Classifications

• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23J—PROTEIN COMPOSITIONS FOR FOODSTUFFS; WORKING-UP PROTEINS FOR FOODSTUFFS; PHOSPHATIDE COMPOSITIONS FOR FOODSTUFFS
  • A23J3/00—Working-up of proteins for foodstuffs
  • A23J3/14—Vegetable proteins
  • A23J3/16—Vegetable proteins from soybean
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23K—FODDER
  • A23K10/00—Animal feeding-stuffs
  • A23K10/30—Animal feeding-stuffs from material of plant origin, e.g. roots, seeds or hay; from material of fungal origin, e.g. mushrooms
  • A23K10/33—Animal feeding-stuffs from material of plant origin, e.g. roots, seeds or hay; from material of fungal origin, e.g. mushrooms from molasses
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07K—PEPTIDES
  • C07K1/00—General methods for the preparation of peptides, i.e. processes for the organic chemical preparation of peptides or proteins of any length
  • C07K1/14—Extraction; Separation; Purification
  • C07K1/36—Extraction; Separation; Purification by a combination of two or more processes of different types
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23J—PROTEIN COMPOSITIONS FOR FOODSTUFFS; WORKING-UP PROTEINS FOR FOODSTUFFS; PHOSPHATIDE COMPOSITIONS FOR FOODSTUFFS
  • A23J1/00—Obtaining protein compositions for foodstuffs; Bulk opening of eggs and separation of yolks from whites
  • A23J1/14—Obtaining protein compositions for foodstuffs; Bulk opening of eggs and separation of yolks from whites from leguminous or other vegetable seeds; from press-cake or oil-bearing seeds
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23J—PROTEIN COMPOSITIONS FOR FOODSTUFFS; WORKING-UP PROTEINS FOR FOODSTUFFS; PHOSPHATIDE COMPOSITIONS FOR FOODSTUFFS
  • A23J3/00—Working-up of proteins for foodstuffs
  • A23J3/14—Vegetable proteins
• • 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
  • A23L2/00—Non-alcoholic beverages; Dry compositions or concentrates therefor; Their preparation
  • A23L2/52—Adding ingredients
  • A23L2/66—Proteins
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23V—INDEXING SCHEME RELATING TO FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES AND LACTIC OR PROPIONIC ACID BACTERIA USED IN FOODSTUFFS OR FOOD PREPARATION
  • A23V2002/00—Food compositions, function of food ingredients or processes for food or foodstuffs
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
  • Y02P60/00—Technologies relating to agriculture, livestock or agroalimentary industries
  • Y02P60/80—Food processing, e.g. use of renewable energies or variable speed drives in handling, conveying or stacking
  • Y02P60/87—Re-use of by-products of food processing for fodder production

