Sheepskin and sheep hoof co-production collagen peptide graded degreasing gradient control double enzyme cutting system

Abstract

This invention belongs to the field of bioengineering equipment technology, specifically relating to a graded degreasing and gradient-controlled dual-enzyme digestion system for the co-production of collagen peptides from sheepskin and hooves. The system comprises a graded degreasing module and a gradient-controlled dual-enzyme digestion module connected in sequence. The graded degreasing module consists of a first-stage physical degreasing machine with a built-in ultrasonic generator and centrifugal drum, connected in series with a second-stage chemical degreasing tank equipped with a heating jacket, specifically addressing the problem of significant differences in fat distribution and incomplete degreasing in the mixed raw materials of sheepskin and hooves. The gradient-controlled dual-enzyme digestion module consists of a first-stage acidic enzymatic hydrolysis vessel and a second-stage neutral enzymatic hydrolysis vessel equipped with a variable-frequency temperature control jacket and an online pH monitoring device. Gradual temperature programming is achieved through a central PLC control cabinet, ensuring that different proteases are always at near-optimal catalytic temperatures. This system achieves efficient co-production of sheep-derived by-products, significantly improving degreasing thoroughness, collagen peptide conversion rate, and the proportion of small-molecule active peptides, making it suitable for continuous industrial production.

Description

Technical Field

[0001] This invention belongs to the technical field of bioengineering and deep processing equipment for animal by-products, specifically relating to a system for producing collagen peptides using sheepskin and sheep hooves, particularly a collagen peptide production system with graded defatting and gradient temperature-controlled dual enzymatic digestion functions. Background Technology

[0002] Collagen is the most abundant and widely distributed functional protein in mammals. Collagen peptides are small-molecule polypeptides obtained by enzymatic hydrolysis of collagen. Due to their small molecular weight, they are easily digested and absorbed by the human body, and possess various biological activities such as improving skin elasticity, enhancing bone strength, and anti-oxidation. They have broad application prospects in functional foods, health products, and biomedicine.

[0003] Sheepskin and hooves are high-volume byproducts of mutton processing. Sheepskin is rich in type I collagen, while hooves contain abundant type I and type III collagen, as well as collagen tripeptides. Using both as co-products for collagen peptide preparation can not only significantly improve the comprehensive utilization rate of sheep byproducts but also enrich the peptide composition of the product and enhance its functional diversity.

[0004] Existing technologies primarily design equipment for single raw materials, neglecting the co-processing of sheepskin and hooves. Furthermore, they suffer from significant shortcomings in areas such as specialized degreasing equipment configuration, dual-enzyme digestion process control, and adaptability for continuous production. In summary, the current collagen extraction equipment field suffers from a fundamental flaw: existing equipment struggles to handle mixed raw materials like sheepskin and hooves, which exhibit vastly different tissue characteristics. Sheepskin's fat is primarily subcutaneous fat, easily separated mechanically; however, hooves contain not only tissue fat but also a large amount of stubborn fat deeply embedded in the bone marrow. Existing single degreasing tanks, when processing such mixed raw materials, either result in incomplete degreasing leading to low efficiency in subsequent enzymatic hydrolysis and a fishy odor in the product, or excessive use of chemical reagents causing collagen denaturation.

[0005] In addition, most existing enzymatic hydrolysis equipment uses constant temperature control, which cannot meet the dynamic temperature requirements of different proteases at different stages of enzymatic hydrolysis, resulting in rapid enzyme activity decay and low conversion rate of small molecule active peptides. Summary of the Invention

[0006] The purpose of this invention is to overcome the shortcomings of the prior art and solve the technical problems of incomplete degreasing caused by the large difference in fat distribution in the co-processing of sheepskin and hooves, and low collagen peptide conversion rate caused by isothermal single enzymatic hydrolysis, and to provide a graded degreasing ladder-controlled double enzymatic hydrolysis system for co-processing collagen peptides from sheepskin and hooves.

[0007] The technical solution adopted by the present invention is as follows: The sheepskin and sheep hoof co-production collagen peptide graded defatting gradient-controlled double enzymatic digestion system provided by the present invention includes a graded defatting module and a gradient-controlled double enzymatic digestion module connected in sequence through pipelines.

[0008] The graded degreasing module includes a first-stage physical degreasing machine and a second-stage chemical degreasing tank. The first-stage physical degreasing machine is equipped with a centrifugal degreasing drum and an ultrasonic generator. The second-stage chemical degreasing tank is connected to the outlet of the first-stage physical degreasing machine via a feed pump. The second-stage chemical degreasing tank is equipped with a heating jacket, a stirring device, and a metering pump connected to the degreasing liquid storage tank.

