Process and systems for the upcycling of pomace at an industrial-scale winery using out of service fermentors

Abstract

A system and process for the bioconversion of pomace derived from wine production into a product for incorporation into food, is operated in whole or in part at an industrial-scale winery. Off-season or decommissioned industrial fermenters are used to conduct an anaerobic microbial fermentation to provide an ethanolic pomace, and a bacterial fermentation to provide an acidic pomace. The acidic pomace is processed to obtain the product in puree and powder forms. The process includes process control points and may optionally include compositional adjustments to obtain the product according to selected specifications. Microbial starters are propagated at the winery to ensure there are available cultures for the fermentations, such as yeast, lactic acid bacteria and acetic acid bacteria. When using acetic acid bacteria, the fermenter is isolated from the wine cellar or a wine cellar area.

Description

[0001] PROCESS AND SYSTEMS FOR THE UPCYCLING OF POMACE AT AN INDUSTRIAL-SCALE WINERY USING OUT OF SERVICE FERMENTORS

[0002] FIELD OF THE INVENTION

[0003] [1] This disclosure pertains to the field of fermenting fruit wine derivatives into useful food products and / or food ingredients using fermentation technology on site at an Industrial-Scale Winery.

[0004] BACKGROUND

[0005] [2] Presented below is background information regarding certain aspects of the present invention as they may relate to technical features referred to in the detailed description, but not necessarily described in detail. The subject matter discussed in this section should not be assumed to be prior art merely as a result of its mention in this section. Similarly, a problem mentioned in this section or associated with the subject matter provided as background should not be assumed to have been previously recognized in the prior art. That is, individual compositions or methods used in the present invention may be described in greater detail in the publications and patents discussed below, which may provide further guidance to those skilled in the art for making or using certain aspects of the present invention as claimed. The discussion below should not be construed as an admission as to the relevance or the prior art effect of the patents or publications described.

[0006] [3] The application incorporates all documents referenced herein.

[0007] [4] The winemaking industry produces millions of tons of leftovers and residues, which represent an ecological and economical waste management issue for the wineries. The leftovers and residues include organic wastes, inorganic wastes, wastewater, and emission of greenhouse gases (CO2, volatile organic compounds, etc.) Due to growing issues around groundwater and soil contamination, wineries send most of it to the landfill or compost, costing the winery fees for bin drop-off, removal, haulage and tipping fees in addition to winery management costs. Addressing these issues in an appropriate manner places a financial burden on most of the wineries, especially the smaller ones.

[0008] [5] The winemaking process generates two major residues, which can potentially be further processed. The major residues from the winemaking process after the de-stemming and crush steps are known as derivatives. Derivatives comprise grape pomace (pomace) and lees. For every two bottles of wine made, typically the equivalent of one bottle of derivatives is produced. Winery derivatives may comprise: a) pomace consisting of grape skin, grape pulp and grape seed derived from varietal grapes, which have been crushed and pressed as part of the winemaking process, and may occasionally include grape petioles; and b) lees consisting mainly of spent wine yeast, tartaric acid, malic acid, lactic acid, grape skin pigment, and grape pulp sediment, which has been separated from the wine after fermentation and again after aging.

[0009] [6] Grape pomace provides substantial nutritional potential for supplements and to fortify food. For example, 15 grams (~1 tbsp.) of powdered derivative may contain up to 900 mg of phenolic compounds, 150 mg of tannins (catechin), 1000 mg of unsaturated fat, 2000 mg of protein, 180 mg of potassium, 120 mg of magnesium, 4 mg of iron, 4% DV of riboflavin, 125% DV of vitamin E and 3% DV of vitamin K).

[0010] [7] In general, wine lees is residue that forms at the bottom of wine fermentation tanks consisting of: 1) first and second-fermentation lees, which are formed during the alcoholic and malolactic fermentations, respectively (herein, lees); 2) during storage or after treatments (herein, first-rack lees); and 3) aging wine lees formed during wine aging in wooden barrels, or collected after the filtration or centrifugation of the wine (herein, second-rack lees). The main characteristics of wine lees are acidic pH (between 3 and 6), a chemical oxygen demand above 30 g / L, potassium levels around 2500 mg / L, and phenolic compounds in amounts up to 1000 mg / L Approximately 30% of red wine lees is protein that is produced from yeast cell wall material, which contains 30-60 % 3-b-D-glucan in dry weight.

[0011] [8] Derivatives are sometimes used in livestock and poultry feed to extend the shelf-life of milk, nutrient-rich dairy by-products, and meat. There is extensive research on the anti-microbial benefits as a replacement for antibiotics for poultry and livestock. There is even research showing that it can cut bovine methane emissions by 30%

[0012] [9] Although there is an identified market for these derivatives, the current processes used to transform derivatives or some fraction thereof into shelf-stable nutrient-rich products creates a carbon footprint, is prohibitively expensive and causes significant loss in the quality in the derivatives.