Definitions

• This invention relates to the production of soybean products, in particular, to the production of soy protein isolate (SPI), and may be used in the food industry, specifically in meat processing, bread baking and confectionary; in cosmetology and the pharmaceutical industry; for the production of high-protein sports and children ' s food, food additives, energy drinks and animal feeds.
• SPI soy protein isolate
• Soy's value is in the great content of balanced protein with valuable biological properties, which can be very well assimilated by the human body. Soy is rich in amino acids, vitamins, phospholipids and isoflavones. the latter being one of the most active components in soy proteins. They reduce the risk of cardiovascular diseases and bring down the level of cholesterol content in the blood serum.
• Soy protein is used in sausage products as a substitute for expensive myofibrillar protein, to produce low-grade meat emulsions, and to reduce fat content in a formulation without worsening the organoleptic properties of the finished product.
• soy- protein isolates There are many production processes and corresponding equipment for obtaining soy- protein isolate. Preferred methods are those that are based on further processing of soybean meal obtained after the extraction of oil from oilseeds. Most soy isolates tha are marketed are obtained by extraction, precipitation and neutralization at pre-set pH values, and subsequent spray drying of the obtained product.
• the authors propose a plant for obtaining protein isolate, where the starting material is preferably the "white flake", which is basically soy flakes obtained from edible grades of dehulled soy seeds and defatted with hexane, international abbreviation (WF). having characteristics as shown in Table 1 .
• WF international abbreviation
• the plant claimed herein makes it possible to work with source raw material i.e. white flake or white flake waste, possessing both high and low solubility in the PDI range of from 55 to 95, and flake thickness in the range of from 0.2 mm to 1.0 mm.
• source raw material i.e. white flake or white flake waste
• flake thickness in the range of from 0.2 mm to 1.0 mm.
• soy protein isolate production is the problem of low yield of the valuable isolate from the production process.
• standard soy protein isolate production processes entail, as a rule, large-scale water consumption and a very large amount of industrial liquid waste.
• the closest analogue to the invention being claimed is the plant for soy protein isolate production manufactured in accordance with the production process as per RF patent 2233097. 2000, comprising a raw material feeding unit; a raw material grinding unit; a raw material soaking tank; raw ? material, water, alkali and process liquids input nozzles and product output nozzles; devices for raw material extraction; decanters for separating the extract and fiber; an acidic protein precipitation tank; a decanter for protein separation; a protein washing tank; a decanter for washed protein separation; a device for protein drying; and a device for finished product packing; all connected with appropriate piping.
• enzymes are used to create conditions necessary for protein separation from the solid substance both before and during extraction, and rigorous extraction conditions are applied, which results in significant protein damage.
• soy isolates are not tit for food production; they may be used only for the production of cosmetics.
• One technical result of the invention is the reduction of water consumption by 80% and the saving of energy products needed to heat water up to the operational temperature of the production process, since the recycling of the liquid phase takes place at the temperature of 55°C, while newly fed water usually has the temperature of 20°C.
• the liquid phase is recycled to the stage of raw material soaking after washing for the purpose of water and energy saving.
• fresh water accounting just for 10 % of the total water consumption.
• low proportion as 10% of fresh water makes it possible to prevent the build-up of minerals, sugars and other microelement concentration in liquid phases that could result in deterioration of the chemical and physical properties of the process.
• Another technical result of the invention is an increase in high-molecular protein yield due to the high-qual ity raw material preparation, reduction of the time raw material is processed at extraction stages, recycling of virtually all liquids after the stages of protein precipitation and washing. Moreover, the process can use white flake waste as raw material, which cannot be used for protein extraction in other processes.
• the proposed plant for soy protein isolate production offers a "clean " production process, i.e. complete absence of industrial liquid waste, which will allow, first, to save significantly on whey water disposal and waste- water treatment facility construction, secondly, to significantly reduce water consumption in the production process, and thirdly, to produce high-quality soy protein isolate.
• the total water makeup requirement is about 5,000 liters per hour.
• the plant is intended for 330 operational days per year, 24 hours a day with the following hourly production capacity (may vary depending on raw material composition): - raw material for extraction - 2.5 tonnes,
• the plant for soy protein isolate production comprising a raw materia! feeding unit; a raw material grinding unit; a raw material soaking tank; raw material, water, alkali and process liquids input nozzles and product output nozzles; devices for raw material extraction; decanters for separating the extract and fiber; an acidic protein precipitation tank; a decanter for protein separation; a protein washing tank; a decanter for washed protein separation; a device for protein drying; and a device for finished product packing, all of the above connected with appropriate piping, is additionally equipped with
• a gravitational turbulence mixer positioned before the raw material soaking tank, said mixer executed in the form of a vertical pipe with a spiral inside, wherein raw material, water, alkali and process liquid input nozzles are positioned in the upper portion of the pipe,
• the condensate drainage piping is connected to the raw material grinding unit, the raw material soaking unit, the device for the second raw material extraction and the protein washing tank; while the piping for process liquid drainage from the fiber separation decanter and washed protein separation decanter is connected to the gravitational turbulence mixer.
• the plant is additionally equipped with units for protein stabilization, modification and pasteurization installed before the drying device.
• connection of liquid drainage piping from the fiber separation decanter and washed protein separation decanter to the gravitational turbulence mixer makes it possible to recycle the liquid phase generated during protein separation to the beginning of the production process to dissolve the incoming raw material and improve extraction properties thereof. It enables a significant reduction of water consumption (by 80%), and at the same time, with the help of proteins and sugars of the liquid phase mixed with an alkaline solution, activate the extraction properties of the source raw material to the maximum extent.
