Process for converting raw bagasse into processed bagasse and processed bagasse made accordingly

Abstract

The present disclosure relates to converting bagasse into dietary fiber and dietary fiber made accordingly. Raw bagasse is chopped into bagasse pieces. The chopped bagasse pieces are washed with water. The bagasse pieces are soaked and heated in water to remove wax. The bagasse pieces are treated with hydrogen peroxide. The hydrogen peroxide-treated bagasse pieces are again washed. The washed hydrogen peroxide bagasse pieces are treated with alkali. The alkali-heated bagasse pieces are dried in a multi-stage drying and moisture is removed. The dried bagasse pieces are pulverized. The pulverized bagasse pieces are sieved. Dietary fiber is obtained having size up to 100 microns.

Description

[0001] PROCESS FOR CONVERTING RAW BAGASSE INTO PROCESSED BAGASSE AND PROCESSED BAGASSE MADE ACCORDINGLY

[0002] This application is a divisional application to provisional patent application number 202321070202 which is fully incorporated here.

[0003] FIELD

[0004] This disclosure relates to a process for converting raw bagasse into processed bagasse and processed bagasse made according to the process.

[0005] DEFINITIONS

[0006] As used in the present disclosure, the following terms are generally intended to have the meaning as set forth below, except to the extent that the context in which they are used indicates otherwise.

[0007] Bagasse: The term bagasse will mean fresh sugarcane bagasse obtained from a sugarcane crushing facility. Typically, such a bagasse will have moisture to the extent of about 60%.

[0008] BACKGROUND

[0009] Bagasse obtained from sugarcane crushing contains lignin, cellulosic and hemicellulosic material. Various processes have in tried out for converting this bagasse to make it suitable for biomethanation and into other useful substances. However, because of the toughness of the fiber the bagasse is not useful and is disposed off in landfills. Bagasse is a sustainable product and it has very low impact on an environment.

[0010] There is, therefore, felt a need for having a process for converting bagasse into a useful material, particularly suitable for use in biomethanation, as a dietary fiber and also possibly use as an absorbent material.

[0011] OBJECTS

[0012] Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows: An object of the present discloser is to provide a process for converting bagasse into a useful material, particularly suitable for use as a dietary fiber and also possibly use as an absorbent material.

[0013] Another object is to disclose a process that is an economical green, easy to perform, produces a useful material and does not have any byproduct.

[0014] Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.

[0015] SUMMARY

[0016] The present disclosure relates to a process for converting a raw bagasse into processed bagasse fiber.

[0017] In an aspect, the present disclosure relates to a process for converting a raw bagasse into processed fiber. The process comprises a raw bagasse is chopped into a raw bagasse piece. The chopped bagasse pieces are washed with water. The bagasse pieces are soaked and heated in water to remove the wax from bagasse pieces. The bagasse pieces are treated with hydrogen peroxide. The hydrogen peroxide-treated bagasse pieces are washed. The washed hydrogen peroxide bagasse pieces are treated with an alkali. The treated alkali bagasse pieces are dried in a multi-stage drying and moisture is removed. The dried bagasse pieces are pulverized. The pulverized bagasse pieces are sieved. Dietary fiber is obtained having size up to 100 microns.

[0018] In an embodiment of the present disclosure, the raw bagasse is taken for processing within 12 to 36 hours after it is received from the sugarcane crushing mill.

[0019] In an embodiment of the present disclosure, the bagasse is chopped into pieces in the range of 3cm to 5 cm.

[0020] In an embodiment of the present disclosure, the pieces of chopped raw bagasse is washed with a potable water for about 10 to 25 minutes, the washing is carried out in a main or vessel auxiliary and after washing the washed water is drained.

[0021] In an embodiment of the present disclosure, for removing wax from the chopped bagasse the chopped bagasse is soaked in water and the soaked bagasse is heated at a temperature in the range of 55°C to 65°C, the heated mixture is agitated slowly and after agitation the heated mixture is allowed to stand for 2 hrs and wax is floated on the surface of hot water. The wax is removed by skimming and the hot water is drained out.

[0022] In an embodiment of the present disclosure, the water is drained out after the washing or after the removal of the wax.

[0023] In an embodiment of the present disclosure, the 2% hydrogen peroxide of minimum 85% purity i.e. High-test peroxide (HTP) is added in a ratio of 1:1.5, with respect to the mass of the chopped bagasse, the bagasse hydrogen peroxide mixture is slowly agitated is to depith the chopped bagasse.

