WO2018186774A1

WO2018186774A1 - Method for production of feed, production line, and feed produced by said method

Info

Publication number: WO2018186774A1
Application number: PCT/RU2018/050035
Authority: WO
Inventors: Вячеслав Валерьевич ЗЫКОВ; Петр Константинович КУЦЕНОГИЙ
Original assignee: Вячеслав Валерьевич ЗЫКОВ; ЦВЕТКОВА, Ирина Владимировна; ЛАЛЕТИНА, Светлана Валерьевна; Петр Константинович КУЦЕНОГИЙ
Priority date: 2017-04-03
Filing date: 2018-03-30
Publication date: 2018-10-11
Also published as: RU2667161C1; EA201992224A1

Abstract

The technical solution claimed relates to feed production. The technical result of the claimed invention is obtaining feed that retains the safe properties thereof for a prolonged time,including during storage, being balanced and best assimilated by animal bodies, preventing diseases of the gastrointestinal tract and having a light therapeutic effect with potentially infected feedstock, and making it possible to use biological wastes and crop production wastes for feed production. The technical result is achieved on account of the fact that cooling is additionally included in a method for feed production comprising separate comminution of plant feedstock and moisture-containing protein feedstock, mixing, extrusion and granulation, while the operations are performed in the following order: comminution, mixing, extrusion, cooling and granulation, wherein the feedstock is subjected to enzymatic hydrolysis during and after extrusion. The claimed method is industrially applicable.

Description

METHOD FOR PRODUCING FODDER, PRODUCTION LINE AND

FOOD RECEIVED IN THE APPROVED METHOD

Application area

The claimed technical solution relates to the field of feed production.

State of the art

There are various methods of obtaining feed for productive and unproductive animals by grinding biological waste and grain mixtures. Some of these technologies include not only grinding, but also heat treatment, extrusion and fermentation.

Known described in patent RU2581223 "METHOD AND DEVICE FOR PREPARATION OF EXTRUDED FOOD AND FODDER PRODUCTS". The invention relates to the food and feed industry, and in particular to equipment for the extrusion processing of food and feed products. In the process, raw materials and water are fed into the extrusion chamber. Moistened raw materials are sent by conveyor screw elements sequentially to the zone with kneading screw elements, then by transporting screw elements to the zone of reversible screw elements, to the steam removal zone with transporting screw elements and then to the pre-extrusion zone of the extrusion chamber. Then the raw material is extruded through the forming die matrix. In the area with kneading screw elements carry out preliminary welding of raw materials with regenerative steam. Steam is diverted from the steam extraction zone through a steam line with an expansion chamber, a control valve and a nozzle. Through the nozzle, steam is fed into the zone with kneading screw elements. In the area of the reversible screw elements, the temperature is maintained at 160-200 ° C, the pressure is 3-10 MPa and the moisture content of the raw material is 12-20%. The device includes an extrusion chamber with successively located zones: conveying screw elements, kneading screw elements, conveying screw elements, reversible screw elements, conveying screw elements, pre-mold zone and forming die dies. Immediately after the zone of reversible screw elements, the transporting screw elements are made with a step 1.5-2 times greater than the step of the remaining screw elements, with the formation of a steam extraction zone communicated with the expansion chamber of the steam line. The steam line is equipped with a control valve and is connected to using a nozzle with a zone of kneading augers of elements. The length of the steam extraction zone is 1.0-1.5 turns of the conveying screw element in this zone.

The method directly describes the extrusion and installation for its implementation. There are no stages of preliminary preparation of raw materials for processing. Biomass is not safe for a long period of time during the preparation of a product. In addition, in the described method there is no fermentation step, which does not allow us to talk about the high quality of the resulting product.