• the liquid phase Prior to the stage of acidic precipitation, the liquid phase is mixed with acid in the pipeline with the help of a swirl mixer in the form of a spiral funnel installed in the pipeline before the protein acidic precipitation tank.
• the equipment of the plant with an evaporation system and a condensate tank, with the condensate drainage piping connected to the raw material grinding unit, the raw material soaking unit, the device for the second raw material extraction and the protein washing tank, makes it possible to cut water losses in these operations and increase protein yield due to improved raw material extraction properties. Besides, it provides an opportunity to additionally produce a valuable feed product, soy molasses, which is used in mixed animal feed production.
• the equipment of the plant with units for protein stabilization, modification and pasteurization installed before the drying device allows to impart desired functional properties to the final product and obtain a dry product (isolate) in powder form with a moisture content of about 5%.
• Pasteurization device comprising sterilization steam diffuser 18 and homogenizer 19
• the plant operates as follows:
• the required quantity of raw material e.g. white flake with a PDI of 55 to 95, white flake or waste thereof being 0.1 mm to 1.5 mm thick
• raw material grinding unit 2 whereto water alkali solution, foam suppressor and condensate from condensate tank 26 are also fed via respective nozzles (water, alkali and process liquids input nozzles and product output nozzles are not shown in the drawing).
• a defoamer (foam suppressor) is added, because large amounts of foam can be generated.
• FOAM BLAST 300K defoamer may be used as a foam suppressor.
• Gravitational turbulence mixer 3 is a vertical pipe with a spiral installed inside (not shown in the drawing).
• the suspension proceeds to extract separation decanter 6 for the liquid phase containing extracted protein and water-soluble proteins and sugars to be separated from the solid phase (containing insoluble carbohydrates, mostly fiber, and unextracted proteins).
• the extract passes through swirl mixer 25 (whereto the HCL acid is fed) installed in the pipeline before protein acidic precipitation tank 12.
• Swirl mixer 25 is a spiral funnel (not shown in the drawing).
• the extract is fed to protein acidic precipitation tank 12 at a pH corresponding to the isoelectric point of soy proteins.
• hydrochloric acid HCL is added to the solution.
• the preparatory mixing of the liquid phase with an acid in the pipeline with the help of swirl mixer 25 makes it possible to uniformly reduce the pH level of the liquid phase as early as in the pipeline, before the extract find itself in protein acidic precipitation tank 12.
• the practical advantage of such addition of an acid consists in there occurring no pH fluctuations from the 4.5 level in the protein acidic precipitation tank 12. That pH level, monitored with the help of a special sensor (pH-meter), also known as the isoelectric point of soy proteins, or the protein least solubility level, at which level about 85% of soluble proteins are precipitated and can be separated from soluble sugars and so-called "whey" proteins.
• the solid phase from extract separation decanter 6 proceeds to second extraction tank 7. where it gets mixed with water and the process liquid namely the condensate from condensate tank 26 for subsequent, more complete, separation of residual proteins and sugars.
• second extraction about 5-10% of proteins that have not dissolved at the first extraction stage, get additionally dissolved in water.
• Parameters of the second extraction temperature 48°C to 65°C; pH 6.8 to 8.8; moisture content 89 to 92%; extraction time from 2 to 40 minutes depending on the material balance of the process; liquid phase precipitate: 2-3 %.
• the auxiliary "thermal shock damping" system is activated, namely the unit of suspension steam treatment 8.
• the suspension is treated with direct saturated steam over the entire cross-section of the flow to ensure careful mixing and uniform distribution of heat, which results in a sharp increase of temperature from 60°C to 82-102°C.
• pressure in the pipeline is maintained at 2.2-4.0 bar for the period of 0.5 to 2.5 sec. Then the temperature is sharply lowered to 48-65°C by directing the flow to vacuum tank 9 used for the suspension cooling.
• the suspension is then fed to fiber separation decanter 10, where the extract containing additionally 5 to 7 percent of water-soluble proteins and sugars, is separated from the solid phase (containing insoluble carbohydrates, most of them fiber, and residual water-insoluble proteins).
• the extracted liquid phase is fed to the gravitational turbulence mixer 3, while the solid phase (having a moisture content of about 80%) is fed to fiber collector 1 1.
• the liquid phase (whey) with a moisture content of 97% proceeds to vaporization system 24, where its moisture content is brought to 50%, and it proceeds further, in the form of soy molasses, to molasses storage tank 23 and the mixed feed production plant.
• the coagulum of precipitated proteins is fed to protein washing tank 14 to better remove sugars and minerals, and to washed protein separation decanter 15. Unconcentrated whey consisting of residual dissolved sugars and minerals proceeds from washed protein separation decanter 15 to gravitational turbulence mixer 3.
• the precipitated protein may be subjected to neutralization, modification, pasteurization and/or removal of soybean odor. For that purpose, it is fed to moisture content and pH stabilization tank 16 and final stabilization tank 17; then to the pasteurization device comprising sterilization steam diffuser 18 and homogenizer 19, and subsequently to vacuum tank for protein cooling 20, protein drying device 21 and finished product packing device 22.
• Spray drying is used.
• the dried product (isolate) in powder form with a moisture content of about 5% proceeds to packing.
• Table 2 shows characteristics and yield of the product 2. The production amount and characteristics of consumed products are presented in Table
• the proposed plant offers a "clean" production process, i.e. complete absence of industrial liquid waste, which will allow, first, to save significantly on whey waters disposal and waste-water treatment facility construction, secondly, to significantly reduce water consumption in the production process, and thirdly, to produce, as a by-product, a valuable feed product, namely soy molasses.

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• 2016
  • 2016-07-12 RU RU2016128004A patent/RU2633501C1/ru not_active IP Right Cessation
  • 2016-12-15 WO PCT/RU2016/000878 patent/WO2018013000A1/en active Application Filing

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