WO2021173536A1 - Procédé et appareil de floconnage d'une matière - Google Patents

Procédé et appareil de floconnage d'une matière Download PDF

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Publication number
WO2021173536A1
WO2021173536A1 PCT/US2021/019212 US2021019212W WO2021173536A1 WO 2021173536 A1 WO2021173536 A1 WO 2021173536A1 US 2021019212 W US2021019212 W US 2021019212W WO 2021173536 A1 WO2021173536 A1 WO 2021173536A1
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WO
WIPO (PCT)
Prior art keywords
tank
bean
raw material
temperature
steam
Prior art date
Application number
PCT/US2021/019212
Other languages
English (en)
Inventor
Tianyuan LOU
Wenge SU
Feina WANG
Jiajia XUE
Original Assignee
The Quaker Oats Company
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from CN202010111194.8A external-priority patent/CN112493409A/zh
Priority claimed from CN202011055329.XA external-priority patent/CN112515105A/zh
Application filed by The Quaker Oats Company filed Critical The Quaker Oats Company
Priority to MX2022010292A priority Critical patent/MX2022010292A/es
Publication of WO2021173536A1 publication Critical patent/WO2021173536A1/fr

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Classifications

    • AHUMAN NECESSITIES
    • A23FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23LFOODS, 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
    • A23L7/00Cereal-derived products; Malt products; Preparation or treatment thereof
    • A23L7/10Cereal-derived products
    • A23L7/117Flakes or other shapes of ready-to-eat type; Semi-finished or partly-finished products therefor
    • AHUMAN NECESSITIES
    • A23FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23LFOODS, 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
    • A23L11/00Pulses, i.e. fruits of leguminous plants, for production of food; Products from legumes; Preparation or treatment thereof
    • A23L11/05Mashed or comminuted pulses or legumes; Products made therefrom

Definitions

  • a method, system, and apparatus for flaking material is described.
  • the described method and apparatus are useful for making flaked beans and some special grains without the need to soak the beans, as is traditional.
  • bean as used in the following description includes broad bean or fava bean, tepary bean, runner bean, lima bean, pinto bean, kidney bean, black bean, red bean, green bean, yellow bean, Appaloosa bean, moth bean, adzuki bean, urad bean, mung bean, Bambara bean (ground-bean), ricebean, cowpea, black-eyed pea, yardlong bean, chickpea, garbanzo bean, pea, Indian pea, tuberous pea, lentil, hyacinth bean, soybean, pigeon pea, velvet bean, jack bean, sword bean, lupini bean.
  • bean as used in the following description is meant to exclude legumes with tiny seeds and which are used exclusively for forage, hay, and silage purposes (such as clover and alfalfa
  • Certain plants classified as grains may be effectively processed according to the described method and in the described apparatus.
  • special grains or “special grain” and they refer to the following: corn, Job’s tears (may also be known as oixseed, tear grass, coix lacryma-jobi L., and Yi Yi), sorghum, poria cocos, Gorgon fruit, highland barley, kanjac, lotus seed, lilium and the like.
  • the beans and special grains that have not yet been processed will be referred to as “raw material”.
  • a method for flaking a raw material includes providing the raw material and then cleaning the raw material to remove exogenous material such as stones, metal, and other material that might be present with the raw material as a result of the harvesting of the raw material.
  • the moisture content of the raw material is measured and optionally modulated to a level of about 6% to about 13% by weight. Modulation of the moisture content may be achieved by heating or roasting to reduce the inherent moisture content of the raw material to a level of about 6% to about 13% by weight.
  • the raw material (whether its moisture has been modulated or not) is cooked with steam in a tank.
  • the tank has a plurality of valves disposed laterally on the side walls of the tank and positioned to inject steam.
  • the raw material is introduced to an inlet on a first end of the tank and steamed for a predefined time and at a predefined temperature effective to form a cooked material.
  • An appropriate temperature of the steam is in the range from about 110°C to about 170° to achieve an average bulk temperature of the material in the top section in the range of 80°C to about 120°C, i.e., the cooking temperature.
  • the tank is oriented more nearly horizontal, i.e., more nearly parallel with respect to a work surface such as an operating floor.
  • the height of the inlet of the tank with respect to the work surface is higher than the height of the outlet of the tank with respect to the work surface.
  • an angle defined by the exterior wall of the tank and a plane parallel to the work surface is less than 90° and may be between about 5° to about 80°.
  • the raw material is moved through the interior of the tank from the first end, through the inlet, to a second end, through an outlet, via a rotating shaft.
  • the rotating shaft is aligned substantially parallel to a longitudinal axis that extends from the first end to the second end.
  • the rotating shaft includes a mixing implement that moves the raw material through the interior of the tank from the inlet to the outlet.
  • the mixing implement includes a number of spaced apart paddles arranged radially about the shaft and extend along the longitudinal extent of the shaft from the inlet of the tank to the outlet of the tank. In some instances the paddles are arranged so that there are three rows of paddles along the longitudinal extent of the shaft with each row of paddles radially spaced at about 120° from each other.
  • the paddles are also configured so that the gap between the outermost portion of the paddle and the interior wall of the tank is minimized. In some instance, the gap is between about 1 cm to about 10 cm. In other embodiments, the paddles are configured so that the angle of the paddle can be changed to provide a leading edge and a trailing edge as viewed from the side.
  • the rotating shaft further may also include spikes to break up agglomerations of raw material in the tank.
  • the spikes are also arranged radially about the shaft and extend along the longitudinal extent of the shaft from the inlet of the tank to the outlet of the tank. In some instances the spikes are arranged so that there are three rows of spikes along the longitudinal extent of the shaft with each row of spikes radially spaced at about 120° from each other.
  • the spikes extend radially outward from the shaft toward the interior of the tank but do not touch the interior wall of tank; but instead is spaced from the interior wall of the tank by a gap in the range from about 1 cm to about 10 cm.