[0010] The extraction of useful nutrient-rich products from wine derivatives is known in the art. However, most of these processes seek to isolate a specific compound, require multiple steps, and / or require drying the product into a powder that can be easily sold in capsule, tablet, powder form, etc. Drying the product and / or using chemical processes to isolate nutrient-rich products therefrom can diminish the bioavailability of the biomolecules desired in the final nutrient-rich products. Extraction of a component also inherently leaves a disposal residue, as opposed to the complete utilization of pomace by upcycling. Current common byproducts of wine production include: cream of tartar (potassium bitartrate), grape seed oil, grappa, and food colouring.

[0013]

[0011] It is widely recognized that the nutrient value of many foods has been diminishing since at least the 1950’s, such that a need has developed for cost effective strategies to fortifying foods in the food supply.

[0014]

[0012] There is tremendous potential value in monetizing these derivatives. One key issue today is economics; finding a cost-effective way to process derivatives in an ecological manner, without losing flavour and nutritional value. Patent publication WO 2024 / 065962 provides a commercial process for collecting pomace leftover from the wine making process at a winery and transporting it to a pomace processing facility. This, however, is a capital intensive approach to processing pomace to create products that can be incorporated into food. While this publication also mentions the possibility of using a winery’s fermenters during the off-season, no details are provided regarding how to achieve this on an industrial scale.

[0015] SUMMARY OF THE INVENTION

[0016]

[0013] The invention relates to the industrial scape processing of pomace derived from wine production at an Industrial-Scale Winery, using out of service fermenters of the winery adapted for use to ferment the pomace. The fermentation and further processing of the pomace results in a product for incorporation in into food.

[0017]

[0014] In one aspect there is provided a system for the bioconversion of pomace derived from grape wine production at an industrial-scale winery, comprising: a) a holding container for receiving and optionally storing pomace at the industrial-scale winery; b) a first industrial-scale winery fermenter located at the industrial-scale winery, not in use for winemaking, configured for use to anaerobically ferment the pomace to provide an ethanolic pomace, and, optionally, an acidic pomace derived from the further anaerobic fermentation of the ethanolic pomace; c) an optional second industrial-scale winery fermenter, not in use for winemaking, isolated from a wine cellar or wine cellar area and configured for use to aerobically ferment the ethanolic pomace to provide the acidic pomace; d) an industrial-scale material transfer subsystem for moving pomace through the system to carry out the bioconversion of the pomace; e) one or more propagation tanks for propagating sufficient microbial populations, as needed, to conduct fermentations in the first and optional second industrial-scale fermenters; and f) one or more monitoring means for managing one or more selected process control point (PCP) tests during the operation of the system to carry out the bioconversion of the pomace into the acidic pomace that can be further processed into a product for incorporation into food.

[0018]

[0015] In another aspect there is provided a method of building a system for the bioconversion of pomace derived from fruit wine production at an industrial-scale winery, comprising the steps of: a) designating a holding container at the industrial-scale winery for receiving and optionally storing pomace at industrial-scale winery; b) configuring a first industrial-scale winery fermenter located at the industrial-scale winery, not in use for winemaking, for use to anaerobically ferment the pomace to provide an ethanolic pomace and, optionally, an acidic pomace derived from the further anaerobic fermentation of the ethanolic pomace; c) optionally, configuring a second industrial-scale winery fermenter, not in use for winemaking and isolated from a wine cellar or wine cellar area, for use to aerobically ferment the ethanolic pomace to provide an acidic pomace; d) configuring an industrial-scale material transfer subsystem using equipment at the industrial-scale winery for moving pomace through the system to carry out the bioconversion of the pomace; d) designating, or incorporating one or more propagation tanks at the industrial-scale winery for propagating sufficient microbial populations, as needed, to conduct fermentations in the first and optional second industrial-scale fermenters; and e) optionally, configuring one or more monitoring means as a monitoring subsystem for managing one or more selected process control point (PCP) tests during the operation of the system to carry out the bioconversion of the pomace into the acidic pomace that can be further processed to provide a product for incorporation into food.

[0019]

[0016] In yet a further aspect there is provided an industrial-scale process for the bioconversion of pomace derived from grape wine production into a nutrient-rich product, comprising the steps of: a) receiving or collecting the pomace at an industrial-scale winery; b) conducting one or more PCP tests to accept or reject the pomace for processing; c) using an industrial-scale material transfer system to move accepted pomace to a holding container and to one or more industrialscale fermenters if any one of the one or more fermenters required to process the pomace is not the holding container; d) optionally, stabilizing and storing the pomace in the holding container, or in a first industrial-scale fermenter, not in use for winemaking, located at the industrial-scale winery for a period of time prior to fermenting the pomace; e) propagating in a propagating tank at the industrial-scale winery, an anaerobic microbial culture, if there is insufficient yeast in the pomace, to inoculate the pomace with the anaerobic microbial culture; f) fermenting the pomace in the first industrial-scale fermenter with the yeast in the pomace and supplementing with the anaerobic microbial culture, as needed, to provide an ethanolic pomace; g) propagating a bacterial culture and inoculating the ethanolic pomace with the bacterial microbial culture; h) fermenting the ethanolic pomace inoculated with the bacterial culture to provide an acidic pomace in the first industrial-scale fermenter, or in a second industrial- scale fermenter outside of the wine cellar or wine cellar area by transferring the ethanolic pomace from the first industrialscale fermenter to the second industrial-scale fermenter prior to inoculating the ethanolic pomace; i) processing the acidic pomace to generate a raw puree; and j) conducting one or more selected process control point (PCP) tests throughout the process to ensure the raw puree meets selected specifications.