[0009] The gradient temperature-controlled dual-enzyme digestion module includes a primary acidic enzymatic hydrolysis vessel and a secondary neutral enzymatic hydrolysis vessel connected in sequence, as well as a central PLC control cabinet. The primary acidic enzymatic hydrolysis vessel has a first variable frequency temperature control jacket on its outer wall and a first temperature sensor and a first pH online monitoring and adjustment device inside. The secondary neutral enzymatic hydrolysis vessel has a second variable frequency temperature control jacket on its outer wall and a second temperature sensor and a second pH online monitoring and adjustment device inside. The central PLC control cabinet is electrically connected to the first variable frequency temperature control jacket, the first temperature sensor, the first pH online monitoring and adjustment device, the second variable frequency temperature control jacket, the second temperature sensor, and the second pH online monitoring and adjustment device, respectively.

[0010] Preferably, the bottom of the first-stage physical degreasing machine is equipped with an oil drain valve, which is connected to a waste oil collection tank via a pipeline.

[0011] Preferably, the discharge port of the second-stage chemical degreasing tank is also connected to a cleaning device.

[0012] Preferably, the primary acidic enzymatic hydrolysis vessel is further connected to a first enzyme adder, and the secondary neutral enzymatic hydrolysis vessel is further connected to a second enzyme adder.

[0013] Preferably, both the first and second online pH monitoring and adjustment devices include a pH sensor, a micro-metering pump, and a drug storage tank.

[0014] Preferably, both the primary acidic enzymatic hydrolysis vessel and the secondary neutral enzymatic hydrolysis vessel are equipped with anchor-type stirrers and baffles.

[0015] Preferably, the feed end of the grading and degreasing module is connected to a pretreatment module, which includes a washing tank, a hair removal machine, and a coarse crusher connected in sequence.

[0016] Preferably, a homogenization module is connected between the graded defatting module and the gradient temperature-controlled dual enzymatic digestion module, and the homogenization module includes a colloid mill and a homogenizing tank.

[0017] Preferably, the discharge end of the gradient temperature-controlled dual enzyme digestion module is connected to a separation and purification module, which includes a tubular centrifuge, a nanofiltration membrane assembly, and an ion exchange column connected in sequence.

[0018] Preferably, the discharge end of the separation and purification module is connected to a drying and receiving module, which includes a spray drying tower and a receiving hopper.

[0019] Beneficial effects This invention achieves non-obvious technical effects through an innovative combination of hardware structures.

[0020] Firstly, it solves the problem of degreasing mixed raw materials, enabling efficient co-processing of sheepskin and hooves. This system innovatively designs a two-stage degreasing module: "ultrasonic centrifugal physical degreasing + heated chemical saponification degreasing," specifically tailored to the physical characteristics of the mixed sheepskin and hooves. The first-stage physical degreasing machine utilizes ultrasonic cavitation to disrupt the subcutaneous fat cell structure and rapidly separates free oil through centrifugal force. The second-stage chemical degreasing tank uses sodium carbonate under heating conditions to carry out a saponification reaction, removing stubborn fat deep within the bone marrow and tissues of the hooves.

[0021] Secondly, gradient temperature-controlled dual enzymatic digestion can significantly improve the conversion rate of collagen peptides. Addressing the problem of rapid enzyme activity decay caused by isothermal enzymatic digestion in existing technologies, this invention incorporates a primary acidic enzymatic digester and a secondary neutral enzymatic digester equipped with a variable frequency temperature control jacket, temperature sensor, and online pH monitoring and adjustment device. A central PLC control cabinet enables gradient temperature control, ensuring the enzyme remains close to its optimal temperature throughout the catalytic process.

[0022] Thirdly, it boasts a high degree of automation and stable product quality. The central PLC control cabinet performs automated closed-loop control of key process parameters such as temperature and pH, reducing the uncertainty of manual operation and ensuring the consistency of product quality between batches, making it particularly suitable for continuous industrial-scale production. Attached Figure Description

[0023] Figure 1 This is a block diagram of the overall system structure of the present invention.

[0024] Figure 2 This is a schematic diagram of the graded degreasing module structure of the present invention.

[0025] Figure 3 This is a schematic diagram of the gradient temperature-controlled dual enzyme digestion module of the present invention.

[0026] Figure 4 This is a partially enlarged cross-sectional view of the interior of the physical degreasing machine of the present invention.