  • the paddles and spikes may be constructed so that each paddle is radially opposite each spike.
  • the tank has a valve disposed in an interior of the tank to define a top section and a bottom section.
  • the raw material is introduced into the top section and cooked by applying steam for a predefined time and at a predefined temperature effective to form a cooked material.
  • An appropriate temperature of the steam is in the range from about 110°C to about 170° to achieve an average bulk temperature of the material in the top section in the range of 90°C to about 100°C, i.e., the cooking temperature.
  • the material is held at the cooking temperature for a period of time ranging from about 1 minute to about 60 minutes.
  • the valve is opened and the cooked material falls by gravity to the bottom section where the cooked material is held to be moistened for a predefined time and predefined temperature effective to form a moistened product that is subsequently discharged from the tank.
  • the temperature of the material during moistening ranges from about 50°C to about 90°C and the period of time is from about 5 minutes to about 90 minutes. In some aspects, there is no added moisture heat or cooling applied to the cooked material while moistening.
  • the residence time of the raw material in the tank ranges from about 1 minute to about 60 minutes.
  • the steamed material is directed to a pre-drier downstream of the tank and upstream of the flaker.
  • the pre drier operates at a temperature of about 35° C to about 75° C and is configured to modulate the moisture content of the steamed material prior to flaking.
  • the pre-dried material is then conveyed to a flaking mill configured to flake the pre-dried material to provide a flaked material having a thickness from about 0.1 mm to about 3 mm.
  • the flaked material is directed to a drier operating at a temperature from about 45°C to about 75°C for a period of time from about 1 minute to about 15 minutes to remove moisture from the flaked material.
  • a system for flaking a raw material includes an optional cleaner and heater, where the heater is effective to modulate the moisture content of the raw material to a level between about 6% to about 13% by weight; a tank configured to impart steam to the raw material; an optional pre-drier before the flaker operating at a temperature of about 35°C to about 75°C configured to lower the moisture content of the cooked material before flaking; a flaking mill configured to flake the material exiting the tank or pre-drier to provide flaked material having a thickness within a range of about 0.1 mm to about 3 mm; and a drier operating at a temperature of about 45°C to about 75°C and configured to dry the flaked material.
  • an apparatus for steaming and moistening the raw material is provided that is useful in the above method and system.
  • the apparatus is a tank for steaming a material.
  • the tank has a first end with an inlet through which the raw material may be introduced into the tank and a second end spaced from the first end and having an outlet.
  • the tank has a length and a continuous internal diameter such that the tank length is equal to or larger than the internal diameter.
  • At least one vapor inlet is provided in the wall of the tank so that steam, at an appropriate temperature and pressure, may be introduced into the interior of the tank.
  • the at least one vapor inlet is disposed on a wall of the tank so that the steam is directed toward the center of the tank, (i.e., orthogonally to the longitudinal axis of the tank).
  • the at least one vapor inlet may be in the form of one or more annular pipes disposed on the interior wall of the first section.
  • Each of the annular pipes may include at least one outlet from which steam exits and is directed to the interior of the tank.
  • the at least one vapor inlet may be in the form of a nozzle or injector.
  • the nozzle or injector may be provided with at least one, and in some cases a plurality, of outlets disposed about the periphery of the opening of the nozzle or injector so that the steam will be directed toward the interior of the tank.
  • the vapor inlet may be a combination of inlets disposed on the wall of the tank and a combination of nozzles or injectors positioned inside the tank.
  • the nozzles or injectors may be orthogonally disposed to the longitudinal axis of the tank.
  • At least one rotating shaft is provided in the interior of the tank adjacent to and upstream from the outlet.
  • the rotating shaft includes a mixing implement to move the raw material from the first end of the tank to the second end of the tank.
  • the mixing implement comprises paddles and spikes.
  • the paddles and spikes are spaced along the length of the rotating shaft in a corkscrew pattern to facilitate the movement of material through the tank.
  • the rotating shaft is aligned substantially parallel to a longitudinal axis that extends from the first end to the second end. The spikes help to break any clumps of steamed material and the paddles translate the material through the tank from the first end to the second end during the steaming process.
  • the apparatus is a continuous cylindrical tank for steaming and moistening a material.
  • the tank has a top with an inlet through which the raw material may be introduced into the tank and a bottom spaced from the top and having an outlet.
  • the tank has a height and a continuous internal diameter such that the tank height is equal to or larger than the internal diameter.
  • a valve is provided in the interior of the tank at a location to define a first section and a second section of the tank, with the second section downstream of the first section.
  • the first section may also be referred to as the top section and the second section may also be referred to as the bottom section.
  • the first section has a first volume and the second section has a second volume such that the second volume is about the same as or larger than the first volume.
  • At least one vapor inlet is provided in the first section so that steam at an appropriate temperature and pressure may be introduced into the first section.
  • the at least one vapor inlet is disposed on a wall of the tank so that the steam is directed toward the center of the tank, (i.e., orthogonally to the longitudinal axis of the tank).
  • the at least one vapor inlet may be in the form of one or more annular pipes disposed on the interior wall of the first section.
  • Each of annular pipes may include at least one outlet from which steam exits and is directed to the interior of the tank.
  • the vapor inlet may be in the form of a nozzle oriented substantially parallel to the longitudinal axis of the tank and in some instances along the longitudinal axis of the tank.
  • the nozzle may be provided with at least one and in some cases a plurality of outlets disposed about the periphery of the nozzle so that the steam will be directed outward toward the interior of the tank wall.
  • the vapor inlet may be a combination of inlets disposed on the wall of the tank and a nozzle positioned inside the tank substantially parallel to the longitudinal axis of the tank.
  • At least one rotating spiked shaft is provided in the interior of the tank adjacent to and upstream from the outlet.
  • the shaft aids in breaking any clumps of moistened material that may be present upon completion of the moistening step and as the moistened material moves to the outlet of the tank.
