high temperature so that the product will obtain a baked bread like smell.
  • the B fraction from brans is relatively robust and can be treated with high temperature without any negative effects on product quality, and in fact a high level of stabilization is achieved with high temperature. Due to the content of starch in the B fraction and the possible use in bread baking, the temperature is normally set at a level that coagulates enzymes but without damaging the starch.
  • C fraction from bran is vulnerable to high temperature due to its high starch content, and its temperature has to be kept in a narrow band to avoid negative effects on product quality. Due to the high gluten and starch content in the C fraction, and the possible use in bread baking, the temperature is normally set at a level that coagulates enzymes without damaging the starch. Therefore use of a control system to keep the temperature in a very accurate and narrow band is important for the C-fraction.
  • a combined vacuum pump and compression system 7 acts by sucking in transport gas on one side and sending out transport gas at the other end.
  • Transport gas leaves the density separator and goes to the filter 8, gets cleaned, sucked into the compressor on low pressure end ( ⁇ 1 bar).
  • Gas is compressed to 1.2 - 1.3 bar absolute and compressed against a release valve; some gas is diverted through heat exchangers 9, 10, 1 1 . The temperature rises in the compressor.
  • the gas When the gas leaves, its temp, is approx. 120 °C.
  • the gas For fluidizing the C-fraction the gas is cooled down via the glycerine loop.
  • the C-fraction transport system operates at around 65 °C.
  • the compressor pushes the transport gas through wind boxes, 99, 100, 101 and transports it to the bagging machine 30. Gas returns to the low pressure tank via fan filter.
  • the gas temperature is raised to around 120 °C for the B fraction because it typically contains more enzymatic material.
  • the gas is heated by heat exchanger 1 1 to around 200 °C or above.
  • the A- fraction benefits from using the highest temperatures because it has the most risk for fungi (which has to be killed off in order for the fraction to be acceptable in the industry).
  • a self cleaning bag filter 6 is used before vacuum pump/compressor 7 to clean the gas, and catch the small amount of mainly mineral dust that is not separated out in the density separator unit.
  • the filter can be equipped with, e.g., HEPA filter bags.
  • the filter systems make it possible for recirculation of gas via gas tank 3 and the glycerine scrubber in tank 3, and thereby reduce overall gas consumption and avoid the influence of ambient conditions on the process.
  • the hygroscopic nature of glycerine withdraws water from the transport gas.
  • the temperature in the glycerine scrubber is typically at the temperature at which the process is run. Transport gas is returned for use in the process free of water that has been picked up from the raw materials or product, or is present in ambient air. This is particularly useful in locations that have high humidity, e.g. , the Tropics, where the scrubber can additionally remove ambient moisture from the gas.
  • the filter system also makes it possible to use gas from vacuum pump/compressor 7 for pneumatic transport of products.
  • the closed loop of gas in the system, and HEPA filtration (if so equipped), ensures a high level of product safety in respect of possible contamination from microbiological sources such as fungi, and also means that that the process is largely independent of ambient conditions.
  • a combined oil-free vacuum pump and compressor 7 is used to create the needed low pressure (0.4 - 0.8 bar absolute) for homogenizer unit 13, and to generate pressure and most of the heat for product transport and stabilization. The heat is generated due to the rise in gas temperature due to the adiabatic compression process.
  • a purpose built pressure control unit shown on the left far corner of vacuum pump 7 in FIG. 3A, keeps the pressure at a set level for a pneumatic transport system, and sends exclusive gas streams via a cooler 8 to gas tank with glycerine scrubber 3.
  • the use of gas from combined vacuum pump/compressor for transport and stabilization dramatically reduces energy consumption for the overall apparatus.
  • a self cleaning bag filter 5 is used before transport loop fan (not visible in FIG. 3A), e.g., fitted with HEPA filter bags, to clean the gas and catch the small amount of product and mineral dust that is not caught in the cyclones. All material filtrated out from the gas is bagged thereby giving a good dust free working environment with low demands on ventilation in building in which the apparatus is installed.
  • the two filter systems 5, 6 make it possible for recirculation of gas via air tank and glycerine scrubber 3, and together minimize the influence of ambient conditions on the process.
  • the closed loop of gas in the system, and HEPA filtration guarantee a high level of product safety independent of ambient conditions.
  • a rotating sifter 14 (rotation is achieved internally, driven by an electric motor) is used to separate the protein part of the A fraction from the pericarp, as the density difference is too low to get full separation in density separator 12. This form of separation is possible because proteins break apart from pericarp in small parts that can be sifted out from bran product. Material that passes through the sifter is referred to as penetrate material.
  • Penetrate material in the A fraction that passes through the mesh from rotation pre separation 14 can be separated further into a fine flour like fraction high in protein, and a coarser more fiber rich fraction, in a planar sifter 18, according to customer demands.
  • A- l the penetrate
  • A-2 the A-2 fraction
  • Both A- subfractions are fibrous; the difference between them lies in texture and particle size.
  • Exemplary particle size ranges for the three fractions are as follows: A-fraction - 0.5 mm - 1 .5 mm; B-fraction - 0.2 mm - 1 .0 mm; and C-fraction: 10 microns to 0.2 mm.
  • the ranges for each primary fraction (A, B, or C) embrace ranges for both sub-fractions, respectively.
  • a sifter has several, for example 3 or 5, layers of mesh, layered in order of most coarse to most fine.
  • the layers are computer controlled. Adjustment of the process can therefore include adjustment of the sifters, such as by removing one or more mesh layers from the flow, thereby controlling the overall particle size in the product(s). This allows the process to suit a wide range of customer demands.
  • B fraction material is cleaned from rest of the pericarp, and A fraction reflux from rotation pre separation 14, and can be further cleaned from the rest of fine particulates such as fiber particles in a planar sifter 17 according to customer demands.
  • the result is a fine fiber-rich fraction, and a clean bran fraction low in starch.
  • the sifting process is controlled to remove the finest part, which is not protein but is fiber (e.g., from A-fraction) from the flour. In this way, one can control composition by regulating particle size.
  • the C fraction is cleaned from any oversize particulates, also according to customer demands, by another planar sifter 16.
  • the result is fine flour and a coarser flour of full grain type. This means that, in some embodiments, there are also two sub-types of C-fraction.