[0020]

[0017] In embodiments, the holding container is also the first industrial-scale fermenter. In other embodiments, the first industrial-scale fermenter is isolated from the wine cellar or wine cellar area and also configured for use to aerobically ferment the ethanolic pomace to provide the acidic pomace. In yet other embodiments, the first industrial-scale fermenter is used to perform one or more of a yeast fermentation, a lactic acid fermentation and a acetic acid fermentation. In further embodiments, the optional second industrial fermenter is used to perform an acetic acid fermentation. In related embodiments, the optional second industrial-scale fermenter is located off-site of the industrial-scale winery. In still other embodiments, the system further comprises a grinding means to process the acidic pomace and provide a raw puree.

[0021]

[0018] In embodiments, the system further comprises a processing means to process the acidic pomace and provide a raw puree. In other embodiments, the system further comprises a processing subsystem to process the raw puree into the product.

[0022]

[0019] In embodiments, the first and second industrial-scale winery fermenters are industrial red wine fermenters. In other embodiments, the first industrial-scale winery fermenter is configured for performing anaerobic and aerobic fermentations of pomace. In still other embodiments, one or more additional system components is portable.

[0023]

[0020] In embodiments, the pomace is a Kosher pomace. In other embodiments, the acidic pomace has a titratable acidity between 2.2-5% as well as including all titratable acidity ranges and specific values within the 2.2-5% range.

[0024] BRIEF DESCRIPTION OF THE FIGURES

[0025]

[0021] Figure 1 is a flow diagram, showing the steps of bio-converting fruit pomace derived from a winery into a packaged product, according to some embodiments.

[0026]

[0022] Figure 2A is a process diagrams, according to some embodiments, showing the technology and steps for making a red wine that are typical for an Industrial-Scale Winery. Figure 2B is a process diagram, according to embodiments, showing the transfer of pomace obtained from red wine and a white wine production processes to a General Process System.

[0027]

[0023] Figure 3 is a process diagram, according to some embodiments, showing the technology and steps for adapting the Industrial-Scale Winery during the off season in order to accomplish the storage and processing of the pomace into a food product. The technology that is from the winery is the fermenter, which is designated as an OS-Fermenter during the off season. The additional technology is portable or mobile when possible to allow for the modular configuring of a General Process System and for the efficient removal or storing away of equipment from the winery, or isolation outside of a wine cellar area for the winery to resume their normal operations during the season of crush / winemaking (production).

[0028]

[0024] Figure 4A is a process diagram, according to some embodiments, showing the steps for how an Industrial-Scale Winery could transfer the pomace after all the wine has been extracted back into a fermenter during the “off season,” such that the fermenter is now an OS-Fermenter. FIG. 4A also shows processes for pre-milling and ozonating prior to transfer into the OS- Fermenter and shearing the pomace while in the OS-Fermenter and stored under an inert gas such as nitrogen. FIG. 4B shows the same process but omitting the pre-milling and ozonation steps. The technology that is from the winery is the fermenter, which is designated as an OS- Fermenter during the offseason. The additional technology is portable or mobile when possible to allow for the modular configuring of a General Process System and for the efficient removal or storing away of equipment from the winery or isolation from a wine cellar area for the winery to resume normal operations during the season of crush / winemaking. Conveyor and material transfer equipment, however, may be sourced from the winery.

[0029]

[0025] Figure 5 is a process diagram, according to some embodiments, showing the technology and steps for adapting the Industrial-Scale Winery during the off season in order to accomplish the storage and processing of the pomace into a food product. The technology that is from the winery is the fermenter, which is designated as an OS-Fermenter during the offseason. The additional technology is portable or mobile when possible to allow for the modular configuring of a General Process System and for the efficient removal or storing away of equipment from the winery, or isolation from a wine cellar area for the winery to resume normal operations during the season of crush / winemaking.

[0030]

[0026] Figure 6 is a process diagram, according to some embodiments, showing the steps for an alternate to the FIG. 4 process, wherein in this embodiment, the pomace is not pre-milled prior to transfer into the OS-Fermenter, but it is ozonated prior to transfer into the OS-Fermenter and sheared while in the OS-Fermenter and stored under an inert gas such as nitrogen.

[0031]

[0027] Figure 7A and 7B are process diagrams, according to some embodiments, showing the technology and steps for how the microbial starters could be propagated to the amount required by Industrial-Scale Fermenters. FIG. 7A is an embodiment where the propagation tank has a stirring mechanism / means and FIG. 7B is an embodiment where the propagation tank does not have a stirring mechanism / means.