[0024] In an embodiment of the present disclosure, the hydrogen peroxide treated bagasse is washed with water with under slow agitation for a period of about 10 minutes and the water is drained and is used for making the hydrogen peroxide solution.

[0025] In an embodiment of the present disclosure, the hydrogen peroxide-treated washed bagasse is treated with 0.1N to 0.15N NaOH [LR grade] , the mass of bagasse to alkali additive was 1:2, the alkali and bagasse mixture is slowly agitated for a period of 30 to 35 minutes and wet washed alkali-treated bagasse is obtained by draining out the alkali liquor.

[0026] In an embodiment of the present disclosure, multi-stage drying comprises a passing the alkali treated bagasse having moisture in the range of 50% to 60% through a sheet making roll press to obtain a sheet of bagasse having moisture in the range of 25% to 30%; chopping the mat into pieces of 1cm to 1.5 cm width; passing the bagasse pieces obtained in step b. through a tunnel dryer to obtain partially dried bagasse pieces having moisture in the range of 10% to 15%; and treating the partially dried bagasse pieces obtain in step c. with dried heated air to remove all moisture from the bagasse pieces.

[0027] In an embodiment of the present disclosure, the bagasse fibers >100 microns are re-fed to the pulverizer for further grinding to obtain as a dietary fiber.

[0028] In an embodiment of the present disclosure, Treated and processed bagasse fibers having size of less than or equal to 100 microns for use as a dietary fiber.

[0029] BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING The present disclosure will now be described with the help of the accompanying drawing, in which:

[0030] Figure 1 illustrates a schematic system of the process of production of processed bagasse in accordance with an embodiment of the present disclosure;

[0031] DETAILED DESCRIPTION

[0032] The present disclosure relates to a method for the production of dietary fiber.

[0033] Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing in Figure (1).

[0034] Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.

[0035] The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units and / or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.

[0036] When an element is referred to as being "mounted on," “engaged to,” "connected to," or "coupled to" another element, it may be directly on, engaged, connected or coupled to the other element. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed elements. The terms first, second, third, etc., should not be construed to limit the scope of the present disclosure as the aforementioned terms may be only used to distinguish one element, component, region, layer or section from another component, region, layer or section. Terms such as first, second, third etc., when used herein do not imply a specific sequence or order unless clearly suggested by the present disclosure.

[0037] Terms such as “inner,” “outer,” "beneath," "below," "lower," "above," "upper," and the like, may be used in the present disclosure to describe relationships between different elements as depicted from the figures.

[0038] Bagasse obtained from sugarcane crushing contains lignin, cellulosic and hemi-cellulosic material. Various processes have in tried out for converting this bagasse to make it suitable for dietary fiber and into other useful substances. However, because of the toughness of the fiber the bagasse is not useful and is disposed off in landfills.

[0039] There is, therefore, felt a need for having a process for converting bagasse into a useful material, particularly suitable for use as a dietary fiber and also possibly use as an absorbent material.

[0040] In accordance with one embodiment of this disclosure, the raw but fresh sugar cane bagasse is taken as raw material. Typically, the bagasse is taken for processing within 12 to 36 hours after it is received from the sugarcane crushing mill. Typically, the bagasse that is taken for treatment according to the process as a moisture content between 50 to 60%. This bagasse may be termed as raw bagasse. In one embodiment according to this disclosure, the raw bagasse is chopped by means of a chopper arrangement to pieces of around 3 cm to 5 cm in length.

[0041] In one embodiment according to this disclosure, the chopped bagasse is washed with potable water for a predetermined time, typically about 15 minutes for removing extraneous matter.

[0042] In one embodiment according to this disclosure, this wash may be carried out in an auxiliary vessel or in the main process vessel.

[0043] In one embodiment according to this disclosure, the wash water obtained after washing, with dirt, is drained out from the base outlet of the process vessel.

[0044] In one embodiment according to this disclosure, the washed chopped bagasse is soaked in potable water. The drained washed chopped bagasse is covered with water in the process vessel. Water is filled to cover the material completely and the material in the vessel is heated, typically using electrical heating.

[0045] In one embodiment according to this disclosure, the material in the process vessel is heated to a temperature in the range of 55°C to 65°C.