A known method for producing an extruded product described in patent RU2585470 "METHOD FOR PRODUCING AN EXTRUDED PRODUCT OF HIGH FOOD VALUE ENRICHED BY A SCORPONOR". The invention relates to the food industry. A method of obtaining an extruded product of high nutritional value, enriched in scorzoner, includes the preparation of raw materials, which are used as potato starch, or corn, or wheat, or rice, or tapioca, or mixtures thereof, or wheat flour, or rye, or potato, or corn or mixtures thereof, or dry mashed potatoes in the form of flakes, or granules, or granules, or grains, or mixtures of various starch-containing raw materials, mixing the raw materials with an additive that increases the nutritional value of the product, and serving the resulting mixtures simultaneously with carbon dioxide in the solid phase into a twin screw extruder. As an additive, they are used in dry powdered or raw powdered form to the scorzoner separately or in a mixture with other plant materials in a different ratio. Carbon dioxide in the solid phase is supplied in an amount of 0.5 May. %, the extrusion is carried out at 100-200 ° C, the rotational speed of the metering screw and working screws 90-95 min-1. Unfinished extrudate is coated in sugar syrup, or in salt brine, or in sugar-juice syrup, or in sugar-fruit syrup, followed by drying.

In the described method, a method for preparing a product of predominantly plant content is presented, which imposes certain restrictions on the scope of the invention. In the described method there are no stages of grinding and fermentation.

The known method described in patent RU2179398 "METHOD FOR PRODUCING FOOD FOR PETS BASED ON A LIQUID HYDROLYZATE FROM MEAT RAW MATERIALS". The invention is intended for use in the feed industry, in the production of pet food (cats and dogs). Method for the production of pet food includes the sequential carrying out of enzymatic and acid hydrolysis of raw materials, in which use pre-minced chicken offal (offal) to the state of minced meat, while the processing of raw materials is carried out with a proteolytic enzyme preparation in the ratio of endo- and exopeptidases 1: 1; 1: 1.5; 1.5: 1 in an amount of 0.1% by weight of the raw material at 50-60 ° C for 0.5-1.0 hours, and acid hydrolysis is carried out at 95 ° C for 20-30 minutes until pH 5.0- 5.5, the resulting hydrolyzate is divided into parts and one part is fed with the feed to the extruder to introduce the granules formed in it in an amount of 1-2% and the other to a cutter for spraying onto the surface of the granules in an amount of 5% of the weight of the granules. The consumption of pet food based on a liquid hydrolyzate has a positive effect on the restoration of the skin and improve the structure of animal hair. Amino acids and peptides that are part of the hydrolyzate, increase the immunity of animals.

In the described method, enzymatic and acid hydrolysis is carried out before extrusion, which does not allow to obtain a safe product for a long time. In the described method, the emphasis is on the processing of raw meat, therefore, fermentation is carried out only by a proteolytic enzyme preparation, and the preparation stage of the compound feed is not described, which does not allow to draw any conclusions about the carbohydrate component of the resulting product.

The known method described in patent RU2315485 "METHOD FOR PREPARING FOOD FOR ANIMALS". The invention is intended for feed production. A method of preparing animal feed involves grinding green plants and treating them with a filler and feed additives under pressure and temperature, the treatment being carried out in a press extruder at a pressure of 20-30 kg / cm2 and a temperature of 60-80 ° C for 30-60 seconds s zeolite in an amount of 0.5% by weight of feed and carbon ammonium salt in an amount of 0.5% by weight of feed. The nutritional value of the feed increases and its shelf life increases.

In the described method, the emphasis is on the preparation of feed from raw materials mainly plant content. The method includes grinding, enrichment, pressure treatment, heating, and also adding zeolite.

The known method disclosed in patent RU2223673 "METHOD FOR PRODUCING COMBINED EXTRUSION PRODUCTS FROM MEAT AND VEGETABLE RAW MATERIALS". The invention relates to the food industry, mainly to the meat industry and the production of extruded food. The method involves the preparation of meat and vegetable raw materials. Lentils and semolina are used as plant materials. With lentils pre-crushed to a particle size of 0.5-1.0 mm, as meat raw material

105 use collagen mass obtained by processing secondary collagen-containing raw materials of the meat industry with proteolytic enzyme preparations, for example megaterin or protosubtiline, and mechanically deboned poultry meat. Raw meat is dehydrated by freeze drying to a moisture content of 14-18% and crushed to a particle size of 0.5-1.0 mm Additionally use

110 combined food additives in the form of powdered dairy and vegetable semi-finished products. All components are metered, mixed and extruded with a meat-and-vegetable mixture at a certain ratio of components in May. % After extrusion, flavoring agents (powdered sugar, table salt, spices) are applied to the surface of the products. The method allows to increase the biological value

115 combined extrusion products from meat and vegetable raw materials, enrich them with physiologically active biopolymers, as well as expand the functionality of low-grade collagen-containing raw materials of the meat industry, which is not very popular for food purposes.