  • Fig. 1 schematically shows a method for flaking a raw material according to the described method and using the described apparatus.
  • Fig. 2 shows an exemplary apparatus useful for steaming and pre-drying the raw material.
  • FIG. 3 shows a projection view of the exemplary apparatus of Fig. 2.
  • Fig. 4 schematically shows a method for flaking a raw material according to the described method and using the described apparatus.
  • Fig. 5 shows an exemplary apparatus useful for steaming and moistening the raw material.
  • FIG. 6 shows an exemplary rotating spiked shaft useful in the apparatus shown in Fig. 4
  • Fig. 7 shows an alternative embodiment of a vapor inlet that may be used in the apparatus shown in Fig. 4.
  • the method includes providing a raw material 20, cleaning the raw material 30, optionally modulating the moisture content of the raw material 40, cooking or steaming the raw material to provide a cooked material 50, optionally pre-drying the cooked material to provide a pre-dried material 60, flaking the pre-dried material 70, drying the flaked material 80, and optionally packing the flaked material 90.
  • bean as used in the following description includes broad bean or fava bean, tepary bean, runner bean, lima bean, pinto bean, kidney bean, black bean, red bean, green bean, yellow bean, Appaloosa bean, moth bean, adzuki bean, urad bean, mung bean, Bambara bean (ground-bean), ricebean, cowpea, black-eyed pea, yardlong bean, chickpea, garbanzo bean, pea, Indian pea, tuberous pea, lentil, hyacinth bean, soybean, pigeon pea, velvet bean, jack bean, sword bean, lupini bean.
  • bean as used in the following description is meant to exclude legumes with tiny seeds and which are used exclusively for forage, hay, and silage purposes (such
  • Certain plants classified as grains may be effectively processed according to the described method and in the described apparatus.
  • special grains or “special grain” and they refer to the following: corn, Job’s tears (may also be known as oixseed, tear grass, coix lacryma-jobi L, and Yi Yi), sorghum, poria cocos, Gorgon fruit, highland barley, kanjac, lotus seed, lilium, and the like.
  • a raw material is harvested and provided 20.
  • the provided raw material 20 may be cleaned 30 and when implemented, the cleaning seeks to remove the exogenous material found in the field and transportation process that may be comingled with the raw material and for which it is desirable to remove so that the raw material is suitable for human consumption. This may be accomplished in any known manner such as by screening, passing the material through a magnetic separator, and the like.
  • the cleaned material may then be graded or sized and may also be analyzed to determine the moisture content of the raw material.
  • the raw material has a moisture content at least about 6%, 7%, 8%, 9%, or 10% and less than about 13%, 12%, or 11% and may between about 6% to about 13%, or about 7% to about 11% or about 8% to about 9% or about 8% to about 13%.
  • the raw material moisture content may be modulated 40 to achieve the useful moisture content.
  • the raw material is heated or dried to achieve the useful moisture content.
  • the raw material (whether its moisture has been modulated or not) is cooked with steam 50 to form a cooked material in a tank that will be explained later with reference to Figs. 2, 3 and 5-7.
  • the steaming and/or cooking is performed using steam having a temperature in the range from about 110° C to about 170° C or from about 120° C to about 140° C. In some instances, the temperature of the steam is from about 130° C to about 160° C, or from about 140° C to about 150° C.
  • the steam may be applied intermittently or continuously so that so that the average bulk temperature of the material in the tank 100 as it is being cooked ranges from about 90° C to about 100° C.
  • the steam may be injected at a pressure from about 0.1 MPa to about 1 MPa or from about 0.2 MPa to about 0.8 MPa, or from about 0.3 MPa to about 0.6 MPa.
  • the steaming and/or cooking is performed for a period of time such that the residence time of the raw material in the tank ranges from about 1 minute to about 60 minutes. In other aspects, the cooking period of time ranges from about 1 minute to about 60 minutes, or from about 2 minutes to about 40 minutes, or from about 3 minutes to about 30 minutes.
  • the moisture content of the steamed material ranges from about 12% to about 19%, or from about 13% to about 18%, or from about 14% to about 17%, or from about 15% to about 16%.
  • the cooked material may then be optionally pre-dried to remove some of the moisture imparted to the material during the cooking/steaming process so that the material can be effectively flaked.
  • the pre-drier removes between about 1% to about 5% moisture or from about 2% to about 3% moisture. It is to be noted that the moisture content of the material exiting the pre-drier ranges from about 12% to about 14% and may be as low as 10% or lower.
  • the average bulk temperature of the material in the pre-drier 130 ranges from about 35° C to about 75° C, or from about 40° C to about 50° C, of from about 50° C to about 60° C, or from about 60° C to about 70° C.
  • the pre-drying step 60 is conducted for a period of time from about 5 minutes to about 90 minutes, or from about 5 minutes to about 80 minutes, or from about 10 minutes to about 70 minutes for from about 10 minutes to about 60 minutes.
  • the optionally pre-dried material is then directed to a flaking mill, which may include a roller press that will compress the pre-dried material to a size range from about 0.1 mm to about 3 mm, or about 0.2 mm to about 2 mm.
  • the flaked material may then be conveyed to a drier operating at a temperature from about 45° C to about 75° C for a period of time from about 1 minute to about 10 minutes or about 5 minutes to remove moisture from the flaked material. Thereafter, the dried material may be packed 90 for shipment.
  • FIG. 2 one embodiment of an apparatus for cooking and steaming and for optionally pre-drying is depicted. Referring specifically to Fig.
  • an exemplary apparatus for cooking and steaming is configured as a tank 100 that may be generally cylindrically shaped with a longitudinal axis 102 and a length (I) defining the distance from the first end of the tank 104 to the second end of the tank 106.
  • the tank 100 has a wall 103 extending from the first end 104 to the second end 106 to define a continuous interior 108 of the tank that is smooth and has a continuous interior diameter (d).