[0046] In one embodiment according to this disclosure, the heated material is agitated with the help of an agitator. The typical speed of the agitator is between 10 rpm to 20 rpm. The use of hot water and relatively slow agitation removes wax from the material being processed. The wax floats on the surface. The wax is removed by skimming the surface on the upper part of the vessel. The supernatant liquid is separated using an outlet at the bottom of the vessel.

[0047] In one embodiment according to this disclosure, the water drained out from the bottom outlet of the vessel is collected in an effluent tank and further filtered so that it can be used again for one of the steps of the process including the earlier step of soaking the cut bagasse or washing the bagasse.

[0048] In one embodiment according to this disclosure, the soaked bagasse is treated with hydrogen peroxide. Typically, the hydrogen peroxide is a solution of 2% hydrogen peroxide [Industrial grade]. The hydrogen peroxide is added to the vessel and the mass is agitated. Typically, the mass is agitated at 20 rpm for a period of 30 minutes to 40 minutes in the vessel. This treatment not only helps in depithing of the chopped bagasse and carbohydrate protection but also oxidizes and further any microbes are totally destroyed because of nascent oxygen. The ratio of bagasse to oxidizing agent is maintained at a pre-determined ratio typically 1:1.5. Instead of hydrogen peroxide any other suitable oxidizing agent can be used.

[0049] Following the treatment with hydrogen peroxide, the liquor is removed from the process vessel and a freshwater wash is given to the remaining mass with an agitation speed of 10 rpm to 20 rpm for a period of 10 minutes. The wash liquid is also drained using the bottom outlet.

[0050] The washed mass is treated in the vessel with 0.1N to 0.15N of NaOH in a typical ratio of mass to alkali additive will be 1:2. Instead of NaOH any other suitable alkali may also be used. Typically, the treatment with alkali is done under agitation, typically at a speed of 20 rpm for a period of 30 to 35 minutes. After alkali treatment, the liquor is drained out and the wet mass is taken out of the vessel. The wet mass is approximately 50% to 60%. In one embodiment according to this disclosure, the wet mass is passed through a sheetmaking roll press, typically with a load of 800 kg to 1000 kg.

[0051] In one embodiment according to this disclosure, the treatment in the roll press helps in removing moisture percent in the range of 25 to 30%.

[0052] In one embodiment according to this disclosure, from the roll press, a sheet is formed which is cut to a suitable size. Typically, the mat is cut into pieces of 1cm to 1.5cm in width. These cut pieces of treated bagasse mat have a moisture.

[0053] In one embodiment according to this disclosure, the moisture deficient cut pieces are passed through a dryer. Typically, the dryer is a tunnel drier. The cut pieces are passed using conveyor belts so that the pieces are exposued to dry heat having moisture 10% to 15%.

[0054] In one embodiment according to this disclosure, dehumidified heated air is used typically, at a temperature of 55°C to 60°C which is consistently maintained. This step takes out some more moisture and finally the treated bagasse pieces has 0% to 1% of moisture in it.

[0055] In one embodiment according to this disclosure, the output processed bagasse from drier is fed to a micro-pulveriser in which using asieve of 80 to 100 micron particulate matter of different sizes are obtained.

[0056] In one embodiment according to this disclosure, In one embodiment according to this disclosure, the sieve was able to sieve for 100 microns or less. The sieved product can be used as a dietary fiber.

[0057] In one embodiment according to this disclosure, all contact surfaces are of food-grade steel.

[0058] In one embodiment according to this disclosure, the dietary fiber was tested for its ingredients using the standard method for nutrient testing. The tests conducted were chemical tests, by instruments to identify the elements and microbiological tests. The results of the test are tabled here below in table (A).

[0059] The invention well now be described with an illustrative example and trials which do not anyway restrict the invention.

[0060] Example 1:

[0061] 500 gm of a raw bagasse having a moisture of about 50% was taken for the process. The raw bagasse was chopped into small pieces about 30 to 50 mm length. Further, the chopped bagasse was washed with water for 15 min. The chopped bagasse in the process vessel was heated to a temperature of 60 degrees. The heated bagasse was agitated with the help of an agitator rotated at 20 rpm. After likely the heated bagasse was allowed to stand for 2 hrs. The wax separated from the bagasse floated on the surface of the water, and by skimming the surface the wax was removed, and the excess water was drained from the bottom outlet of the vessel to obtain the wax-deficient soaked bagasse.