In the presented method, only plant materials are presented

120 lentils and semolina. There is a processing of raw meat proteolytic enzymes. Mixing heterogeneous raw materials occurs after processing with enzymes. Extrusion is carried out after fermentation and mixing of the components.

The known method disclosed in patent RU2215427 "METHOD FOR PROCESSING 125 WASTE ANIMAL AND VEGETABLE ORIGIN", which is the prototype of the claimed invention. The invention described in RU221527, is intended for use in feed production and is aimed at the disposal of animal and vegetable waste to obtain protein additives to the feed ration of animals, birds and fish. A method of processing animal and plant waste 130 includes dosing the components, crushing, mixing, extruding and cooling. After extrusion, rapid forced pneumatic removal of steam and air from the extrudate is carried out. When the humidity of the initial mixture above 30%, repeated extrusion is carried out with rapid forced pneumatic removal of steam and air from the extrudate. The waste content of 135 animal origin in the initial mixture is 10-80%. The product during processing is exposed to temperature and pressure for a short period of time, therefore, the digestibility of the protein and the digestibility of lysine are ensured. The specified patent discloses a method of processing animal and vegetable raw materials, which includes dosing, grinding components, mixing,

140 extrusion and cooling, as well as rapid forced air removal. In the described method there is no fermentation step. The main disadvantages of this technology is that the resulting product is conditionally safe only at the exit of the extruder. In addition, according to this technology, only a limited number of types of raw materials can be processed, which imposes

145 certain restrictions on the breadth of processing biological waste.

Thus, we can conclude that the currently existing technical solutions do not use the full potential of the extrusion and fermentation bundle to the full and therefore do not provide a product with high consumer properties.

150 The objective of the proposed method for the manufacture of feed by extrusion of biological and agricultural raw materials is to obtain a safe product for a long period of time, including storage, with balance and better absorption by the body of animals, additionally with prophylactic properties that prevent

155 diseases of the gastrointestinal tract and light therapeutic effect, the use of plant and moisture-containing protein raw materials. In addition, another feature of the claimed invention is the ability to use in the process of processing all types of biological raw materials, including crop waste and slaughter.

Production of feed by extrusion of biological and agricultural

160 raw materials are produced as follows.

Grinding of vegetable and moisture-containing protein raw materials is carried out separately. In cases where this is required, grinding is carried out in several stages with a gradual decrease in the size of the fraction. At this stage, if necessary, add mycelium of fungi, yeast cells or other components according to

165 recipes.

Then the raw materials of plant and animal origin are fed into the mixing system, where they are mixed until a homogeneous mass. Moreover, if necessary, carry out additional disinfection by quartzization, ozonation or any other known method.

170 After that, the resulting homogeneous mass is fed into the extruder unit and extruded. This implies finding the raw material at a temperature of from 20 ° C to 180 ° C and a pressure of 3 to 50 atmospheres for 5 to 30 seconds. Relief of pressure in the medium at exit from the extruder barrel leads to a decrease in the solubility of gases in the cell cytoplasm and the release of gases (such as oxygen, nitrogen, carbon dioxide) with a rupture of the cell

175 membranes. At the same time, cells and cellular organisms die, the functioning of which requires the presence of a living cell membrane (for example, helminths, cell bacteria and pathogenic fungi).