  • the first end of the tank 104 has an inlet 110 through which the raw material enters the tank 100 and the second end of the tank 106 has an outlet 112 through which the cooked material exits the tank 100.
  • the tank 100 is oriented either generally parallel to or slightly angled with respect to a support surface (not shown) such as a floor that is horizontally oriented.
  • the tank may be located in a working factory with an operating floor (not shown) that supports a variety of equipment typically provided for processing of the exemplary raw material.
  • the tank 100 is oriented at least parallel with the operating floor (i.e. , parallel with the horizon) and may be oriented at an angle with the operating floor (i.e., at an angle to the horizon) so that the inlet 110 is vertically higher than the outlet 112.
  • an angle defined by the operating floor (or a plane parallel to the operating floor, or a plane parallel to the horizon) and the wall 103 ranges from about 5° to about 80°.
  • a rotating shaft 114 is provided between the first end 104 and the second end 106 of tank 100.
  • the speed of the rotating shaft 114 may be adjusted depending on the raw material and the desired residence time for the raw material.
  • the rotating shaft 114 includes a mixing implement 115 to move the raw material from the first end 104 of the tank to the second end 106 of the tank while thoroughly mixing the raw material with steam injected into the tank 100.
  • the mixing implement 115 includes a plurality of paddles 116, although any suitable type of mixing implement can be provided so long as it is configured for and capable of moving the material from the first end 104 to the second end 106 of the tank 100.
  • the rotating shaft 114 is aligned substantially parallel to a longitudinal axis 102 that extends from the first end 104 to the second end 106.
  • the plurality of paddles 116 are spaced apart, arranged radially about the shaft 114, and extend along the longitudinal extent of the shaft 114 from the inlet 110 of the tank to the outlet 112 of the tank 100.
  • the paddles 116 are arranged so that there are three rows of paddles 116 along the longitudinal axis 102 of the shaft 114 with each row of paddles 116 radially spaced at about 120° from each other so that, from an axial end, the paddles 116 appear to be arranged in a corkscrew manner.
  • the paddles 116 are also configured so that the gap between the outermost portion of the paddle and the interior wall of the tank is minimized. In some instances, the gap is between about 1 cm to about 10 cm. In other embodiments, the paddles 116 are configured so that the angle of the paddle can be changed to provide a leading edge 116a and a trailing edge 116b as viewed from the side.
  • the mixing implement 115 may also include spikes 117 to break up agglomerations of raw material in the tank.
  • the spikes 117 are spaced apart, arranged radially about the shaft 114, and extend along the longitudinal extent of the shaft from the inlet 110 of the tank to the outlet 112 of the tank 100.
  • the spikes 117 are arranged so that there are three rows of spikes 117 along the longitudinal axis 102 of the shaft 114 with each row of spikes 117 radially spaced at about 120° from each other so that from an axial end, the spikes 117 appear to be arranged in a corkscrew manner.
  • each spike 117 is located radially opposite a respective paddle 116.
  • the spikes 117 extend radially outward from the shaft toward the interior wall of the tank but do not touch the interior wall of tank; but instead is spaced from the interior wall of the tank by a gap in the range from about 1 cm to about 10 cm.
  • At least one vapor inlet 120 is provided in the tank 100 so that steam at an appropriate temperature and pressure may be introduced into the tank 100.
  • the vapor inlet 120 is disposed on the wall of the tank and has an opening 124 at the interior of the tank 100 so that the steam is directed toward the center of the tank 100, (i.e., orthogonally to the longitudinal axis of the tank). It is contemplated that a plurality of vapor inlets 120 may be disposed on the wall of the tank 100 spaced from each other about the periphery of the wall of the tank 100 so that the steam is directed toward the center of the tank.
  • vapor inlets 120 when a plurality of vapor inlets 120 are provided, the plurality of vapor inlets 120 are provided in a manner so that they are spaced longitudinally from each other. In some instances, vapor inlets 120 may be located in a manner such that there is at least one vapor inlet at approximately 1/3 of each of the first third, second third, and final third of the longitudinal extent of the tank.
  • the openings 124 of the vapor inlets 120 may be in the form of injectors or nozzles.
  • the injectors or nozzles may be disposed on the interior wall of the tank 100 and have at least one outlet 124 to direct steam toward the interior 108 of the tank 100.
  • more than one vapor inlet 120 is provided. In this instance, each vapor inlet 120 will be spaced longitudinally from another.
  • the openings 124 of the vapor inlets 120 may have any suitable diameter consistent with the size of the tank (i.e., the internal diameter of the tank) so that it does not create an impediment for movement of the steamed material through the tank 100.
  • the vapor inlets 120 may have a diameter from about 5 mm to about 50 mm, or from about 10 mm to about 40 mm, or from about 20 mm to about 30 mm, or about 25 mm.
  • the vapor inlets 120 may have one or more than one outlet 124 from which the vapor or steam exits and is directed toward the interior 108 of the tank 100. Where more than a single outlet 124 is present, the outlets 124 may be spaced apart any suitable distance from each other and, in some instances are spaced a uniform distance.
  • the tank 100 may be provided with one or more sensors 126a and 126b to measure physical properties of the material disposed in the tank 100.
  • the one or more sensors 126a and 126b may be any suitable type of sensor to measure the temperature, such as a thermocouple or resistance temperature detector, or to measure the moisture in the tank 100. Where the sensors 126a and 126b are used to measure the temperature, the sensor is positioned in a manner and location to obtain an average bulk temperature of the material disposed in the tank 100. For example, the sensor may extend from the interior wall into the interior 108 of the tank 100.
  • the sensors 126a and 126b may be disposed laterally at any location on the wall of the tank 100.
  • the sensors 126a and 126b may be oriented orthogonally to a longitudinal axis 102 that extends from the first end 104 to the second end 106. Alternatively, the sensors 126a and 126b may have an L-shaped configuration.