  • the various fractions can be defined by their particulate size.
  • "0-0” is fine white flour, e.g. , suitable for home- baking.
  • each of the A, B, and C fractions are sifted into two sub-fractions each.
  • Each sub-fraction is preferably analyzed separately and independently of the others.
  • Product silos 19 are used as buffers in front of a bagging system (not shown), or as a holding buffer during quality control before transport of the products to further product processing such as mixing, granulation or milling.
  • Each product silo (normally there are from 3 - 6 such silos) is equipped with an inline NIR quality control sensor 20.
  • the product silos 19 make it possible to stop one or more product flows that are out of quality range and divert them, e.g., to waste, or further refinement, without disturbing the total operation of machine. Automatic computer control of diversion of the product which is out of quality range, or marking of bags, can be integrated into the system.
  • a low pressure gas tank combined with a glycerine scrubber 3 is used in a closed loop gas system to first work as a buffer for gas at low pressure (typically 1 .2 bar absolute), and by scrubbing recycled gas with the hygroscopic glycerine in order to reduce moisture level in the gas before it is reused in the system.
  • the tank is built as a floating dome (i.e. , the tank top is floating on glycerine as a gas dome in a glycerine tank) which is a technically straightforward way of achieving nearly constant pressure with variation in gas volume.
  • gas is fed via a computer controlled valve 27 from a gas tank 26, usually situated outside the building in which the rest of the apparatus is housed, or separated by a barrier 42 from the rest of the apparatus. Separation between gas tank 26 and the remainder of the apparatus is normally required because liquid gas cannot be stored alongside the apparatus due to the risk of leaks which can kill workers due to lack of oxygen.
  • Dome 59 floats on glycerine in tank 3.
  • gas pressure goes up, the dome is lifted and a buffer of gas is in the tank.
  • gas is automatically released from valve 27.
  • the gas pressure decreases, and the dome goes down, there is a need to feed in compressed air from the high pressure tank (cf. Fig. 4).
  • Product takes gas away from system as it is being processed, so it is generally necessary add some gas or air during the process.
  • Top valve 27 is also used to bleed off air if the system is converted from air operation mode to inert gas operating mode. Glycerine can be regenerated by a water evaporation system consisting of pump 22, heat exchanger 23, furnace 24 and flash tank 25 (a return pump from the flash tank is not visible in FIG. 3A.
  • Glycerine is used due to its hygroscopic nature and relatively high boiling point, which makes regeneration easy. Glycerine is a naturally appearing component of vegetable products, and does not give rise to any risk of pollution in end products, as food grade glycerine is available in market. Glycerine can be purchased from oil refineries. It has a high boiling point, is hygroscopic, and is naturally occurring in many grain materials. It is available in food grade and can be regenerated (by boiling off water). Its role in the process is to dry the air or inert gas that has made one round in the process. Its use is particularly beneficial in tropical conditions where there is high ambient humidity.
  • the inert gas can be C0 2 or N 2 depending on the products that are processed.
  • the gas can also be either in compressed form or in liquid form.
  • the inert gas is stored in a tank 26 outside the building. Compressed gas can be used, as the apparatus is built to permit total recirculation of gas and therefore requires only a low ongoing consumption of the gas. Although compressed gas is less expensive than liquefied gas, one obtains less gas for a given volume purchased, but the low loss of gas during operation of the system means that this is acceptable. It also means that the apparatus is more convenient to operate in regions where compressed gas is unavailable.
  • Inert gas is fed to the system using a floating gas dome, which keeps the pressure constant at 1.2 bar absolute. Control of oxygen content in the gas is achieved by computerized instrumentation which also controls a bleed of valve 27 on top of the dome and the level of the dome. New gas is fed to the low pressure tank when oxygen is bleeding off, or the level of gas in the dome becomes too low.
  • Used gas is re-circulated to the gas dome over one or more, and preferably all, of the following items: dust filter, microbiological filter (HEPA filter), gas dryer, and heat exchanger.
  • dust filter microbiological filter (HEPA filter)
  • HEPA filter microbiological filter
  • gas dryer gas dryer
  • heat exchanger heat exchanger
  • the apparatus takes its energy supply from an electrical input that can be used to keep the system at the temperature needed for smooth operation. But much energy created by various portions of the system, when running, can be captured and recycled, leading to considerable overall savings in the electrical energy utilized.
  • the energy from compressors and fans in the system are also sufficient to keep the process temperature at a set point. Due to recirculation of gas, some cooling is generally beneficial. This is achieved with a liquid to air closed loop cooling system in order to minimize use of process water, and a heat pump system that makes it possible to create high temperature stabilization of separate fractions according to customer demands.
  • the excess energy from process gas cooling is also used to moderate the temperature of the feed gas from the low pressure tank, and, if liquified gas is used, to evaporate the feed gas so that it can be circulated.
  • a fan is used in a gas stream, the energy added by rotation of the fan creates friction and increases the temperature of the gas. Accordingly, rather than waste the heat, it is used to heat process gases after the separation unit, via heat exchangers 9, 10, 1 1 .
  • the air tank and glycerine scrubber 3 including the glycerine generation system 22, 23, 24, and 25, can be excluded from the system, and the compressor 4 can be reduced to feed only instrument air and air to fluidize the materials in silos 1 and 2.
  • Glycerine is circulated from gas tank and scrubber 3 by a circulation pump 22 through the glycerine regeneration system 23, 24, 25, and returned to gas tank 3 by a return pump (not visible in FIG. 3 A) via heat exchanger 23.
  • Glycerine from gas tank/scrubber 3 is pumped via the glycerine heat exchanger 23 where glycerine is heated by exchange against hot glycerine from flash tank 25.
  • the returning glycerine is cooled down to scrubber temperature and heat is transferred to the glycerine that is going to be regenerated.
  • the heat exchangers reduce the amount of energy used for regeneration of glycerine by evaporation of captured water.
  • heat exchanger 23 helps to heat up glycerine and cool down glycerine that has gained heat during the drying process.
  • a gas fired coil furnace 24 is used to raise the temperature of glycerine further from the temperature achieved by the heat exchanger 23 (typically 140 - 160 °C), to 180 °C before glycerine is flashed over a pressure controlled valve into flash tank 25.