[0032]

[0028] Figure 8 is a process diagram, according to some embodiments, showing the technology and steps for conducting an initial fermentation using a cocktail of microbials (yeast and LAB) on the pomace located in an OS-Fermenter.

[0033]

[0029] Figure 9 is a process diagram, according to some embodiments, showing the technology and steps for conducting a second fermentation step using an AAB microbial culture to ferment a previous anaerobically fermented pomace (e.g. using yeast or yeast / LAB cocktail).

[0034]

[0030] Figure 10 is a process diagram, according to some embodiments, showing the technology and steps for processing pomace according to embodiments, including an optional Kosher wash step.

[0035]

[0031] Figure 11 shows milled pomace, according to some embodiments.

[0036]

[0032] Figures 12A and 12B show the Specification Sheet of a Red Grape Puree, according to an embodiment.

[0033] Figures 13A and 13B show the Specification Sheet of a Gold Grape Powder, according to an embodiment.

[0037]

[0034] Figures 14A and 14B are alternative process diagrams, according to some embodiments, showing steps for pomace receipt and fermentation for Kosher Certification. FIG. 14A illustrates a Kosherization process whereby a Rabbi is involved at one or more points in the process to initiate, inspect and supervise the General Process according to embodiments. FIG. 14B illustrates a Kosherization process incorporating a pomace washing subsystem.

[0038]

[0035] Figures 15A, 15B and 15C are flow diagrams showing in more detail, the steps of bioconverting fruit pomace into a product, according to an embodiment.

[0039]

[0036] Figures 16A, 16B and 16C are flow diagrams showing in more detail, the steps of bioconverting fruit pomace into a product with Kosher Certification, according to an embodiment.

[0040]

[0037] Figures 17A, 17B and 17C are illustrations of one-tank fermentation configurations according to embodiments where all of the anaerobic and aerobic fermentations of the General Process can be done using one (i.e. the same) OS-Fermenter. The pomace could also be stored in the same OS-Fermenter according to related embodiments. FIG. 17A illustrates a Yeast-LAB Pathway, FIG. 17B illustrates a Yeast-AAB Pathway and FIG. 17C illustrates Yeast-LAB-AAB Pathway.

[0041]

[0038] Figure 18 is a summary of various intermediate and final product benchmarks and KPIs for the industrial processing of pomace to the final (merchantable) consumer) product, according to embodiments.

[0042]

[0039] Figures 19A-19H illustrates various configurations of holding (storage) containers and OS-Fermenters relative to winery environment (facility) and relative to a wine cellar and areas thereof. FIGs. 19A, 19D and 19E illustrate an OS-Fermenter for aerobic fermentation is outside of the wine cellar. FIG. 19F illustrates an OS-Fermenter for aerobic fermentation off-site of the winery. FIGs. 19B, 19C, 19G and 19H illustrate how areas of a wine cellar can be isolated so that an OS-Fermenter for aerobic fermentation can be operated in an area outside of the wine cellar area that may be used for wine production. Various configurations for storing pomace are also illustrated, including inside (FIGs. 19A-19E, 19F, 19H) and outside (FIGs. 19E, 19G) of a wine cellar area and in the same vessel that functions as an OS-Fermenter (FIGs. 19C, 19D).

[0043]

[0040] Figures 20A and 20B show a Specification Sheet of a Gold Grape Puree, according to an embodiment.

[0041] Figures 21A and 21B show an alternative Specification Sheet of a Red Grape Puree, according to an embodiment.

[0044]

[0042] Figures 22A and 22B show an alternative Specification Sheet of a Gold Grape Powder, according to an embodiment.

[0045] DETAILED DESCRIPTION

[0046]

[0043] All publications and patents mentioned herein are hereby incorporated herein by reference for the purpose of describing and disclosing, for example, the constructs and methodologies that are described in the publications which might be used in connection with the presently described invention. The publications discussed above and throughout the text are provided solely for their disclosure prior to the filing date of the present application. Nothing herein is to be construed as an admission that the inventors are not entitled to antedate such disclosure by virtue of prior invention.

[0047]

[0044] The description set forth below in combination with the appended drawings is intended as a description of various embodiments of the described subject matter and is not necessarily intended to represent the only embodiment(s).

[0048]

[0045] Features in the figures are given a feature number. When the same feature appears multiple times in a single figure the feature number a letter is also included with the feature number so as to distinguish multiple instances of a feature and its role within a process or system diagram. For example, there may be multiple pumps in a system diagram. Different types of pumps, e.g. water, centrifugal or must pumps will each have their unique numerical feature number and if there are multiple water pumps, each of these will have the same numerical feature number and a letter to distinguish them, (see for example, FIGs. 2A, 2B and 3. Additionally, a generalized feature such as a “stabilization means” is given a feature number while embodiments of such a means are also given their uniqure feature number.

[0049]

[0046] In certain instances, the description includes specific details for the purpose of providing an understanding of the described subject matter. However, it will be apparent to those skilled in the art that embodiments may be practiced without these specific details. In some instances, structures and components may be shown in block diagram form in order to avoid obscuring the concepts of the described subject matter. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or the like parts.