  • the outlet 112 may be provided with a valve 113 such as a gate valve or an orifice valve that can be manually or automatically actuated from a closed position to an open position, such that in the open position, steamed (cooked) material may be discharged from the tank 100.
  • a valve 113 such as a gate valve or an orifice valve that can be manually or automatically actuated from a closed position to an open position, such that in the open position, steamed (cooked) material may be discharged from the tank 100.
  • the raw material is introduced into the inlet 110 of the tank 100 and steamed by injecting steam for a predefined time and at predefined temperature that is effective to form a uniformly steamed material. Because the raw material typically expands when cooked (particularly with steam), it is desirable to provide an unfilled gap (a space not occupied by the raw material) in the interior 108 of the tank 100. Accordingly, in some embodiments, the raw material fills from about 50% to about 90% of the total volume of the tank, or from about or from about 60% to about 80%, or from about 65% to about 75%, or about 70% of the total volume of the tank.
  • the outlet 112 may include a valve 113 that may be manually operated or may controlled in a known manner such a pneumatically, hydraulically, electrically, magnetically, or some other manner. Where the valve 113 is not manually controlled, the valve 113 or an actuator controlling the valve 113 may communicate with a controller (not shown) that is operable to control the opening and closing of the valve 113 based on control logic, derived from conditions such as time, temperature, moisture content, etc. Such operations are well known and need not be further described.
  • the optional pre-drier 130 comprises a vibratory system using forced air to pre-dry the steamed (cooked) material prior to flaking 70.
  • the pre-drier further has an inlet 132 for the steamed material and an outlet 134 for the pre-dried material. Forced air enters through a forced air inlet 138a on the outlet 134 side of the pre drier 130 and is exhausted out through a force air outlet 138b on the inlet 132 side of the pre-drier 130. Liquid condensate 136 exits through the outlet 134 side of the pre drier.
  • the pre-dried material passes through the outlet 134 of the pre-drier and into a flaker (not shown).
  • raw material processed according to the above-described method and apparatus are effectively processed to achieve flaked material that is quickly hydrated for consumption.
  • 30 g of flaked black beans are added to a container and infused with water having a temperature of 80°-100° C for three minutes.
  • the product was evaluated and was determined to be fully hydrated, soft and with a well-cooked texture.
  • a current commercially available flaked black bean required at least 5 minutes of infused water having a temperature of 80°-100° C to achieve full hydration.
  • black beans and chick pea processed according to the described method and with the described apparatus will provide flaked black beans and flaked chick pea that, can be hydrated within two minutes, as compared to presently commercially available flaked black beans and flaked chick pea, which are hydrated in about five minutes. Therefore, one skilled in the art will appreciate that a desirable commercial product can be effectively and efficiently produced according to the described method and apparatus.
  • the tank 300 is generally shaped as a cylindrical tank having a longitudinal axis 302 and a height (h) defining the distance from the top of the tank 304 to the bottom of the tank 306.
  • the tank 300 has a continuous interior 308 that is smooth and has a continuous interior diameter (d).
  • the top of the tank 304 has an inlet valve 310 through which the raw material enters the tank 300 and the bottom of the tank 306 has an outlet valve 312 through which the cooked and moistened material exits the tank 300.
  • the tank height (h) is equal to or larger than the interior diameter (d) so that the raw material is more effectively cooked.
  • the ratio of the height (h) to the internal diameter (d) is from about 5:1 to about 20:1 or about 10:1 .
  • the tank has a height h of about 4.2 m and a diameter of about 400 mm.
  • a separator valve 314 Disposed between the top 304 and the bottom 306 of the tank 300, there is a separator valve 314 disposed in the interior 308 of the tank 300 to define a first or top section 316 and a second or bottom section of the tank 318, with the second or bottom section 318 downstream of the first or top section 316.
  • the separator valve 314 may be any suitable valve such as a gate valve. When the separator valve is closed, material cannot move from the first section 316 to the second section 318 (and vice versa) and when the separator valve is open, the material can move from the first section 316 to the second section 318.
  • the valve may be manually or automatically actuated.
  • the first section 316 has a first volume has a first volume and the second section 318 has a second volume such that the second volume is about the same as or larger than the first volume.
  • the ratio of the volume of the second section to the volume of the first section ranges from about 1.1 to about 5:1 or about 1 .2:1 to about 2.5:1 or about 1 .3:1 .
  • At least one vapor inlet 320 is provided in the first section 316 so that steam at an appropriate temperature and pressure may be introduced into the first section 316.
  • the vapor inlet 320 is a vapor inlet 322 disposed on the wall of the tank and having an opening 324 at the interior of the first section 316 of the tank 300 so that the steam is directed toward the center of the tank 300, (i.e., orthogonally to the longitudinal axis of the tank). It is contemplated that a plurality of vapor inlets 322 may be disposed on the wall of the first section 316 spaced from each other about the periphery of the wall of the first section 316 so that the steam is directed toward the center of the tank. It is also contemplated that when a plurality of vapor inlets 322 are provided, the plurality of vapor inlets 322 are provided in a manner so that they are spaced longitudinally from each other.
  • the vapor inlet 322 is in the form of an annular pipe 323 disposed on the interior wall of the tank 300 and having at least one outlet 325 to direct steam toward the interior 308 of the first section 316 of the tank 300.
  • more than one annular pipe 323 is provided.
  • each annular pipe 323 will be spaced longitudinally from another.
  • the annular pipe 323 may have any suitable diameter consistent with the size of the tank (i.e., the internal diameter of the tank) so that it does not create an impediment for movement of the cooked material to the second section 318.
  • the annular pipe 323 may have a diameter from about 5 mm to about 50 mm, or from about 10 mm to about 40 mm, or from about 20 mm to about 30 mm, or about 25 mm.
  • the annular pipe 323 may have one or more than one outlets from which the vapor or steam exits and is directed toward the interior 308 of the first section 316 of the tank 300. Where more than a single outlet is present, the outlets are typically spaced apart from each other a uniform distance. It is contemplated to provide each annular pipe 323 with two, four, six, eight, or ten outlets 324.