  • a separate loop of glycerine is taken out before pressure valve (not shown) and used in transport gas heaters 9, 10, 1 1 as heating media, Glycerine is returned by circulation pump 22 (FIG. 6A) to furnace 24.
  • Glycerine is flashed over pressure control valve 27 in the flash tank 25, and water is evaporated and exits via the water-steam evacuation stack.
  • flashing is meant, as is understood in the art: pumping the liquid into a tank where the water content is super-heated; by releasing the pressure, the water is separated by evaporation.
  • Regenerated glycerine is pumped back to gas tank/scrubber 3 by a pump (not visible in FIG. 3A) via heat exchanger 23, where it is cooled down by the counter flowing glycerine from the gas tank, to the operational temperature in scrubber.
  • An air bleed valve 21 is used to ventilate out air during filling of gas tank 26 with inert gas, and also to bleed a small amount of gas if the gas dome level becomes too high in the scrubber.
  • glycerine drier refers to the combined unit of glycerine scrubber with a glycerine loop that contains a pump, heat exchanger, flash tank, and return pump.
  • FIG. 5 shows the return loop / closed loop transport system for the transport gas.
  • constant pressure to the pneumatic transport system is created by a pressure control system 98.
  • Fan 97 is operating at 1 .2 bar absolute feed pressure and is transporting gas back to low pressure tank 3 over filter system 5 without A pressure control system.
  • Fan 97 creates gas flow for pneumatic transport of raw material, and balances gas pressure at the pneumatic transport system cyclones 40, 39, 38 for the individual fractions, and raw material transport system 52 so that rotating valves can be avoided.
  • the raw-material pneumatic transport system is also powered by the fan 97 but this system is not disturbed by pulses created by rotating valves, so for cyclone 31 on the feed hopper a balanced gas flow is not needed.
  • Compressor filter system (6) is not shown in FIG. 5, for clarity.
  • the air-based system can be run as an open-loop.
  • Tank 3 and the glycerine drier are not necessary in the air-based system. This is especially true in clean / dry ambient conditions.
  • an oil free air compressor 4, FIG. 3B, with condense dryer is used to feed air tank with necessary air, and also to feed instrument air to the apparatus for valve control and fluidization of the raw materials in silos 1 and 2.
  • a condense drier comprises a cooling unit to cool compressed air ⁇ e.g. , to - 5 °C). Water condenses out under those conditions, and is removed; the now-dry air can be reheated back to its original temperature.
  • An air filter 21 for example of HEP A type, FIG. 3B, is used for all intake air to system.
  • the apparatus comprises a homogenization unit that relies on high impact forces to homogenize dry materials, such as the raw materials as described elsewhere herein. Dry materials may contain small amounts of moisture locked up inside them but are still considered to be dry, in the sense that the materials are solid in form ⁇ e.g. , powdery, particulated, or granulated).
  • the homogenization unit is designed to operate on solid materials, without addition of water or other liquids that would create a slurry.
  • the high impact homogenization unit is specially constructed to work on organic materials, such as byproducts from grain milling industry.
  • FIG. 8D shows a perspective view of the exterior of homogenization unit 13 of the system of FIGs. 3A and 3B.
  • the homogenization unit has two rotating discs, within a housing 203, which are powered with two separate electrical motors housed respectively in enclosures 201 , 202, as shown in FIG. 8D.
  • Raw material is fed into the homogenizer, e.g. , by pneumatic transport (air or gas- driven, cf. FIG. 5), via a cyclone 52 through a hollowed shaft that leads to the upper of the two rotating discs.
  • the material is further diverted to the homogenization zone, or colliding zone, in between the two rotating discs.
  • Both the electrical motors are frequency controlled, which makes it possible to vary the rotation speeds of the discs typically up to 20,000 rpm for an individual disk, and hence the forces that are applied to the raw material as they are processed by the impact of the rotation.
  • the direction of rotation of the two discs can be varied so that they both rotate in the same direction or they rotate in directions counter to one another, to thereby achieve an increased relative speed. For example, motion in the same direction at different speeds gives rise to low forces applied to the raw material; rotation in different directions can give rise to very high forces applied to the raw material.
  • homogenization of the raw material is achieved when the material is in the space between the two rotating discs. Homogenization is achieved as a result of the geometry of the two discs, and the impact forces that are imparted to the particles of raw materials within the confines of that geometry.
  • FIG. 9 shows elements of an exemplary colliding zone, separated from the remainder of the apparatus for clarity,
  • the bottom disc has a radially disposed channel system, comprising radial channels 21 1 , that diverts raw material from the central shaft 215 towards a peripheral colliding zone, disposed in a concentric ring 217 centered on the disc center.
  • Material is accelerated and "pumped" by the centrifugal force in channel system 21 1 towards the colliding zone 21 7 situated between elements 90 and 93, both of which are attached to the upper surface of the lower disc.
  • Colliding zone 21 7 is defined in part by the boundaries between the end face 223 of elements 90 and the abutting face 225 of element 93.
  • Pegs 87 pass through the channel 21 7 and collide with raw material in that location.
  • the radial channels 21 1 are defined by fixed elements 90, attached to the upper surface of the bottom disc. An expanded view of such a fixed element is shown in FIG. 10. Cavities 219 in element 90 are for the purpose of saving weight; a lighter overall construction for either of the discs permits faster rotation speeds as well as energy savings.
  • the outer side edges 221 of elements 90 define the channels through which raw material passes.
  • Items 93 are rhomboid in shape and are disposed in an angled orientation with respect to the channels 21 1. In this way, the gaps 213 between adjacent elements 93 provide a way of feeding the raw material outwards. Therefore the channel system at the perimeter of the bottom disc is slightly angled instead of being a straight continuation of the channel system 217 that leads from the centre. The angle between the two portions of the channel makes it possible, by choosing a rotation direction, to keep material in the colliding zone 217 for a longer time (angle of entering the peripheral channels 213 is towards the rotation direction) or for a shorter time (angle of entering the peripheral channels 213 is away from the rotation direction). The time spent by the raw material in the colliding zone is thereby largely controlled by choosing the direction of bottom disc rotation. The amount of forces in the colliding zone is controlled by the direction of rotation of top disc. Very little mechanical adjustment is needed to meet the specific demands for different products.