Further, in the extruded product, autolysis begins. During cell metabolism, there is a constant synthesis / destruction of RNA (m-RNA, t-RNA), which requires

180 ribonucleases in the cytoplasm. At this time, the contents of the substrate are subject to the action of endogenous enzymes, primarily ribonuclease. Upon destruction of the cell wall, ribonuclease enter the substrate, but continue to be active until inactivation. During this process, the potential pathogenic viral load decreases and long fragments of the nucleic acid chains break into shorter ones,

185 which increases the energy and nutritional value of the substrate.

After that, at a temperature of from 20 ° C to 60 ° C, a complex of exogenous protease and cellulase class enzymes occurs together or separately in the feed. Cellulases complete the destruction of long carbohydrates (plant cellulose, cell wall fragments), begun at the extrusion stage, to short carbohydrates,

190 reducing the allergenicity of the product and increasing its nutritional value. Proteases increase the digestibility of the protein component of the substrate, destroying proteins, including native, pathogenic proteins (protein toxins, prions) and structural proteins of viruses, if present, which helps to increase the safety of the substrate. Also, proteases destroy endogenous enzymes, terminating the process of autolysis, which contributes to

195 stabilize the composition of the substrate, and inactivate ribonuclease.

However, the use of a complete set of enzymes is optional. For example, if it is necessary to stimulate the immune system, cellulase is not used. This leads to a decrease in the nutritional value of the product, but increases its immunostimulating effect.

200 After this, the raw materials are cooled, dehydrated and mixed again. At this stage, there is the possibility of additional disinfection of raw materials, for example, by quartzization or ozonation. In addition, at this stage there is the possibility of additional enrichment of the product with additives. At this stage, proteases are inactivated during heating and drying.

205 Then granulation is carried out with a granule size depending on the specific consumption. After this, the product is packaged and packaged in consumer packaging with a volume sufficient to contain the finished product. The technical result of the claimed invention is to obtain feed that retains its safe properties for a long time, including

210 storage, which has a balance and the best assimilation of animals by the body, preventing gastrointestinal diseases and a light therapeutic effect, with conditionally infected raw materials, use biological waste and crop waste to obtain feed.

The technical result is achieved due to the fact that in the manufacturing method

215 feeds, including separate grinding of vegetable and moisture-containing protein raw materials, mixing, extrusion and granulation, cooling is additionally turned on, and operations are carried out in the following order: grinding, mixing, extrusion, cooling and granulation, while during and after extrusion the raw materials are subjected enzymatic hydrolysis.

220 The inventive method is industrially applicable.

The second object of the claimed invention is a production line for implementing the above method of manufacturing feed by extrusion of biological and agricultural waste.

The known line described in patent RU33485 "Biological processing line

225 wastes. ” This is a biological waste processing line, including extruders, devices for feeding waste and filler to a mixer, a device for feeding the resulting mixture to an extruder and a system for removing and cooling the finished product, characterized in that parallel extruders are combined in blocks of two or more and share a common system loading and general pneumatic conveying system and

230 cooling of the finished product.

The presented technological line is very limited in its capabilities, it does not allow to process any biological waste, it does not allow maximum avoidance of human contact with conditionally infected raw materials.

The known line described in patent RU99283 "PRODUCTION LINE

235 EXTRUDED PRODUCTS. ” The utility model relates to the processing of food raw materials and can be used in the production lines of extruded products for humans, animals, birds and fish. An extruded products production line containing bins, mixers, an extruder, a cooler, conveyors, a granulator is divided into a preparation section comprising a bunker of at least two

240 crushers, mixer, cyclone precipitator and storage hopper, an extrusion section including at least two storage hoppers, an extruder and hood, a grinder preparation section, including a crusher, precipitating cyclone and storage hopper, a plot of auxiliary materials, including a mixer, a crusher and a cyclone precipitator, a granulation section, including a storage hopper, a granulator, a cooler

245 and a dust collector, a packing and packaging section, including a storage hopper and a bag-loading complex. Thus, the use of the invention allows to expand the types of raw materials used to create extruded products, for example, milk thistle, expired food products, wheat and so on.

The presented production line does not allow to avoid organization

250 cutting sites and does not minimize human contact with conditionally infected raw materials.