[0062] The wax-deficient soaked bagasse was again placed in the process vessel and was treated with 750 ml of 2% hydrogen peroxide and agitated in the process vessel at 20 rpm for 30 minutes to obtain an oxidized bagasse. Freshwater was added to wash the oxidized bagasse. For washing, the vessel was agitated at a speed of 10 rpm for 10 minutes to obtain washed bagasse. The excess water was drained from the vessel. The washed bagasse was then treated with 1 liter of 0.1N NaOH and agitated at a speed of 20 rpm for 30 minutes to obtain alkali- treated bagasse. After alkali treatment, the liquor was drained out to obtain alkali-treated wet bagasse mass. The alkali-treated wet bagasse mass was then passed through a sheet-making roll press with a load of 800 kg to remove moisture and obtain a bagasse sheet. The obtained bagasse sheet was chopped to a suitable size such as 1 mm. The chopped pieces had a moisture of about 25%. The chopped pieces were passed through a tunnel dryer, where heated air at a temperature of 55 °C was used. The dehumidified bagasse pieces had a moisture of about 10%. The dehumidified bagasse pieces were further dried with hot air and pulverized using a micro-pulverizer to obtain pulverized bagasse. The pulverized bagasse was sieved by using a sieve to obtain the dietary fiber up to 100 microns. Fibers remaining on the top of the sieve were returned to the pulverizer.

[0063] This dietary fiber was added to food products for improving their fiber content.

[0064] Trials were conducted by adding the dietary fiber obtained in this process, in wheat flour and meat sausages in which satisfactory results were obtained. The dietary fibers obtained can be added to other food ingredients to retain tissue moisture even in the event of temperature fluctuation.

[0065] Trails were conducted with the fiber produced according to this process as a dietary fiber and their trials are recorded below.

[0066] Trial 1: Thirty subjects who presented with unsatisfactory bowel movements typically had symptoms like constipation and delayed bowel movement. Poor peristalsis and gas(flatulence). Subjects were asked to consume wheat flour Rotis (flat unleavened bread) in which the dietary fiber was added. The subjects were asked to record their bowel movement over a period of 7 days on a scale of 1 to 10 where 1 is the least satisfactory bowel movement and 10 represents the most satisfactory bowel movement. The average bowel movement comments of 30 subjects were recorded after 7 days in table (2)

[0067] Trial 2: The same subjects of trial (1) were now given Rotis in which 20 gm of dietary fiber was added in 1 kg of “Atta” (wheat flour). The dietary fibers had particle size less than 100 microns of which more than 8O%<88 microns, the subjects were again asked to record the satisfaction of bowel movements over a period of 30 days on a daily basis.

[0068] The average comments over 30 days were recorded in Table (3). This clearly shows that the dietary fiber processed according to the present disclosure can be used as a satisfactory dietary fiber. The particle size of the fiber is compatible with wheat flour and its action during bowel movements is because the fiber absorbs water in the gut, giving the bowels a “lubricating” action.

[0069] Trial 3: 20 gm of the dietary fibers produced according to the process disclosed above but having a particle size greater than 100 microns, mainly less than 200 microns was added to the wheat flour. It was found that the dough made from such flour mixed with fiber could not be rolled and therefore the fiber is not suitable for use as a dietary fiber.

[0070] Trial 4: the sausages were made from processed meat (ground meat) and stored in a freezer the temperature of the freezer was made to fluctuate between room temperature up to -20°C over a period of 7 days. When sausages were removed after 7 days they were found to be spongy and the tissue fluids leaked from the product. These sausages had to be discarded and could not be used as a food.

[0071] Trial 5: 30 gm of dietary fiber as per example (1) was added to 1 kg of ground meat and the fiber-containing ground meat was converted into sausages. The sausages were again treated in a freezer under fluctuating temperature as in trial (4). The sausages were taken out and it was seen that there was no leakage of tissue fluid outside the product and sausages were not spongy and could be consumed satisfactorily. Therefore, one possible reason for this, the fiber according to this disclosure is able to absorb and retain fluid in the product. Trial 6: 30 gm of dietary fiber greater than 100 microns but less than 200 microns was added to 1 kg of ground meat. The ground meat could not be converted to sausages.