[0047] The words and phrases used herein should be understood and interpreted to have a meaning consistent with the understanding of those words and phrases by those skilled in the relevant art. No special definition of a term or phrase, i.e., a definition that is different from the ordinary and customary meaning as understood by those skilled in the art, is intended to be implied by consistent usage of the term or phrase herein. To the extent that a term or phrase is intended to have a special meaning, i.e., a meaning other than that understood by skilled artisans, such a special definition is expressly set forth in the specification in a definitional manner that directly and unequivocally provides the special definition for the term or phrase. The technical title for a professional skilled artisan in the technical craft of wine production is “enologisf ’ also spelled oenologist, especially in European contexts.

[0050]

[0048] The term “comprising” means "including but not limited to", unless expressly specified otherwise. When used in the appended claims, in original and amended form, the term "comprising" is intended to be inclusive or open-ended and does not exclude any additional, unrecited element, method, step or material. The term "consisting of' excludes any element, step or material other than those specified in the claim. As used herein, "up to" includes zero, meaning no amount is added in some embodiments.

[0051]

[0049] The term "about" generally refers to a range of numerical values (e.g., + / -1 -3% of the recited value) that one of ordinary skill in the art would consider equivalent to the recited value (e.g., having the same function or result). In some instances, the term "about" includes the values disclosed and may include numerical values that are rounded to the nearest significant figure. Moreover, all numerical ranges herein should be understood to include all integer, whole or fractions, within the range recited.

[0052]

[0050] It should be noted that, as used in the specification, appended claims and abstract, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. That is, unless clearly specified otherwise, as used herein the words "a" and "an" and the like carry the meaning of "one or more" or "at least one." The phrases "at least one," "one or more," "or," and "and / or" are open-ended expressions that can be both conjunctive and disjunctive in operation. For example, each of the expressions "at least one of A, B and C," "at least one of A, B, or C," "one or more of A, B, and C," "one or more of A, B, or C," "A, B, and / or C," and "A, B, or C" can mean A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together. It is also to be noted that the terms "comprising," "including," and "having" can be used interchangeably.

[0053]

[0051] Described herein is a system, methods and processes for converting winery derivatives into nutritionally beneficial food ingredients, products and / or supplements in an ecological manner, and various products which are generated by such system, methods and processes. Integration of this system into a winery assists the winery to manage its previously-considered waste products in an ecological manner, which can optionally provide a novel revenue stream. The system, methods, and processes are used to convert winemaking derivatives into bioactive products comprising antioxidants and other bioactive molecules that reside within the pomace. These products can be used as natural flavour, texture and color enhancers, in addition to nutritional ingredients to fortify processed foods and consumer recipes. They can also be used as health supplements.

[0054]

[0052] It should be appreciated that the disclosed system, methods, and processes, and the resultant products made thereby, could be adapted for wineries producing specific types of fruit wine, other than grape. In some embodiments, the system is integrated with a winery that produces fruit wine other than grape-based wine. In some embodiments, the system is integrated with a winery that produces both grape wine and other specific-type of fruit wine. In some embodiments, the system, processes, nutrient-rich products made thereby and use thereof include the derivatives produced by both the grape winemaking process and the non-grape fruit winemaking process. If a distinction is not made, descriptions pertaining to fruit winemaking are intended to include grape winemaking.

[0055]

[0053] The term “OS-Fermenter” is used to denote a fermenter that is “out of service” and onsite at an Industrial-Scale Winery. In other words, an OS-Fermenter may be a fermenter that can be, but is not being used for winemaking, a fermenter that has been brought on-site to the winery to perform a fermentation step of the General Process, or a fermenter that is off-site of the winery to perform a fermentation step as part of the General Process, and wherein another fermentation step of the General Process is conducted on-site at the winery. For example, an OS-Fermenter may be a fermenter that is not in use for wine making because it is off-season after the grape harvest and the related wine production has ceased, or it may be a fermenter that has been decommissioned within an otherwise active winery, or as part of a fully decommissioned winery facility.

[0054] The term, “pomace” is used to denote pressed fruit residue (e.g., crushed berries), which may include stems, petioles, seeds, skins and some pulp, as well as unfermented juice from fruits including grape juice and other fruits. As appropriate to a context presented in the present disclosure, a reference to “pomace” can also more particularly be understood to be a reference more to grape pomace.

[0056]

[0055] The term “wine cellar” is used to denote an area or areas at a winery where a process of wine production is being actively undertaken, wherein in each area of a wine cellar one or more of the production steps is conducted, such as pressing the fruit, transferring all or part of the pressed fruit content to a wine making fermenter, fermenting the pressed fruit content, and the bottling and storage of wine for aging prior to distribution from the winery for sale. As described herein, if an area is “outside” or “external to” a wine cellar it is to be understood as an area isolated from wine production activities, including without limitation, an area offsite of the winery, a wine production area that is not being used for wine production (e.g. off season when a fruit harvest has been fully processed and no wine production is underway), or a separate area of the winery where wine production activities are not normally conducted. In all cases, an area outside of or external to a wine cellar is an area of a wine cellar isolated in such a way so to prevent any activities in the isolated area from causing cross-contamination or other disruption to the wine production process.