  • pegs 87 located on the underside of the upper disc, pass through circumferential channel 217 as the discs rotate. Pegs 87 pass close to the ends of channels 21 1 and the abutting faces 225 of 93, but not so close that material is crushed between the pegs 87 and the end faces 223 of elements 90 and faces 225 of 93.
  • the clearance must be bigger than processed material biggest particles in order to avoid milling of products. For, e.g., bran, the clearance is approximately 4 mm. Other raw materials may require other clearances, either larger or smaller.
  • the clearance is adjustable because pegs 87 of different sizes may be swapped in and out of the homogenizer.
  • the clearance is important because the processed material should not be ground to powder (i.e. , the aim at this stage is not to mill the material and convert all of the material to a C- like fraction), but instead the different substances such as brittle starch should break up in fine spherical particulars with high density, proteins in needle, or slightly flaky form typically with lower density than starch, and a fiber fraction in large flaky particulars.
  • a suitable separation system is an air speed/centrifugal force based separation system, an exemplary form of which can be seen in U.S Patent No. 4,680,107, to Manola, which is incorporated herein by reference in its entirety.
  • Most key parts of the homogenizer can be constructed from ceramics or hard metals. This includes the elements shown in FIGs. 10 and 1 1 .
  • FIGs. 8A, 8B, 8C and 8D An exemplary embodiment of a complete homogenizer unit 13 is shown in FIGs. 8A, 8B, 8C and 8D.
  • Product inlet flange 72 is a connection point to the main raw material feed from the remainder of the apparatus.
  • Hollow shaft 85 is used to allow product and air or inert gas stream to enter a processing area in between top disc 86 and bottom disc 92, which enhances a smooth product flow and gradual acceleration of material and gas in channel system.
  • the top of the central shaft is equipped with a high precision high speed two row roller bearing 79 (also referred to as the top disk first roller bearing), which allows axial movements that are created by temperature differences during operation.
  • roller bearing 79 is replaced by a unit having magnetic bearings, which can operate without lubrication.
  • An enclosure 80 for the top bearing (also called the roller bearing house) includes an oil mist spray system and sealings with oil drainage by vacuum pump that eliminates risk of oil pollution in the product.
  • Drive motor 74 for the top disc assembly is equipped with frequency control and the possibility to operate in both clockwise and counter-clockwise direction when viewed in a given direction along the central axis of the homogenizer. Motor function can be set by computer control, and settings for different products can be stored in a recipe library together with other machine settings.
  • the normal mode of operation for the top disc drive is clockwise, which is opposite to the bottom disc 92. Such a mode of operation creates high impact forces on processed raw material fed into a collision zone between the first and second discs.
  • Drive motor 75 for the bottom disc assembly is also equipped with frequency control and the possibility to operate in both clockwise and counter clockwise direction when viewed in a given direction along the central axis.
  • Motor function for drive motor 75 can also be set by computer control, and settings for different products can be stored in a recipe library together with other machine settings.
  • the normal mode of operation for the bottom disc drive is counterclockwise, which is opposite to top disc 86. Such a mode of action creates high impact forces on processed material and enhances discharge of material depending on the form of peripheral elements 93 on the bottom disc.
  • the top disc and bottom disc are driven by, respectively, belt transmissions 76, 77, which make it possible to reach higher rotation speeds at the discs than is possible with, e.g., direct drive, and allows direct feed of raw-material through the hollow shaft in the centre of disc system.
  • the high speed rotating discs are enclosed in a high strength enclosure 78.
  • the enclosure is typically circular, and can be made of a material such as manganese steel that is thick enough and strong enough to protect against eventual rupture of discs or pegs even at full rotating speed (about 600 m/sec peripheral speed).
  • a conical shaft lock 81 is used. This item connects the belt wheel and the shaft. Normally the components are tight fitting; due to high rotation speeds deployed in the homogenizer, it is important for the belt wheel and shaft to be very tight fitting: the conical lock provides this tightness, and also reduce vibrations during operation. Conical shaft locks are also used in gas turbine technology.
  • An enclosure 82 for the bottom bearing also called the rotation disc bottom enclosure and bearing house
  • An enclosure 82 for the bottom bearing also called the rotation disc bottom enclosure and bearing house
  • An enclosure 82 for the bottom bearing includes an oil mist spray system and sealings with oil drainage by vacuum pump that eliminates risk of oil pollution in product.
  • FIG. 8A shows only an exploded view of the top disc assembly.
  • the bottom disc assembly is analogous in structure, though inverted with respect to the order of components shown for the top assembly, and is not shown in exploded form for the sake of clarity.
  • a fixation nut 83 for bottom bearing, with locking system, allows adjustment of space between discs.
  • a double row high precision high speed angular contact ball bearing 84 can sustain both radial and axial loads. Oil mist spray can be used for lubrication and cooling.
  • roller bearing 84 is replaced by a unit having magnetic bearings, which can operate without lubrication.
  • Top rotating disc 86 carries pegs 87, and rotates at up to 8,500 rpm.
  • Pegs 87 can be made of ceramic materials.
  • Pegs 87 on the top disc collide with the raw material at very high speed (up to 600 m/sec) at the end of channel walls. If a full speed counter-rotating regime is used, the resulting collision speed is up to 1200 m/sec, which creates high acceleration and de-acceleration forces that are repeated as the material is forced to change its direction of rotation through the collisions. Specifically, the material is forced out along the channels in a radial direction but also having a rotational velocity component due to the rotation of the bottom disc. The material then changes its direction of rotation suddenly when it makes contact with rotating pegs 87. The material changes its direction of rotation suddenly again when it comes into contact with peripheral bottom disc pegs 93.
  • Powerful vortices regions of alternating high and low pressure are created around the pegs. These vortices have the effect of imparting mechanical forces to the materials that enhance separation of the constituent components (e.g., a break-up of the binding between proteins and fibers, and between starch and proteins) of the processed raw material.
  • bottom rotating disc 92 carries the elements 90, which define radial channels 21 1 , and peripheral pegs 93.
  • pegs 87 and correspondingly 1 8 elements 90 there are 18 pegs 87 and correspondingly 1 8 elements 90.
  • the apparatus is not limited to the particular number of pegs shown. The number of pegs utilized depends in part on the size of the discs, as well as the size of the pegs themselves. In some embodiments the numbers of pegs can range from 10 to 32, for example, 12, 16, 20, 24, 28 and 30.