[0072] Hence, fiber greater than 100 microns is not suitable for use as a dietary fiber.

[0073] TECHNICAL ADVANCEMENTS

[0074] The present disclosure described herein above has several technical advantages including, but not limited to, the realization of a process for converting bagasse into processed bagasse, that:

[0075] • can be suitable for use as a dietary fiber;

[0076] • can be used as an absorbent material; and

[0077] • is an economical green process for producing processed bagasse, easy to perform, produces a useful material, and does not have any byproduct; and

[0078] • can be used as a dietary fiber or as an absorbent.

[0079] The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.

[0080] The foregoing description of the specific embodiments so fully reveals the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and / or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.

[0081] The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.

[0082] Any discussion of documents, acts, materials, devices, articles, or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.

[0083] The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher / lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.

[0084] While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.

Claims

CLAIMS:

1. A process for converting bagasse into dietary fiber and dietary fiber made accordingly, said process comprising a following step: i. chopping the raw bagasse into raw bagasse pieces; ii. washing the chopped bagasse pieces; iii. soaking and heating the washed bagasse pieces to remove wax from the bagasse pieces; iv. treating the bagasse pieces with hydrogen peroxide; v. washing the hydrogen peroxide-treated bagasse pieces; vi. treating the washed hydrogen peroxide treated bagasse pieces with alkali; vii. multi-stage drying of the alkali-treated bagasse pieces to remove the moisture from the bagasse pieces and obtained dried treated bagasse pieces; and viii. pulverizing the dried bagasse pieces and sieving the pulverized bagasse pieces to obtain dietary fiber having size up to 100 microns;2. The process as claimed in claim 1, in which the raw bagasse is taken for processing within 12 to 36 hours after it is received from the sugarcane crushing mill.

3. The process as claimed in claim 1, in which in step (i) the bagasse is chopped to pieces of 3cm to 5 cm.

4. The process as claimed in claim 1, in which wherein in step (ii) washing is carried out with potable water for about 10 to 25 minutes, the washing is carried out in a main or vessel auxiliary and after washing the washed water is drained.

5. The process as claimed in claim 1, in which in step (iii) for removing wax from the chopped bagasse the chopped bagasse is soaked in water and the soaked bagasse is heated in the temperature in the range of 55°C to 65°C, the heated mixture is agitated slowly and after agitation the heated mixture is allowed to stand to unable wax to float on the surface of the hot water, the wax is removed by skimming and the hot water is drained out.

6. The process as claimed in claim 5, in which the water drained out in step (iii) is reused after filtration in either step (i) and / or step (iii) of the process.

7. The process as claimed in claim 1, in which in step (iv) the hydrogen peroxide is a 2% solution of hydrogen peroxide, and is added in a ratio of 1:1.5, with respect to the mass of the chopped bagasse, the bagasse hydrogen peroxide mixture is slowly agitating is to depith the chopped bagasse.

8. The process as claimed in claim 1, in which in step (v) the hydrogen peroxide treated bagasse is washed with water with under slow agitation for a period of about 10 minute and the water is drained and is used for making the hydrogen peroxide solution.

9. The process as claimed in claim 1, in which in step (vi) in which the hydrogen peroxide treated washed bagasse is treated with 0.1N to 0.15N NaOH, the mass of bagasse to alkali additive is 1:2, the alkali and bagasse mixture is slowly agitated for a period of 30 to 35 minutes and wet washed alkali treated bagasse is obtained by draining out the alkali liquor.

10. The process as claimed in claim 1, in which in step (vii) the multi-stage drying comprises: a. passing the alkali treated bagasse having moisture in the range of 50% to 60% through a sheet making roll press to obtain a sheet of bagasse having moisture in the range of 25% to 30%; b. chopping the mat into pieces of 1cm to 1.5 cm width; c. passing the bagasse pieces obtained in step (b). through a tunnel dryer to obtain partially dried bagasse pieces having moisture in the range of 10% to 15%; and d. treating the partially dried bagasse pieces obtain in step (c). with dry heated air to remove all moisture from the bagasse pieces11. The process as claimed in claim 1, in which in step (viii) the bagasse fibers >100 microns are re -fed to the pulverizer for further grinding to obtain dietary fiber.

12. Treated and processed bagasse fibers having size of less than or equal to 100 microns for use as dietary fiber.

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