[0057] The Source of the Pomace

[0058]

[0056] The term "fruit wine" as used herein generally refers to a natural fluid (unfermented juice) that is directly extracted or expressed from a fruit and then fermented so that some of the natural sugars in the juice are transformed into ethanol. Thus, the term "fruit wine" as used herein can refer to wine (i.e., grape-derived wine, including red, white, rose, and champagnestyle or sparkling wines), fortified wines (e.g., port or brandy), fruit wines, ciders, perry, or fruit brandy. Accordingly, the fruit wine can be fermented juice from fruit including, but not limited to, grapes, various berries (e.g., blackberry, elderberry, strawberry, blueberry, raspberry, currant (e.g., red currant, black currant, white currant), cranberry, mulberry, seaberry, etc.), apples, pears, cherries, plums, pineapples, rose hips, lychee, bananas cantaloupe, watermelon, mango and less traditional seasonal fruits, such as pumpkins, pomegranates, pumpkin, honeydew, among other sources not explicitly listed herein or combinations thereof. In some embodiments, the fermented fruit juice is wine.

[0057] The present invention is generally illustrated and described herein (for example with reference to the Figures and Example section) as utilising pomace derived as a by-product from the production of grape wine; however, it should be appreciated that the disclosed invention may also utilise (or be adapted for) pomace derived as a by-product from the production of other fruit wines.

[0059]

[0058] Grapes, botanically the berry which grows on the vines of the genus of Vitis plants (including many species such as vinifera, riperia, ruprestris, amurensis, labrusca, berlandieri. Rotundifolia, and interspecific hybrids thereof). Interspecific hybrids impart disease resistance, growth modification, are always used for root stocks, and sometimes used to create direct- bearing disease resistant, winter hardy, hybrid cultivars, especially well-suited to produce organic wines without sprays), and are classified as red or white, but actually range in color from crimson, black, dark blue, yellow, green, orange, and pink. Grapes, which are referred to as white are actually green in color. Phenolic compounds such as anthocyanins and other pigments give rise to the varying shades of purple in red grapes; genetic mutations in the purple grape turn off the production of anthocyanins, resulting in the color of white grapes.

[0060]

[0059] Orange wine is typically produced from white grapes. The colour is from phenolic compounds that are not normally extracted during white wine manufacture and the enhanced astringency of the palate of the wine in not normally present in white wines.

[0061]

[0060] The composition of grape pomace varies according to the strategy used to extract the juice. If a more aggressive extraction is used, there will be lower residual materials in the pomace. On the other hand, some white wines may be produced by “whole cluster press” in which the grapes are not destemmed and thus the pomace contains skin, seeds, pulp, and pedicels. The Phenolic content of grape skin varies with the type of grape, the composition of the soil, climate, etc. For example, petioles are the short stem that holds a berry onto the cluster.

[0062] Some are always present after clusters are de-stemmed, and are always present when grapes are whole cluster pressed, to produce low phenolic white wine. White pomace from a whole cluster press will have higher phenolics than from destemmed berries.

[0063]

[0061] Purple grapes have a higher total phenolic content than white grapes and the color is almost entirely due to the concentration of anthocyanins versus white grapes where the most abundant polyphenols are flavan-3-ols (i.e., catechins). The flesh of grapes from pale to color is dependent upon the anthocyanin content. Some grape seeds, such as muscadine contain about twice the amount of total polyphenol content as their skins.

[0064]

[0062] An enologist extracts the juice from grapes by crushing or pressing the berries during a process known as “crush”. As grape skin varies in color due to the varying composition of phenolic compounds (pigments, tannins, antioxidants, etc.) present in the different varieties of grapes, an enologist will decide how long to leave the grape juice (juice) in the presence of the pressed grape material (skin, flesh and seeds) to extract phenolic compounds from the skins to impart color and flavor to the juice to be fermented. In general, red wines are made by fermenting the juice in the presence of pressed red grapes and white wines are made by fermenting the juice in the absence of pressed grapes, which can be either white or red grapes. For example, some champagnes are made by pressing Pinot noir grapes, which skins are deep red in color and the flesh lacks pigment, to make a sparkling white wine that is slightly colored. There are a number of variations, however, for making wines such as a rose or an “orange wine,” where the winemaker will decide to ferment the juice in the presence of the pressed grape material for a limited amount of time in order to extract a relatively smaller proportion of the phenolic compounds. In some cases, an enologist may add enzymes to assist in releasing some of the compounds from the grape material.

[0065]

[0063] Once the juice (fermented, non-fermented or partially fermented) is separated from the pressed grape material, which is termed “pomace” (or marc), the pomace will range in color, from crimson to dark blue to yellow to pink, etc. The pomace will be transferred from the press / crush station to a transport container for transport to a processing site / location.