  • Exemplary dimensions for the pegs 87 are square in cross-section, and having a length of side in the range of 1 0 - 60 mm, and a height of 5 - 50 mm, raised above the surface of the disc. Particularly useful dimensions are 15 - 30 mm in length of side, and 10 - 20 mm in height.
  • discs having diameters of- 800 mm are effective for wheat bran and other raw materials referenced herein. It is contemplated that discs having dimensions within the range 500 mm - 1 ,000 mm, and particularly, 700 - 900 mm, will be suitable for most purposes.
  • Elements 90 can also be made of ceramic materials or hard metal, to increase resistance against abrasive effects of the processed material.
  • Channels 21 1 on the bottom rotating disc are covered and secured with a cover plate 89, which creates a locked channel to accelerate the raw material and process gas towards the zone 217 of high force de-acceleration and acceleration.
  • locked is meant that the channel constrains the raw material particles to move radially along it; there is no opportunity for the particles to move vertically out of the channel, either upwards or downwards.
  • Further bolts 91 are used to fix both cover plate 89 and elements 90 in the bottom disc, which makes it easy to exchange parts during maintenance.
  • Ceramic pegs 93 on the periphery of the bottom rotating disk are designed to create a second de-acceleration/acceleration of processed material to increase the efficiency of material separation.
  • the rhombic form of the pegs 93 makes it possible to, by adjusting rotation direction, control the time that processed material is held in the processing area.
  • Cover ring 94 fixes peripheral pegs 93 to the bottom disc 92, and creates a locked channel for process flow similar to that created by cover plate 89. The cover ring also reduces friction between the counter-rotating discs.
  • An exemplary peg 87 is designated 96 in FIG. 8C to show the general location of pegs 87 in relation to the bottom disc when the machine is assembled.
  • the homogenizer also admits the possibility of optionally feeding in a second raw material (a secondary product feed). Both the shaft holding the bottom disc and top disc are open to permit feeding products in from top and bottom simultaneously.
  • a second raw material a secondary product feed
  • Both the shaft holding the bottom disc and top disc are open to permit feeding products in from top and bottom simultaneously.
  • a high protein flour with additional starch to produce a hard flour one can feed wheat middlings from bottom, and bran from the top.
  • the shaft from bottom disc 92 has also a connection and a computer controlled needle valve, which makes it possible to add a controlled gas- or air-stream with or without secondary product feed.
  • Homogenized product is discharged via product outlet flange 73.
  • the motion of the raw material is formed by a combination of the centripetal forces created by the high speed rotation of the discs, and the gas- or air-flow through the unit. If secondary product is fed through the bottom product intake, a totally uniform product mixture is discharged together at this point.
  • Exemplary rotation speeds and processing speed are as follows.
  • material is constantly fed through the homogenizer.
  • the embodiment shown in FIGs. 8A - 8D processes up to 6 ton of raw material per hour.
  • each disc independently, may be varied up to 20,000 rpm. Typical rotation speeds suitable for most raw materials contemplated herein are: 7,000 rpm; 7,500 rpm; 8,500 rpm; and 10,000 rpm. These rotational speeds give rise to an effective radial velocity (peripheral speed) in the colliding zone of 400 - 800 m/s. A typical radial velocity is 600 m/s. Accordingly, a relative velocity of up to 1600 m/s, e.g. , typically 1200 m/s, can be obtained by counter-rotating the two discs. [0258] These rotational speeds give rise to speeds of up to 500 m/s of the raw material in the colliding zone.
  • the total system is controlled by a computer system which has the possibility to store "recipes" for different products.
  • the information regarding different products consists on rotating directions on the discs and rotation speeds of the two discs in addition is air- or gas-flow and material feed rate stored so quick changes between products can be made with retrieving optimum settings for the actual product.
  • the computer system comprises: a machine-readable memory, for storing instructions, as well as one or more databases of material properties and associated process parameters; a processor for executing logical instructions, and communicating instructions to various components of the apparatus; various input devices for accepting data, e.g., signals, from sensors in the apparatus, as well as user input; various buses for communication of binary information such as data and instructions between memory, processors, the apparatus, and peripherals; and one or more output devices, e.g., to present information about the process and performance of the apparatus to a user, as well as to report data on product parameters such as composition, and density.
  • a machine-readable memory for storing instructions, as well as one or more databases of material properties and associated process parameters
  • a processor for executing logical instructions, and communicating instructions to various components of the apparatus
  • various input devices for accepting data, e.g., signals, from sensors in the apparatus, as well as user input
  • various buses for communication of binary information such as data and instructions between memory, processors, the apparatus, and peripherals
  • Computer control system 44 can accept inputs from: sensors 20, 46 that monitor the separation stages of the process; as well as sensors that measure properties of the raw materials; and user input 702.
  • Sensors deployed around the apparatus that can provide specific feedback to the computer process control include near infra-red (NIR) sensors, as well as sensors that measure temperature at a particular point, material level (e.g. , in a silo), and particle or transport gas velocity.
  • NIR near infra-red
  • raw material data including both library (e.g., literature) data on a material and measured data on the sample provided to the apparatus
  • the database can be augmented on each occasion that the process is run, to thereby provide a growing compilation of preferred process parameters for particular materials.
  • the combination of stored data, measured data, and user data is used by the computer control system to arrive at decision process parameters that can be used to control various apparatus components such as the density separator and the homogenizor, as well as the bagging system, and the transport gas flow from the gas tank.
  • aspects of process control that can be managed in this way include, but are not limited, to, temperature, pressure, level of materials in a particular place, and transport gas velocity at a given point.
  • the apparatus and process herein can be applied to waste products from the brewing industry.
  • the confectionery industry will also benefit from a perfect blend of the base products.
  • desired ingredients are fiber, in preference to starch; so a finely defined A-fraction is desirable in this industry.
  • the product fractions herein will also lead to the development of a personalized type of product with leavening properties that are highly controlled. Use of such products offers a substantial labor savings and consistent control in the end products. Uniform granulometric control in the base mixture, therefore has a constant control in each phase of the production process.
  • the pasta industry can benefit from the technology because it provides the ability to utilize lesser quality raw material but still arrive at a qualitative improvement in the finished products.