[0027] Figure 5 This is a partially enlarged cross-sectional view of the variable frequency temperature control jacket of the enzymatic hydrolysis vessel of the present invention.

[0028] The components represented by each number in the attached diagram are listed below: 100, Pretreatment module; 101, Washing tank; 102, Hair removal machine; 103, Coarse crusher; 200, Grading and degreasing module; 210, First-stage physical degreasing machine; 211, Centrifugal degreasing drum; 212, Ultrasonic generator; 213, Oil drain valve; 214, Waste oil collection tank; 220, Second-stage chemical degreasing tank; 221, Heating jacket; 222, Stirring device; 223, Degreasing liquid storage tank; 224, Metering pump; 225, Washing device; 300, Homogenizing module; 301, Colloid mill; 302, Homogenizing tank; 400, Gradient temperature controlled dual enzyme digestion module; 410, First-stage acidic enzymatic hydrolysis vessel; 411, First frequency converter. Temperature control jacket; 412, First temperature sensor; 413, First pH online monitoring and adjustment device; 414, First anchor stirrer; 415, First baffle; 416, First enzyme adder; 420, Secondary neutral enzymatic hydrolysis vessel; 421, Second frequency conversion temperature control jacket; 422, Second temperature sensor; 423, Second pH online monitoring and adjustment device; 424, Second anchor stirrer; 425, Second baffle; 426, Second enzyme adder; 430, Central PLC control cabinet; 500, Separation and purification module; 501, Tubular centrifuge; 502, Nanofiltration membrane assembly; 503, Ion exchange column; 600, Drying and collecting module; 601, Spray drying tower; 602, Receiving hopper. Detailed Implementation

[0029] To make the objectives and advantages of this invention clearer, the invention will be specifically described below with reference to embodiments. It should be understood that the following text is only used to describe one or more specific embodiments of the invention and does not strictly limit the scope of protection specifically claimed by the invention.

[0030] like Figures 1 to 5As shown, the sheepskin and hoof co-production collagen peptide graded defatting and gradient temperature-controlled dual-enzyme digestion system includes a graded defatting module 200 and a gradient temperature-controlled dual-enzyme digestion module 400 connected sequentially by pipelines. The graded defatting module 200 includes a first-stage physical defatting machine 210 and a second-stage chemical defatting tank 220. The first-stage physical defatting machine 210 is equipped with a centrifugal defatting drum 211 and an ultrasonic generator 212. The second-stage chemical defatting tank 220 is connected to the outlet of the first-stage physical defatting machine 210 via a feed pump. The second-stage chemical defatting tank 220 is equipped with a heating jacket 221, a stirring device 222, and a metering pump 224 connected to a defatting liquid storage tank 223. The gradient temperature-controlled dual-enzyme digestion module 400 includes a first-stage acidic enzyme connected sequentially. The system includes a primary acidic enzymatic hydrolysis vessel 410, a secondary neutral enzymatic hydrolysis vessel 420, and a central PLC control cabinet 430. The primary acidic enzymatic hydrolysis vessel 410 has a first variable frequency temperature control jacket 411 on its outer wall and a first temperature sensor 412 and a first pH online monitoring and adjustment device 413 inside. The secondary neutral enzymatic hydrolysis vessel 420 has a second variable frequency temperature control jacket 421 on its outer wall and a second temperature sensor 422 and a second pH online monitoring and adjustment device 423 inside. The central PLC control cabinet 430 is electrically connected to the first variable frequency temperature control jacket 411, the first temperature sensor 412, the first pH online monitoring and adjustment device 413, the second variable frequency temperature control jacket 421, the second temperature sensor 422, and the second pH online monitoring and adjustment device 423, respectively.

[0031] As an optional implementation, the bottom of the first-stage physical degreasing machine 210 is equipped with an oil drain valve 213, which is connected to a waste oil collection tank 214 via a pipeline. The outlet of the second-stage chemical degreasing tank 220 is also connected to a cleaning device 225. The first-stage acidic enzymatic hydrolysis vessel 410 is also connected to a first enzyme dosing device 416, and the second-stage neutral enzymatic hydrolysis vessel 420 is also connected to a second enzyme dosing device 426. Both the first and second online pH monitoring and adjustment devices 413 and 423 include a pH sensor, a micro-metering pump, and a reagent storage tank. Both the first-stage acidic enzymatic hydrolysis vessel 410 and the second-stage neutral enzymatic hydrolysis vessel 420 are equipped with anchor-type stirrers and baffles.