[0066]

[0064] An Off-Season Fermenter (OS -Fermenter) can be available to ferment pomace for a number of reasons. One reason, is that the winery has finished its fermentation of wine and now is considered out of season. OS fermenters are always present in a winery post wine fermentation. Industrial-Scale Fermenters in a winery are typically filled to approximately 75% of capacity to provide space for foam or other expanded conditions during fermentation. After fermentation and settling by gravity, wine is removed from sediments and combined into appropriate tanks (a.k.a. cooperage) to be filled and minimize headspace in the receiving tanks. The reduced volume creates empty tanks that can be used for subsequent transfers (racking), blending, or can remain out of service (OS) until the next winery season (crush). Another reason for the availability of OS-Fermenters, is that the entire winery could be temporarily decommissioned (“mothballed”). It may alternatively be the case that part of a winery could be temporarily decommissioned, whereby a number of fermenters are not being used during the normal fermentation season.

[0067] INDUSTRIAL-SCALE BIOCONVERSION PROCESS USING THE OS-FERMENTER

[0068]

[0065] The term Industrial- Scale Winery will be used herein to denote a a large-scale wine production facility that uses advanced technology and equipment to process and manufacture wine on a massive scale. Specifically, Industrial-Scale Wineries require specialized equipment, such as large tanks, pumps, and filtration systems, to handle high volumes of wine. For example, an Industrial-Scale Winery would have permanent dedicated conveyor systems for transporting materials between processing operations, whereas in contrast a commercial-scale winery would tend to use large bins and forklifts to transport the material from one point to another. Industrial- Scale Wineries often employ standardized processes and procedures to ensure consistency and quality across large batches of wine. By contrast, a commercial-scale winery tends to produce a product that is more variable across the years. Thus, their standardised processes and procedures are more directed to maintaining quality than consistency of the product.

[0069]

[0066] Industrial-Scale Wineries can produce hundreds of thousands to millions of gallons of wine per year, making them significantly larger than commercial-sized wineries which tend to produce wine on the order of less than a few hundred thousand gallons / year. Moreover, Industrial-Scale Wineries rely heavily on permanently installed automated machinery and conveyor belts to streamline processes such as grape reception, crushing, fermentation, and bottling. In contrast, commercial-sized wineries tend to utilize portable equipment. The large scale production enables Industrial-Scale Wineries to benefit from continuous processes resulting in economies of scale, reducing costs per unit and increasing efficiency. In contrast, commercial-scale wineries tend to rely on smaller batch processing which renders them more vulnerable to cost fluctuations and also variations in product composition.

[0070]

[0067] Despite the emphasis on efficiency and scale, Industrial-Scale Wineries still prioritize quality control measures to ensure consistent flavor and quality across all batches. This requires a sophisticated and competent in-house laboratory including an HPLC and possibly a GCMS and possibly a MS -GCMS. A commercial-scale winery probably would rely more on sensory evaluation by the enologist and tools such as a Brix refractometer and less frequent chemical testing.

[0068] During or after fermentation, Brix detects the sum total of various components but is no longer an indicator of Brix (sugar) content. For example, ethanol has a refractive index approximately half that of sugar. A must that contains 20% sugar (20 Brix) will produce wine with slightly over 11% alcohol and the final Brix reading will be between 5% and 6%, depending on the final amount of unfermented sugar. In one embodiment, measuring the actual amount of ethanol at an Industrial-Scale Winery can be determined by an ebulliometer.

[0071]

[0069] Industrial-Scale Wineries must comply with strict regulations and standards, including those related to food safety, environmental impact, and labor practices. For example, companies with larger numbers of employees are held to a stricter standard of labor regulations compared to commercial-scale wineries who have a more personal relationship with employees. For example, Industrial-Scale Wineries require significant water resources and must implement effective waste management systems to handle large volumes of wastewater and by-products. For example, Industrial-Scale Wineries would probably treat the waste water to meet a standard that could be used for agricultural irrigation. In contrast, a commercial-scale winery would more typically pre-treat water to a level that would render it acceptable for municipal waste water treatment. General Process and General Process System

[0072]

[0070] The General Process 100 as illustrated in FIG. 1A shows the generalize steps that are performed in the pomace bioconversion process, which may be applied to the pomace that results from fruit winemaking (e.g., grapes), according to some embodiments. It is understood that the General Process 100 is described (including illustrations) herein so as to be implemented in whole or in part at an Industrial-Scale Winery and accordingly encompasses all embodiments thereof as described in the present disclosure and other embodiments thereof that may be readily implemented by one skilled in the art. It is also understood with reference to FIG. IB that the General Process (including all embodiments thereof) are carried out using a General Process System 200 as described (including illustrations) herein. The General Process System 200 is set up in whole or in part at the Industrial-Scale Winery, and encompasses all embodiments thereof as described in the present disclosure and other embodiments thereof that may be readily implemented by one skilled in the art. Accordingly, references to facilities, equipment and subsystems in the description of the General Process can be understood as references to facilities, equipment and subsystems that can be used to set up embodiments of the General Process System. In addition to using fermenters available at an Industrial -Scale Winery, the General Process System may also use certain available conveyors, pumps and piping at the winery to configure a material transfer subsystem to manage material transfer during operation, such as pomace and other material inputs and outputs in and out of the. holding tanks, fermenters and propagation tanks.