  • the vapor inlet 320 may be in the form of a nozzle 326 oriented substantially parallel to the longitudinal axis 302 of the tank 300 and in some instances along the longitudinal axis 302 of the tank 300.
  • the nozzle 326 may have a height of about 0.5 m to about 1 m, or about 0.6 m with a diameter from about 20 mm to about 60 mm or about 40 mm.
  • the nozzle 326 may be provided with at least one and, in some cases a plurality of outlets 328 disposed about the periphery of the nozzle 326 so that the steam from the nozzle 326 will be directed outward toward the interior 308 of the tank wall.
  • the vapor inlet 320 may be a combination of inlets 322 disposed on the wall of the tank (or the annular pipe(s) 323 described above) and a nozzle 326 positioned inside the tank 300 substantially parallel to the longitudinal axis of 302 the tank 300.
  • the top section 316 may be provided with one or more sensors 330a, to measure physical properties of the material disposed in the top section 316.
  • the one or more sensors 330a may be any suitable type of sensor to measure the temperature such as a thermocouple or to measure the moisture in the top section 316. Where the sensor 330a is used to measure the temperature, the sensor is positioned in a manner to obtain an average bulk temperature of the material disposed in the top section 316. For example, the sensor may extend from the interior wall into the interior 308 of the tank 300.
  • the bottom section 318 may be provided with one or more sensors 330b to measure the physical properties of the material disposed in the bottom section 318.
  • the one or more sensors 330b may be any suitable type of sensor to measure the temperature such as a thermocouple or to measure the moisture in the bottom section 318. Where the sensor 330b is used to measure the temperature, the sensor 330b is positioned in a manner to obtain an average bulk temperature of the material disposed in the bottom section 318. For example, the sensor 330b may extend from the interior wall into the interior 308 of the tank 300.
  • At least one rotating spiked shaft 340 is provided adjacent to and upstream from the outlet valve 312.
  • the rotating spiked shaft 340 aids in breaking any clumps of moistened material that may be present upon completion of the moistening step and as the moistened material moves through the outlet valve 312 of the tank 300.
  • a pair of counter-rotating spiked shafts are provided as shown in Fig. 6.
  • any suitable number of rotating spiked shafts 340 may be provided and that the shafts may have any suitable number of spikes.
  • the outlet valve 312 may be any suitable valve such as a gate valve that can be manually or automatically actuated from a closed position to an open position, such that in the open position, moistened material from the second section 318 may be discharged from the tank 300.
  • a gate valve that can be manually or automatically actuated from a closed position to an open position, such that in the open position, moistened material from the second section 318 may be discharged from the tank 300.
  • the raw material is introduced into the top section 316 of the tank 300 and cooked by injecting steam for a predefined time and at predefined temperature effective to form a cooked material. Because the cooked material typically expands when cooked (particularly with steam), it is desirable to provide an unfilled gap (a space not occupied by the raw material) in the first section. Accordingly, in some embodiments, the raw material fills from about 50% to about 90% of the total volume of the first section, or from about or from about 60% to about 80%, or from about 65% to about 75%, or about 70% of the total volume of the first section.
  • An appropriate temperature of the steam is in the range from about 110°C to about 170° C.
  • the steam may be applied intermittently or continuously so that so that the average bulk temperature of the material in the first section as it is being cooked ranges from about 90°C to about 100°C.
  • the temperature of the steam is from about 130°C to about 160°C, or from about 140°C to about 150°C.
  • the cooking period of time ranges from about 1 minute to about 60 minutes, or from about 2 minutes to about 40 minutes, or from about 3 minutes to about 30 minutes.
  • the separator valve 314 When the material is finished being cooked, the separator valve 314 is opened and the cooked material falls by gravity to the second section 318 where the cooked material is held to moisten the material using retained heat and the moisture applied in the first section 316. In other words, in some aspects, there is no further application of heat and/or further application of moisture in the second section 318.
  • the separator valve 314 may be manually operated or may controlled in a known manner such a pneumatically, hydraulically, electrically, magnetically, or some other manner.
  • the separator valve 314 or an actuator controlling the separator valve 314 may communicate with a controller (not shown) that is operable to control the opening and shutting of the separator valve 314 based on control logic, derived from conditions such as time, temperature, moisture content, etc. Such operations are well known and need not be further described.
  • the average bulk temperature of the material in the second section 318 ranges from about 50°C to about 90°C or from about 60°C to about 85°C.
  • the moistening step is conducted for a period of time from about 5 minutes to about 90 minutes, or from about 5 minutes to about 80 minutes, or from about 10 minutes to about 70 minutes for from about 10 minutes to about 60 minutes.
  • the moistening time is longer than the cooking time so that more than a single cooking batch may be held in the second section 318 and so that the cooked materials may be further hydrated and/or gelatinized.
  • the moistened material passes through or past the at least one rotating spiked shaft 340 (best seen in Fig. 6) provided in the interior of the tank 300, adjacent to, and upstream from the outlet valve 312 where the moistened material is then flaked.
  • a pair of counter-rotating spiked shafts 340 are provided.
  • the rotating spiked shaft or shafts 340 act to remove or minimize the number of clumps or agglomerates of moistened material.
  • the moistened material exiting the tank 300 is directed to an inlet of a flaking mill 260.
  • the moistened material may exit the tank directly into the flaking mill 260 or it may be conveyed by any suitable conveyor to the inlet of the flaking mill 260. Thereafter, flaking is conducted by conveying the moistened material through a roller press which will compress the moistened material to a size range from about 0.1 mm to about 3 mm, or about 0.2 mm to about 2 mm.
  • the flaked material may then be (optionally) conveyed to a drier 270 operating at a temperature from about 50°C to about 75°C for a period of time from about 1 minute to about 10 minutes or about 5 minutes to remove moisture from the flaked material. Thereafter, the optionally dried material may be packed 80 for shipment.