[0032] Furthermore, the feed end of the graded degreasing module 200 is connected to a pretreatment module 100, which includes a washing tank 101, a depilator 102, and a coarse crusher 103 connected in sequence. A homogenization module 300 is connected between the graded degreasing module 200 and the gradient temperature-controlled dual-enzyme digestion module 400, which includes a colloid mill 301 and a homogenizing tank 302. The discharge end of the gradient temperature-controlled dual-enzyme digestion module 400 is connected to a separation and purification module 500, which includes a tubular centrifuge 501, a nanofiltration membrane module 502, and an ion exchange column 503 connected in sequence. The discharge end of the separation and purification module 500 is connected to a drying and receiving module 600, which includes a spray drying tower 601 and a receiving hopper 602.

[0033] Using the above structure, in actual production, fresh sheepskin and sheep hooves are mixed in a certain proportion and then fed into the pretreatment module 100. The raw materials are first soaked and cleaned in the washing tank 101 to remove surface dirt and bloodstains. The cleaned sheepskin enters the dehairing machine 102 to remove hair, while the sheep hooves have their hoof shells removed. The dehaired sheepskin and the deshelled sheep hooves are then fed into the coarse crusher 103, where they are chopped into pieces with a particle size of 5–20 mm.

[0034] The scrap material then enters the graded degreasing module 200. The scrap material first enters the first-stage physical degreasing machine 210, where the ultrasonic generator 212 is activated to use the ultrasonic cavitation effect to destroy the structure of fat cells in the raw material. At the same time, the centrifugal degreasing drum 211 rotates at high speed, throwing out the released large pieces of fat and free oil, which are discharged into the waste oil collection tank 214 through the bottom oil drain valve 213.

[0035] The initially degreased material is pumped into the second-stage chemical degreasing tank 220 via a feed pump. A metering pump 224 pumps sodium carbonate solution into the degreasing solution storage tank 223. A heating jacket 221 maintains the tank temperature at a set temperature, and a stirring device 222 continuously stirs the material for deep saponification degreasing. After degreasing, the material is rinsed multiple times with clean water via a washing device 225.

[0036] After deep degreasing, the material enters the homogenization module 300. The material is first wet-ground in the colloid mill 301, and then enters the homogenization tank 302 where water is added to form a homogenate.

[0037] The homogenate is then pumped into the primary acidic enzymatic digestion vessel 410 of the gradient temperature-controlled dual-enzyme digestion module 400. The central PLC control cabinet 430 initiates the gradient temperature control program, controlling the first frequency conversion temperature control jacket 411 to gradually increase the temperature inside the vessel. The first online pH monitoring and adjustment device 413 stabilizes the pH within the acidic range. The first enzyme adder 416 adds pepsin. The first anchor stirrer 414 stirs the mixture, achieving initial unwinding and long-chain cleavage of the collagen.

[0038] After the primary enzymatic hydrolysis is completed, the feed solution is pumped into the secondary neutral enzymatic hydrolysis vessel 420 via a feed pump. The central PLC control cabinet 430 controls the second variable frequency temperature control jacket 421 to gradually increase the temperature inside the vessel. The second online pH monitoring and adjustment device 423 adjusts the pH to a slightly alkaline neutral range. The second enzyme adder 426 adds a complex alkaline protease. The second anchor-type stirrer 424 stirs the solution, performing deep targeted enzymatic cleavage of the initial enzymatic hydrolysis products.

[0039] After the double enzyme digestion reaction, the solution enters the separation and purification module 500. First, it is centrifuged using a tubular centrifuge 501 to remove unreacted skin and bone residue. The supernatant then enters the nanofiltration membrane module 502 for desalting and molecular weight fractionation of the enzymatic hydrolysate. Subsequently, the filtrate is further purified by passing it through an ion exchange column 503 to remove heavy metal ions and impurity ions.

[0040] Finally, the purified collagen peptide solution enters the spray drying tower 601 of the drying and collection module 600, and is spray dried to obtain a powdered small molecule sheep collagen peptide product, which is collected in the collection bin 602.

[0041] The above description is merely a preferred embodiment of the present invention. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention. All standard parts used in this application can be purchased commercially, and can be customized according to the description and drawings. The specific connection methods of each part all adopt conventional methods such as bolts, rivets, and welding, which are mature technologies in the prior art. The machinery, parts, and equipment all adopt conventional models in the prior art, and this application is mainly used to protect mechanical devices. Structures, devices, and operating methods not specifically described or explained in this invention are implemented according to conventional methods in the art unless otherwise specified or limited.