  • the technology also provides an ability to tailor the proportions of the components, for example, the amount of gluten, and leads to a greater level of constancy in the products used.
  • the baking industry will benefit from the technology because it provides the ability to personalize construction of the necessary raw material for every type of product from high, medium, and low fermentation.
  • the technology also leads to less waste of raw material in obtaining finished products of at least the same quality and physical specification as is currently possible with other techniques.
  • the industry is highly mechanized. Consequently, the narrow range of dimensions of granule in the products, and control over the same, facilitates their use in all the phases of the production process. For example, a fine flour is desirable for dough handling at the end of process.
  • the fodder industry will also benefit from the technology because it provides for an improvement of the nutritional values in the feed products, and thereby also an improvement in the digestive process.
  • the industry is characterized by an immense use of biomasses and sour- alimentary refuse.
  • the technology permits a greater use of fibrous products for monogastric creatures (e.g., horses, or pigs, but not cows). Such animals can't digest very coarse fibers because the food does not stay in the stomach for long enough. Therefore, production of protein and fiber fractions in a narrow range of sizes is good. For example, a blend of a fine A fraction and a coarse B fraction works well.
  • the technology leads thereby to considerable cost savings in this industry.
  • the raw material comprises a grain from which bran, or a bran-like quantity, can be separated and processed.
  • the starch and protein content are the principal fractions that are separated by the process and apparatus herein.
  • Palm husk also known as empty fruit bunches (mainly derived from oil palms, see http://en.wikipedia.org/wiki/Oilj3alm)
  • the technology is able to achieve a concentration for any given fraction of between 1 - 90%, with additional 5 - 15% for moisture. This wide variation of ranges arises because the parameters of the process can be adjusted to permit choosing the quantity of a given component in a given fraction. Furthermore, if a raw material is polluted, the process can be carried out to divert the majority of the pollutant(s) to a particular fraction.
  • components that are concentrated in the various fractions can be extracted by further processing, if desired. That is, by removing fractions that do not contain the desired products the concentration of desired products is effectively increased, and the amount of product that is necessary to process by further chemistry processes is decreased.
  • bagasse contain about 80% cellulose and Iignin (fiber A fraction) and about 2% sugar + 2% starch (starch fraction C). The rest is protein (B-fraction) which contains a component that you want to extract such as pectin. By removing 84% of raw material the concentration of that component is effectively increased from, e.g., 0.5/100 kg to 0.5/16 kg, or from 0.5% to 3.12% on dry basis.
  • Components extracted lignin; cellulose; protein; sugar and starch.
  • Fraction A is lignin and cellulose.
  • Fraction B comprises proteins.
  • Fraction C is starch and sugar.
  • Fraction C additionally comprises xylitol and other penta sugars, which can be extracted by further processing of this fraction.
  • Components extracted crude fiber; protein; total sugar and starch.
  • Fraction A is crude fiber.
  • Fraction B is proteins.
  • Fraction C is starch and total sugar.
  • Components extracted starch; total sugars; protein; total fat; and total fiber.
  • Fraction A is total fibers.
  • Fraction B is protein and fat.
  • Fraction C is starch and total sugars.
  • Components extracted starch; total sugars; protein; total fat; and total fiber.
  • Fraction A is total fibers.
  • Fraction B is protein and fat components.
  • Fraction C is starch and total sugars.
  • Fraction A is total fibers.
  • Fraction B is protein and fat components.
  • Fraction C is starch and total sugars.
  • Components extracted starch; total sugars; protein; total fat; and total fiber.
  • Fraction A is total fibers.
  • Fraction B is protein and fat components.
  • Fraction C is starch and total sugars.
  • Components extracted starch; protein; digestible fiber; and total sugars.
  • Fraction A is digestible fiber.
  • Fraction B is protein.
  • Fraction C is starch and total sugars.
  • citrus seeds that can be used come from lemons, grapefruits, and other fruits that are typically used for juices. These seeds are actually similar in structure to a wheat kernel and have a high content of starch and proteins that can be used as feed or food. Grape is another crop that has similarly high potential.
  • Components extracted protein; crude fiber; starch; and fat.
  • Fraction A is crude fiber.
  • Fraction B is protein and fat components.
  • Fraction C is starch.
  • Fraction A is crude fiber.
  • Fraction B is protein and fat components.
  • Fraction A is crude fiber. Fraction B is protein and fat components.
  • Example 12 Palm Kernel Shells
  • Fraction A is crude fiber.
  • Fraction B is protein and fat components.
  • Fraction A is total fiber.
  • Fraction B is protein and fat components.
  • Fraction C is starch.
  • Fraction A is cellulose and lignin.
  • Fraction B is protein and sugar components.
  • Fraction A is total fiber. Fraction B is protein components. Fraction C is starch.
  • Fraction A is total fiber. Fraction B is protein components. Fraction C is starch.
  • Fraction A is total fiber. Fraction B is protein components. Fraction C is starch.
  • Example 18 Soybean
  • Fraction A is total fiber and total fat.
  • Fraction B is protein and fat components.
  • Fraction C is starch.
  • Fraction A is dietary fiber, crude fiber.
  • Fraction B is protein and fat components.
  • Fraction C is protein and starch.
  • Fraction A is dietary fiber and crude fiber.
  • Fraction B is protein and fat components.
  • Fraction C is starch.
  • Fraction A is crude fiber.
  • Fraction B is protein and fat components.
  • Fraction C is starch.
  • Fraction A is fiber.
  • Fraction B is protein and fat components.
  • Components extracted silicon; crude fiber; dietary fiber; and protein.
  • Fraction A is dietary fiber, crude fiber and silicon.
  • Fraction A is total fiber. Fraction B is protein components. Fraction C is sugars.
  • Fraction A is total fibers.
  • Fraction B is protein and fat components.
  • Fraction C is starch and total sugars.
  • Fraction A is total fibers.
  • Fraction B is protein.
  • Fraction C is starch and total sugars.
  • Fraction A is total fibers.
  • Fraction B is protein and fat components.
  • Fraction C is starch and total sugars.
  • Components extracted starch; total sugars; protein; total fat; and total fiber.
  • Fraction A is total fibers.
  • Fraction B is protein and fat components.
  • Fraction C is starch and total sugars.
  • Fraction A is total fiber.