  • a system for flaking a raw material includes an optional cleaner 230 and heater 240, where the optional heater 240 is effective to modulate the moisture content of the raw material to a level between about 6% to about 13% by weight; a continuous tank configured to impart steam to the raw material to form a steamed material; an optional pre-drier configured (see Fig.
  • a flaking mill configured to flake the material exiting the pre-drier or tank to provide flaked material having a thickness within a range of about 0.1 mm to about 3 mm; and a drier operating at a temperature of about 45°C to about 75°C and configured to dry the flaked material.
  • aspects of the described method, system, and apparatus for producing a flaked material includes providing a raw material, cleaning the raw material, optionally modulating the moisture content of the raw material, cooking or steaming the raw material to provide a cooked material, optionally pre-drying the material to provide a pre-dried material, flaking the pre-dried material, and drying the flaked material.
  • Other various aspects are set out in the following set of numbered clauses, in which is described:
  • a tank for steaming and moistening a material comprising: a first end having an inlet, a second end having an outlet and being spaced from the first end to define a tank length, a wall extending from the first end to the second end to define an interior of the tank, a rotating shaft provided in the interior of the tank and comprising a mixing implement to move the material from the first end to the second end, wherein the rotating shaft is aligned substantially parallel to a longitudinal axis that extends from the first end to the second end, and at least one vapor inlet extending through a wall of the tank.
  • Clause 3 The tank of clause 1 or 2 wherein the mixing implement includes a plurality of spikes.
  • Clause 4 The tank of clause 1 , 2, or 3 wherein the at least one vapor inlet comprises a plurality of spaced vapor inlets laterally disposed in the wall of the tank.
  • a system for flaking a raw material comprising: a tank configured to receive the raw material and to impart steam to the raw material to modulate the moisture content of the raw material; optionally, a pre-drier operating at a temperature of 35°C to 75°C and configured to remove moisture from the steamed raw material; a flaking mill configured to flake the material exiting the tank to provide flaked material having a thickness within a range of 1 mm to 2 mm; and a drier operating at a temperature of 45°C to 65°C and configured to dry the flaked material.
  • the tank is a cylindrical tank comprising: a first end having an inlet to receive the raw material, a second end spaced from the first end to define a tank length and having an outlet; a wall extending from the first end to the second end to define an interior of the tank; a rotating shaft provided in the interior of the tank and comprising a mixing implement to move the raw material from the first end to the second end, wherein the rotating shaft is aligned substantially parallel to a longitudinal axis that extends from the first end to the second end, and at least one vapor inlet that imparts steam to the raw material.
  • Clause 8 The system of clause 6 or 7 further comprising a cleaner configured to remove substances exogenous to the raw material.
  • a method for flaking a raw material comprising: optionally, modulating the moisture content of the raw material so that the moisture content of the raw material is between 6% to 13% by weight; introducing the raw material into an inlet of a cylindrical tank; contacting the raw material with an amount of steam at a predefined temperature effective to achieve an average bulk temperature of the raw material between 70°C to 120°C for a predefined period of time to form a moistened material; flaking the moistened material to produce flaked material.
  • Clause 10 The method according to clause 9 further comprising a drier operating at a temperature of 45°C to 75°C and configured to dry the flaked material so that the moisture content of the dry flaked material is from 0% to 10%.
  • Clause 11 The method according to clause 9 or 10 further comprising a pre-drier downstream of the tank and upstream of the flaker, the pre-drier operating at a temperature of 35°C to 75°C and configured to dry the cooked material prior to flaking.
  • Clause 12 The method according to clause 9, 10, or 11 wherein the steam is applied at a temperature in the range from 110°C to 170°C.
  • Clause 13 The method of clause 9, 10, 11 , or 12 wherein the predefined time is from about 1 minute to about 60 minutes.
  • Clause 14 The method according to clause 9, 10, 11 , 12, or 13 wherein the raw material is selected from beans and special grains.
  • Clause 16 The method according to clause 9, 10, 11 , 12, 13, 14, or 15 wherein the special grains are selected from Job’s tears (may also be known as oixseed, tear grass, coix lacryma-jobi L, and Yi Yi), sorghum, poria cocos, Gorgon fruit, highland barley, kanjac, lotus seed, lilium, and combinations thereof.
  • Job’s tears may also be known as oixseed, tear grass, coix lacryma-jobi L, and Yi Yi
  • sorghum poria cocos
  • Gorgon fruit highland barley
  • kanjac lotus seed
  • lilium and combinations thereof.
  • a cylindrical tank for steaming and moistening a material comprising: a top having an inlet, a bottom spaced from the top to define a tank height and having an outlet; the tank having a continuous internal diameter wherein the tank height is equal to or larger than the internal diameter; a separator valve provided in an interior of the tank that defines a first section and a second section, with the second section downstream of the first section; and, at least one vapor inlet provided in the first section.
  • Clause 18 The tank of clause 17 further comprising at least one rotating spiked shaft provided in the interior of the tank upstream of the outlet.
  • Clause 19 The tank of clause 17 or 18 wherein a ratio of the tank height to the internal diameter is from about 1 : 1 to about 30:1 .
  • Clause 20 The tank of any one of clauses 17 thru 19 wherein the first section has a first volume and the second section has a second volume such that the second volume is about the same as or larger than the first volume.
  • Clause 21 The tank of any one of clauses 17 thru 20 wherein a ratio of the second volume to the first volume is about 1 .1 to about 5:1 .
  • Clause 22 The tank of any one of clauses 17 thru 21 wherein the vapor inlet includes a nozzle disposed within the interior of the tank and having a longitudinal axis substantially parallel with a longitudinal axis of the tank.
  • Clause 23 The tank of any one of clauses 17 thru 22 further comprising at least one vapor inlet provided in a wall of the first section of the tank to emit vapor orthogonally to the longitudinal axis.