The known line described in patent RU2304417 "LINE FOR PRODUCTION OF EXTRUDED FOOD". The invention relates to the processing of food raw materials and can be used in extruded production lines

255 feed. The line includes containers for bulk cereal components with dispensers, a mixer, an extruder and a cooler. The line is additionally equipped with silos for storing liquid components with volumetric dispensers, steam shirts and nozzles for spraying liquid components, a conveyor belt, a container for storing fat-vitamin components, with a volumetric dispenser in the lower part

260 and equipped with a steam jacket, high pressure pump, belt dryer and granulator. The belt dryer has a sifter with a confuser for collecting fine fractions. A steam jacket is installed on the mixer body to stabilize the temperature regime of the mixing process. The pre-mold zone of the extruder is made in the form of a die with a coextrusion head to obtain a product with

265 stuffing. The coextrusion head is in the form of a cylinder with a tube located inside it, communicated through a pump with a volumetric dispenser of a container for storing fat-vitamin components. The line has a recirculation pipeline designed for the subsequent use of the spent coolant from the dryer in the steam jackets of the bunkers for storing liquid components, containers for

270 storage of fat-containing components and a mixer. Using the invention will allow to obtain a finished product enriched in fats and vitamins.

In the presented production line there is no cooling column, a system for dehydrolysis and fermentation.

The known line described in patent RU2315535 "PRODUCTION LINE

275 EXTRUDED PRODUCTS. ” The invention relates to the processing of food raw materials and can be used in the production lines of extruded products. The line contains a loading hopper, mixer, device for preliminary hydrothermal processing of feedstock, extruder, knife for cutting granules, sifter, crusher, cyclone. Mixer and pre-cleaner

280 hydrothermal treatment of the feedstock is made in the form of a single horizontal trough-shaped housing with nozzles for supplying steam into the housing, inside of which there is a rotating perforated screw for the passage of steam into the housing. The boot device of the extruder is arranged to move along the surface of the extruder body. The sifter cooler represents

285 cylindrical inclined housing with a funnel for supplying extruded products, nozzles for supplying cooling air and for exhausting exhaust air with pulverulent fractions, in which there is an inclined cylindrical rotating two-section perforated drum, the first section having smaller openings and the second having openings corresponding to the standard diameter

290 extruded products. The lower part of the sifter-cooler housing is divided into two discharge hoppers, the first section of the perforated drum with small holes being located above the first discharge hopper, and the second section of the perforated drum with holes for standard extruded products is located above the second discharge hopper. On the filling machine the finished product

295 is packaged, then packaged in cartons on a packaging machine, and a large fraction of extruded products comes out of the inclined cylindrical drum, which is then crushed by a crusher and sent to an intermediate storage hopper, and a small fraction is sent to an intermediate storage hopper, exhaust air from a sifting cooler with dust fractions

300 cyclone, where they are captured and sent to the intermediate storage hopper, from which they enter the air conditioner for steam treatment and then fed to the extruder for re-molding. The invention allows to eliminate marriage and reduce the loss of raw materials, select the most rational modes for processing non-standard products without compromising their quality.

305 In the presented production line there is no cooling column, a system for dehydrolysis and fermentation.

The objective of the claimed technological line is, in addition to the implementation of the method of manufacturing feed disclosed above, the maximum exclusion of human contact with biological waste as conditionally infected raw materials.

310 Description of the production line

The technological line is illustrated by the drawing, which shows a block diagram and is arranged as follows. At least one grinding device is connected to a mixing device. It should be understood that when working with plant and 315 protein raw materials at the same time it is better to have at least two grinding devices connected in parallel with the mixing device. This will speed up the processing of raw materials.

The mixing device is connected to an extruder, which, in turn, is connected to the cooling column with a dispersion table.

320 A cooling tower with a dispersion table is connected to another mixing device. Further, a granulating device and another cooling column with a dispersion table are connected in series to the mixing device.

It should be understood that all of these devices can be connected 325 together by lifting and transport mechanisms. This will reduce human contact with raw materials and increase the manufacturability of production.