  • Fraction B is all protein and fat components.
  • Fraction C is starch.
  • Example 30 Barley Malt Sprouts
  • Fraction A is total fiber. Fraction B is protein components.
  • Components extracted starch; total sugars; protein; and total fiber.
  • Fraction A is total fibers.
  • Fraction B is protein components.
  • Fraction C is starch and total sugars.
  • Components extracted starch; total sugars; protein; and total fiber.
  • Fraction A is total fibers.
  • Fraction B is protein components.
  • Fraction C is starch and total sugars.
  • Components extracted starch; total sugars; protein; and total fiber.
  • Fraction A is total fibers.
  • Fraction B is protein components.
  • Fraction C is starch and total sugars.
  • Fraction A is total fibers. Fraction B is protein components. Fraction C is starch.
  • Components extracted starch; protein; total fiber.
  • Fraction A is total fibers. Fraction B is protein components. Fraction C is starch.
  • Example 36 Millet
  • Fraction A is total fibers. Fraction B is protein components. Fraction C is starch.
  • Fraction A is total fibers. Fraction B is protein components. Fraction C is starch.
  • Components extracted starch; total sugars; protein; and total fiber.
  • Fraction A is total fibers.
  • Fraction B is protein components.
  • Fraction C is starch and total sugars.
  • Fraction A is total fibers. Fraction B is protein components.
  • Fraction A is total fibers. Fraction B is protein components.
  • Components extracted starch; protein; sugar; and total fiber.
  • Fraction A is total fibers. Fraction B is protein components. Fraction C is starch and sugars.
  • Example 42 Apple Peels
  • Fraction A is total fibers. Fraction B is pectin.
  • Example 43 Wheat Grain
  • Fraction A is total fibers. Fraction B is protein components. Fraction C is starch.
  • Fraction A is total fibers. Fraction B is protein components. Fraction C is starch.
  • Fraction A is total fiber. Fraction B is protein components.
  • Components extracted starch; fiber; protein; and total fat.
  • Fraction A is total fibers.
  • Fraction B is protein and fat components.
  • Fraction C is starch.
  • Cellulose used as human food additive and fodder in the animal feed industry. Once treated, it can be used to make paper, film, explosives, plastics and many other materials with industrial uses.
  • Crude Fat used for oil extraction.
  • [0376J Crude Fiber used as a fuel for burning. Also used as fodder in the animal feed industry. Once treated, it can be used to make paper, film, explosives, plastics and many other industrial uses.
  • Dietary Fiber used as human food and fodder in the animal feed industry. Once treated, it can be used to make paper, film, explosives, plastics and many other industrial uses.
  • Digestible Fiber used as fodder in the animal feed industry.
  • Lignin used as a fuel for burning.
  • Pectin used as a jelling agent in food. Also used in fillings and sweets as a stabilizer in fruit juices and milk drinks.
  • Protein used in many human foods and different animal feeds.
  • Silicon can be used in Solar Panels, Microchips or Optical Fibers.
  • Starch is an important carbohydrate in the human diet. Can also be used as a thickening, stiffening or gluing agent when dissolved in warm water.
  • Total sugar(s) crystalline carbohydrates can be used in many foods, drinks, medicines, etc. They can also be converted to alcohol through hydrolysis and fermentation.
  • Total Fiber used as fuel for Burning. Used as fodder in the animal feed industry. Once treated, it can be used to make paper, film, explosives, plastics and many other materials having industrial uses. Total fiber differs from crude fiber in that crude fiber does not contain the water-soluble parts such as encapsulated proteins and sugars, which are present in total fiber.
  • Xylitol used as a natural sugar substitute.
  • An exemplary high protein flour product (a C-fraction product) produced by an apparatus and process as described herein from, e.g. , wheat bran or wheat feed, has the following general composition.
  • General range (by weight):
  • a target composition range is as follows:
  • the weight percentages are obtained as follows. The sample is washed before analysis. This means that the water-soluble items are washed away. These items include sugars (-4-5%), and a water-soluble carbon-fiber fraction. This means that there are up to 10% residuals, which are not a useful part of the product. Since the exact content of residuals is not explicitly determined, the range of percentages of those components that are measured will often not sum to 100%.
  • This product serves as a specially made flour that can be used by food companies as an excellent blending agent for low protein flours in a wider range of applications, including pasta, bread, and high quality baked foods.
  • the hardness of wheat flours is largely determined by the gluten/protein content.
  • flour-based products have been made utilizing a blend of flours, e.g., high protein flours (such as Manitoba flour) mixed with softer flours.
  • the product herein can used in place of expensive high protein flours, but can yield blended flours of equivalent properties.
  • An exemplary stabilized low starch wheat bran product (an A-fraction product) produced by an apparatus and process as described herein has the following composition.
  • a target composition range is as follows:
  • This stabilized low starch wheat bran product has optimum use as a fiber boosting additive in breakfast cereals, bakery and pasta.
  • the product does not alter taste, appearance, or mouth feel of other products in which it is incorporated.
  • the aroma is appealing and the product can be provided in a variety of mesh size from course to fine.
  • An exemplary high protein wheat bran product (a B-fraction product) produced by an apparatus and process as described herein has the following composition.
  • a target composition range is as follows:
  • this product Similar to the stabilized low starch wheat bran, this product also has optimum use as a fiber boosting additive in breakfast cereals, bakery and pasta. While it is fit for human consumption, it also has use as a high quality animal feed.
  • Corn stands among the most important crops in the world. In 2007, 81.2 million acres of corn were harvested, yielding about 240 million tons of corn. This only accounts for about 40% of the total world production of kernel crops. The corn industry continues to strive for new technology. Not only can the technology described herein provide efficient processing of the kernels, but it can also turn the waste stream into additional food products.
  • the system can be used to process grain (kernels), obtaining a final product called “gries", which is gluten-free and has high protein content.
  • This final product can be used in alimentation as wheat flour. It can also be mixed with wheat to be used in yeast-based products.
  • the system can also process byproducts (the entire cob without the kernels, and the top 30 cm of the stalk), obtaining the following: a) Highly digestible fiber, for use in fodder industries (especially for cattle): 20% b) Carbohydrate, for ethanol or for fodder (especially for pigs): 50%
  • Pastazzo is used to describe the residuals after citrus fruits have been pressed.