  • Clause 24 The tank of clause 23 wherein the at least one vapor inlet includes vapor inlets provided in a wall of the first section of the tank spaced about a periphery of the tank.
  • a system for flaking a raw material comprising: a cleaner configured to remove substances exogenous to the raw material; optionally, a heater effective to modulate the moisture content of the raw material to a level between about 6% to about 11% by weight; a continuous tank configured to impart steam to the raw material and thereafter moisten the steamed raw material; a flaking mill configured to flake the material exiting the tank to provide flaked material having a thickness within a range of about 0.1 mm to about 3 mm; and optionally, a drier operating at a temperature of about 50°C to about 75°C and configured to dry the flaked material.
  • the tank is a cylindrical tank comprising: a top having an inlet to receive the raw material, a bottom spaced from the top to define a tank height and having an outlet; the tank having a continuous internal diameter, wherein the tank height is equal to or larger than the internal diameter; a separator valve provided in an interior of the tank that defines a first section and a second section, with the second section downstream of the first section; and at least one steam vapor inlet that imparts steam to the raw material in the first section.
  • a method for flaking a raw material comprising: optionally modulating the moisture content of the raw material so that the moisture content of the raw material is between about 6% to about 11% by weight; introducing the raw material into a top section of a continuous cylindrical tank having a separator valve disposed in an interior of the tank to define the top section and a bottom section, and thereafter cooking the raw material by contacting the raw material with steam at a predefined temperature effective to achieve an average bulk temperature of the raw material in the top section between about 90°C to about 100°C for a predefined period of time to form a cooked material; introducing the cooked material into the second section by opening the separator valve and thereafter moistening the cooked material for a predefined time and predefined temperature effective to form moistened material; and flaking the moistened material to produce flaked material.
  • Clause 28 The method according to clause 27 further comprising a drier operating at a temperature of about 50°C to about 75°C and configured to dry the flaked material.
  • Clause 29 The method according to clause 27 or 28 wherein the steam is applied at a temperature in the range from about 110°C to about 170°C.
  • Clause 30 The method of any one of clauses 27 thru 29 wherein the predefined time is from about 1 minute to about 60 minutes.
  • Clause 31 The method according to any one of clauses 27 thru 30 wherein during the moistening step, there is no added moisture or heat.
  • Clause 32 The method according to any one of clauses 27 thru 31 wherein the predefined temperature during moistening is from about 50°C to about 85°C.
  • Clause 33 The method according to clause 32 wherein the predefined time during moistening is from about 5 minutes to about 90 minutes.
  • Clause 34 The method according to any one of clauses 27 thru 33 wherein the raw material is selected from beans and special grains.
  • the beans are selected from broad bean or fava bean, tepary bean, runner bean, lima bean, pinto bean, kidney bean, black bean, red bean, green bean, yellow bean, Appaloosa bean, moth bean, adzuki bean, urad bean, mung bean, Bambara bean (ground-bean), ricebean, cowpea, black-eyed pea, yardlong bean, chickpea, garbanzo bean, pea, Indian pea, tuberous pea, lentil, hyacinth bean, soybean, pigeon pea, velvet bean, jack bean, sword bean, lupini bean, and combinations thereof.
  • Clause 36 The method according to any one of clauses 27 thru 34 wherein the special grains are selected from Job’s tears (may also be known as oixseed, tear grass, coix lacryma-jobi L, and Yi Yi), sorghum, poria cocos, Gorgon fruit, highland barley, kanjac, lotus seed, lilium, and combinations thereof.
  • Job’s tears may also be known as oixseed, tear grass, coix lacryma-jobi L, and Yi Yi
  • sorghum poria cocos
  • Gorgon fruit highland barley
  • kanjac lotus seed
  • lilium and combinations thereof.

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  • Life Sciences & Earth Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Nutrition Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Food Science & Technology (AREA)
  • Polymers & Plastics (AREA)
  • Agronomy & Crop Science (AREA)
  • Botany (AREA)
  • Drying Of Solid Materials (AREA)
  • Commercial Cooking Devices (AREA)

Abstract

L'invention concerne un procédé, un système et un appareil pour produire une matière en flocons, consistant à fournir une matière première, nettoyer la matière première, éventuellement moduler la teneur en humidité de la matière première, cuire ou cuire à la vapeur la matière première pour obtenir une matière cuite, éventuellement pré-sécher la matière pour obtenir une matière pré-séchée, floconner la matière pré-séchée, et sécher la matière en flocons. La cuisson est réalisée ou accomplie dans un seul réservoir continu ayant un arbre rotatif horizontal comprenant des mélangeurs de type lame de mélange pour déplacer la matière à travers le réservoir à partir d'une entrée jusqu'à une sortie pendant la cuisson à la vapeur.
PCT/US2021/019212 2020-02-24 2021-02-23 Procédé et appareil de floconnage d'une matière WO2021173536A1 (fr)

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CN202010111194.8 2020-02-24
CN202010111194.8A CN112493409A (zh) 2020-02-24 2020-02-24 用于将材料轧片的方法和装置
CN202011055329.XA CN112515105A (zh) 2020-09-30 2020-09-30 用于将材料轧片的方法和装置
CN202011055329.X 2020-09-30

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Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1998015190A1 (fr) * 1996-10-07 1998-04-16 Sterner Mark H Procede pour la production de lentilles entieres deshydratees
WO2009082679A1 (fr) * 2007-12-21 2009-07-02 Production Systems, L.L.C. Procédé, appareil et produit d'hydratation et de floculation des céréales

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1998015190A1 (fr) * 1996-10-07 1998-04-16 Sterner Mark H Procede pour la production de lentilles entieres deshydratees
WO2009082679A1 (fr) * 2007-12-21 2009-07-02 Production Systems, L.L.C. Procédé, appareil et produit d'hydratation et de floculation des céréales

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