Claims

1. A graded, defatted, ladder-controlled double-enzyme digestion system for the co-production of collagen peptides from sheepskin and hooves, characterized in that, The system includes a graded degreasing module (200) and a gradient temperature-controlled dual-enzyme digestion module (400) connected sequentially by pipelines. The graded degreasing module (200) includes a first-stage physical degreasing machine (210) and a second-stage chemical degreasing tank (220). The first-stage physical degreasing machine (210) is equipped with a centrifugal degreasing drum (211) and an ultrasonic generator (212). The second-stage chemical degreasing tank (220) is connected to the outlet of the first-stage physical degreasing machine (210) via a feed pump. The second-stage chemical degreasing tank (220) is equipped with a heating jacket (221), a stirring device (222), and a metering pump (224) connected to a degreasing liquid storage tank (223). The gradient temperature-controlled dual-enzyme digestion module (400) includes a first-stage acidic enzymatic hydrolysis vessel (410) and a second-stage neutral enzymatic hydrolysis vessel connected sequentially. The reactor (420) and the central PLC control cabinet (430) are respectively equipped with a first variable frequency temperature control jacket (411) on the outer wall of the first-stage acidic enzymatic hydrolysis reactor (410), and a first temperature sensor (412) and a first pH online monitoring and adjustment device (413) inside the reactor; the second-stage neutral enzymatic hydrolysis reactor (420) is equipped with a second variable frequency temperature control jacket (421) on the outer wall, and a second temperature sensor (422) and a second pH online monitoring and adjustment device (423) inside the reactor; the central PLC control cabinet (430) is electrically connected to the first variable frequency temperature control jacket (411), the first temperature sensor (412), the first pH online monitoring and adjustment device (413), the second variable frequency temperature control jacket (421), the second temperature sensor (422), and the second pH online monitoring and adjustment device (423).

2. The sheepskin and hoof co-production collagen peptide fractionation and defatting system according to claim 1, characterized in that, The bottom of the first-stage physical degreasing machine (210) is provided with an oil drain valve (213), which is connected to the waste oil collection tank (214) through a pipeline.

3. The sheepskin and hoof co-production collagen peptide fractionation and defatting system according to claim 1, characterized in that, The discharge port of the second-stage chemical degreasing tank (220) is also connected to a cleaning device (225).

4. The sheepskin and hoof co-production collagen peptide fractionation and defatting system according to claim 1, characterized in that, The primary acidic enzymatic hydrolysis vessel (410) is also connected to a first enzyme adder (416), and the secondary neutral enzymatic hydrolysis vessel (420) is also connected to a second enzyme adder (426).

5. The sheepskin and hoof co-production collagen peptide grading, defatting, ladder-controlled double enzymatic digestion system according to claim 1, characterized in that, Both the first pH online monitoring and adjustment device (413) and the second pH online monitoring and adjustment device (423) include a pH sensor, a micro metering pump and a drug storage tank.

6. The sheepskin and hoof co-production collagen peptide fractionation and defatting system according to claim 1, characterized in that, Both the primary acidic enzymatic hydrolysis vessel (410) and the secondary neutral enzymatic hydrolysis vessel (420) are equipped with anchor-type stirrers and baffles.

7. The sheepskin and hoof co-production collagen peptide fractionation and defatting system according to any one of claims 1 to 6, characterized in that, The feeding end of the graded degreasing module (200) is connected to a pretreatment module (100), which includes a washing tank (101), a hair removal machine (102), and a coarse crusher (103) connected in sequence.

8. The sheepskin and hoof co-production collagen peptide fractionation and defatting system according to claim 7, characterized in that, A homogenization module (300) is connected between the graded defatting module (200) and the gradient temperature-controlled dual enzyme digestion module (400). The homogenization module (300) includes a colloid mill (301) and a homogenizing tank (302).

9. The sheepskin and hoof co-production collagen peptide grading, defatting, ladder-controlled double enzymatic digestion system according to claim 8, characterized in that, The discharge end of the gradient temperature-controlled dual enzyme digestion module (400) is connected to a separation and purification module (500), which includes a tubular centrifuge (501), a nanofiltration membrane assembly (502), and an ion exchange column (503) connected in sequence.

10. The sheepskin and hoof co-production collagen peptide fractionation and defatting system according to claim 9, characterized in that, The discharge end of the separation and purification module (500) is connected to a drying and receiving module (600), which includes a spray drying tower (601) and a receiving bin (602).

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