The technical result of the claimed technological line is the possibility of implementing the above method.

The technical result is achieved due to the fact that in the processing line for 330 feed manufacturing, which includes at least one device for grinding, at least one device for mixing, an extruder, at least one device for granulation, is also installed at least one cooling column with a dispersion table.

A third object of the claimed invention is the feed obtained by 335 described method

Known meat and vegetable feed described in patent RU2163453 "meat-and-vegetable feed for non-productive animals (OPTIONS) and the way to obtain it." The invention is intended for use in feed production. Two feed options are proposed for 340 non-productive animals. The first of them contains, wt.%: Meat raw materials 10 - 50; cereal flour 10 - 20; minced bone 5–50. An additional 5–30% vegetables and 10–20% protein stabilizer are added to the feed. The second version of the feed contains, wt.%: Minced meat 5 - 50; vegetables 10-30; cereal flour 10 - 20; protein stabilizer 10 - 20. An additional 10 - 50% of raw meat is added to the feed. Flavor and vitamin additives, binders are additionally introduced into both 345 feed variants, and cereal flour is pre-processed in an extruder. The inventive feed obtained by a method that includes grinding ingredients of raw materials, mixing the crushed ingredients of the raw materials with ingredients that do not require grinding: conventional or extruded cereal flour, 350 binders, flavoring and vitamin additives, a protein stabilizer, and adding pre-ground edible bone to the state of minced meat, followed by heat treatment of the mixture. Before heat treatment, the mixture is formed in the form of bars of sausages, sausages or sausages. The feed has a high nutritional and biological value, 355 is optimally balanced in composition, the use of edible bone reduces the cost of feed. The method of obtaining feed allows you to rationally use the waste of meat production and produce feed for non-productive animals in the conditions of meat processing enterprises with standard technological means.

This feed is obtained using a completely different technology and at each stage of its 360 production it is impossible to obtain a safe product.

Feed description

The feed obtained by the claimed method may have an initial composition with an arbitrary ratio of plant and protein raw materials, ranging from 10% to 90% of each type of component.

365 At the same time, it is necessary to understand that the peculiarity of its preparation, due to sequential extrusion and enzymatic lysis, allows to prolong autolysis and fermentation, thereby allowing to increase the “work” time of enzymes, reducing the need for further digestion of the product by the end user. In addition, proteases inactivated at the drying stage are not

370 working in a dehydrated product, are activated again only after getting into the digestive tract, which ensures the stability and safety of the feed.

The technical result of the claimed feed is the preservation of its safety properties for a long time, including storage, increased digestibility by the body of animals, the prevention of gastrointestinal diseases and lung

375 therapeutic effect.

Claims

CLAIM

1. A method of manufacturing feed, including the separate grinding of vegetable and moisture-containing protein raw materials, mixing, extruding and

380 granulation, characterized in that it includes cooling, and the operations are carried out in the following order: grinding, mixing, extrusion, cooling and granulation, while during and after extrusion, the raw materials are subjected to enzymatic hydrolysis.

2. The method according to claim 1, in which during mixing the raw material is subjected to 385 sterilization using quartzization or ozonation.

3. The method according to claim 1, characterized in that the grinding is carried out in several stages with a sequential reduction in the size of the fraction.

4. The method according to claim 1, characterized in that during the grinding process, additional components are added to the raw material: mycelia, yeast cells or other additives.

390 5. The method according to any one of the above paragraphs, characterized in that the enzymatic hydrolysis is carried out at a temperature of from 20 ° C to 60 ° C.

6. Processing line for the manufacture of feed, comprising at least one device for grinding, at least one device for mixing, an extruder, at least one device for granulation,

395 characterized in that it also includes at least one cooling column with a dispersion table.

7. The production line according to claim 6, characterized in that all the devices included in its composition are interconnected by lifting and transport mechanisms.

8. The production line according to claim 6 or claim 7, characterized in that at least two devices for grinding vegetable and protein raw materials are simultaneously included in it 400.

9. Food, characterized in that it is obtained by the method according to claim 1.