  • Pastazzo is made up of the skin, seeds, pulp, of oranges, which are not suitable for processing into juice.
  • the apparatus and methods herein can take the pastazzo, which is normally not suitable for use in the alimentation or fodder industries due to its strong acidity and bitter taste, and make it into a usable product. Furthermore, it is possible to extract other value added substances from waste that would normally present a disposal problem and added cost for the producers.
  • the process is carried out in two stages.
  • the first stage is to extract the moisture by means of a flash dryer.
  • the second stage is the use of the system as described herein, which homogenizes the pastazzo, and utilizes the separator.
  • the process is as follows: (a) Drying by desiccation and centrifugation (flash system);
  • base for fiber such as a cellulose/protein mixture which contains useful ingredients that can be extracted with further processing, and which can be used in the cosmetic and pharmaceutical industries;
  • Rice byproducts (specifically husks) pose a big disposal problem. Laws have been enacted in both the United States and Europe which will limit the ability to dispose of the husks by burning. Many rice millers are therefore faced with having to pay for the disposal of the husks. Utilizing the technology described herein solves a big ecological problem. Further, there is a low (or zero) cost base for subsequent processes.
  • vinaccia In Italy the term "vinaccia” is used to describe the residuals after grapes have been pressed for wine making.
  • the vinaccia is made up of the skin, pits and stems.
  • the technology described herein can take the vinaccia, which is normally not suitable for use in the fodder industry due to the high levels of tannic acid and lignin, and make it into a usable product.
  • the process is carried out in two stages.
  • the first stage is to extract the moisture by means of a flash dryer.
  • the second stage is the use of the system described herein, which homogenizes the vinaccia and incorporates the separator.
  • the process is as follows: a) Drying by desiccation and centrifugation (flash system); b) Homogenization (using the homogenizer, as described herein, which does not change basic properties of the materials);
  • the average percentage of the content of the processed vinaccia is as follows (results vary depending on the quality of the biomass used and customer needs): a. 10%-lignin for high caloric fuel (for example, used by Siemens);
  • cellulose fiber which is highly digestible and is used in both human food and animal fodder
  • the resulting substances have the following compositions (results vary depending on the quality of the biomass used and customer needs) and uses:
  • Lignin 10% can be used as a fuel (with a high level of combustibility due to its purity) which can be sold or used in the mill as a source of co-generation;
  • Cellulose 60% a highly digestible fiber for the fodder industry;

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  • Health & Medical Sciences (AREA)
  • Nutrition Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Food Science & Technology (AREA)
  • Polymers & Plastics (AREA)
  • Cereal-Derived Products (AREA)
  • Fodder In General (AREA)
  • Coloring Foods And Improving Nutritive Qualities (AREA)

Abstract

L'invention porte sur un procédé et sur un appareil pour la création de produits alimentaires comestibles à partir de déchets issus de la transformation d'aliments, tels que le son de blé ou le remoulage bis. Les produits alimentaires sont stabilisés, nutritifs, commercialisables et rentables à produire et peuvent être créés en trois fractions distinctes, riches en fibres, riches en protéines et de type farine. L'appareil comprend un dispositif d'homogénéisation, un séparateur de densité et un système de transport de gaz pour la propulsion des matières premières par l'intermédiaire de différentes étapes de traitement avant d'être séparées en différentes fractions de produit.
PCT/GB2011/000324 2010-03-05 2011-03-07 Produits comestibles de grandes valeurs fabriqués à partir de son, et procédé et appareil pour leur production WO2011107760A2 (fr)

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WO2017167966A1 (fr) 2016-04-01 2017-10-05 Nestec S.A. Composition de confiserie comprenant une matière de type son
CN108613543A (zh) * 2018-05-14 2018-10-02 湖南理工学院 一种稻场稻谷快速回收除尘烘干装置
WO2018188704A1 (fr) * 2017-04-13 2018-10-18 Thoegersen Kurt Stensgaard Procédé et appareil de gestion de teneur résiduelle dans un produit alimentaire
US10645950B2 (en) 2017-05-01 2020-05-12 Usarium Inc. Methods of manufacturing products from material comprising oilcake, compositions produced from materials comprising processed oilcake, and systems for processing oilcake
US10759727B2 (en) 2016-02-19 2020-09-01 Intercontinental Great Brands Llc Processes to create multiple value streams from biomass sources
US11412759B1 (en) 2021-07-14 2022-08-16 Usarium Inc. Method for manufacturing alternative meat from liquid spent brewers' yeast

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Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10759727B2 (en) 2016-02-19 2020-09-01 Intercontinental Great Brands Llc Processes to create multiple value streams from biomass sources
US11840500B2 (en) 2016-02-19 2023-12-12 Intercontinental Great Brands Llc Processes to create multiple value streams from biomass sources
WO2017167966A1 (fr) 2016-04-01 2017-10-05 Nestec S.A. Composition de confiserie comprenant une matière de type son
WO2017167965A2 (fr) 2016-04-01 2017-10-05 Nestec S.A. Ingrédient pour aliments
EP4248758A2 (fr) 2016-04-01 2023-09-27 Société des Produits Nestlé S.A. Ingrédient pour aliments
WO2018188704A1 (fr) * 2017-04-13 2018-10-18 Thoegersen Kurt Stensgaard Procédé et appareil de gestion de teneur résiduelle dans un produit alimentaire
US10645950B2 (en) 2017-05-01 2020-05-12 Usarium Inc. Methods of manufacturing products from material comprising oilcake, compositions produced from materials comprising processed oilcake, and systems for processing oilcake
CN108613543A (zh) * 2018-05-14 2018-10-02 湖南理工学院 一种稻场稻谷快速回收除尘烘干装置
CN108613543B (zh) * 2018-05-14 2023-09-29 湖南理工学院 一种稻场稻谷快速回收除尘烘干装置
US11412759B1 (en) 2021-07-14 2022-08-16 Usarium Inc. Method for manufacturing alternative meat from liquid spent brewers' yeast
US11464243B1 (en) 2021-07-14 2022-10-11 Usarium Inc. Spent brewers' yeast based alternative meat
US11839225B2 (en) 2021-07-14 2023-12-12 Usarium Inc. Method for manufacturing alternative meat from liquid spent brewers' yeast

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