[0073]

[0071] The General Process and General Process System can be used to make a product which can be adjusted to result in a number of edible forms. As illustrated herein, the product may for example be in the form of a nutrient-rich puree or a powder. The product may be used in or incorporated into a number of food-related products (some examples of which are described herein). For example, the product can be used as a: flavor enhancer, generally at about 5 % (w / w); as a flavor and texture enhancer. In other use cases, the product can be used generally at about up to or less than approximately 50% (w / w) in meat and dairy analogues, sauces, breads, etc.; as a flavor and texture enhancer up to approximately 90% in some sauces; and as a confection up to approximately 100%, with the addition of sugar, which can be crystalized into a hard candy or combined with a gum such as pectin to make a gummy-candy (e.g., gummy bear).

[0074] Optional Kosher Step

[0075]

[0072] As described below in the section titled “KOSHER CERTIFICATION”, the kosherizing the product of the General Process can be achieved at different stages of the General Process by the involvement of a Rabbi. It is understood that following each step done with the involvement of a Rabbi, it may not be necessary to involve a Rabbi in downstream steps, unless there is a concern that the kosherized material, including the pomace have come into contact with non- kosher materials.

[0076]

[0073] In one embodiment that pomace may be washed before introducing it to the OS- Fermenter in order to render the pomace and therefore the final product able to be certified as Kosher.

[0077]

[0074] In one embodiment, a winery may have access to grapes, such as Concord grapes (used for the production of unfermented grape juice), which have been certified as Kosher, due to having been derived from a Kosher certified vineyard.

[0078]

[0075] In another embodiment, the pomace will be pressed under Kosher conditions by the hand of Rabbi, transferred to a holding container (e.g. OS-Fermenter) that can sealed until the start of fermentation to ensure isolation from non-kosherized pomace. When it is time to begin the processing of the sealed-off pomace, the kosherized pomace is transferred to an OS- Fermenter if not previously stored in one. In another embodiment, the fermentation process may also be initiated by a Rabbi to ensure the Kosher processing of the pomace into a Kosher nutrient-rich product.

[0079]

[0076] The general steps for the bioconversion of pomace according to the present disclosure is described in greater detail below and illustrated in FIGs. 1A and IB:

[0080] Step I: Grind and Prepare and Transfer Pomace to Holding Container

[0081]

[0077] In general, there is minimal preparation or pre-processing of the pomace 102 required prior to transferring pomace to a holding container 103 (which may or may not be an OS- Fermenter 214) other than ensuring that any holding containers / vessels 202 and equipment that will come into contact with the pomace are properly maintained (e.g. serviced and cleaned).

[0082]

[0078] Typically, any steps taken to inspect, store and preserve the integrity of the pomace will be the only steps needed prior to fermentation (see Steps II & III below). The pomace 102 can be stored and fermented according to the present disclosure without pre-milling. The pomace 102, however, may be coarsely sheared prior to, or after transfer to a holding container 202 (which may or may not also be an OS-Fermenter 214) such that a shearing step is done prior to initiating fermentation. A shearing step may, in the alternative, or also be performed after the fermentation(s) of pomace (using a shearing means 219). In this case the shearing may done as part of a shearing and grinding regime to prepare a raw puree for further processing into a consumer product.

[0083]

[0079] If it is desirable, however, to more finely grind and / or fracture seeds in a manner that releases the seed contents comprising phenolics, polyphenolics, lipids and minerals prior to fermentation, there are different technologies known in the art for doing so. These same technologies may be used for the processing of fermented pomace in the latter steps of the General (bioconversion) Process, at Step VIII.

[0084]

[0080] One technology is a mixer grinder, which comprises a screw positioned within a cylindrical elongated housing wherein the screw creates pressure as the pomace is conveyed to the endplate. This pressure forces the material through holes located at the perforated endplate. (This is analogous a meat grinder). One company that manufactures screw grinders is Provisur. Examples of their mixer grinders can be found at:

[0081] One technology is a hammer-mill, which is a device with blades that rotate, possibly at a variable speed, and are capable of fracturing seeds either by impact or cutting. The hammer-mill may have a screen at the exit of the device such that no unbroken seeds will be able to pass through the device. One company that manufactures hammer-mills is Fitzpatrick. Examples of their hammer-mills can be seen on their website: https : / / w. f it Patrick-

[0085]

[0082] One technology is a roll compacter (roller mill), which is a device consisting of one or more adjustable position rollers such that seeds passing under or between the moving rollers are crushed or fractured to enable the contents of the seeds to be released. In one embodiment, two sets of rollers can be used, one an upper set and a lower set where the pomace comprising the seeds is forced to pass between the upper set and the lower set. A variation on this configuration is that only one layer of rollers is used and the pomace comprising seeds is forced to flow between the rollers and the stationary interior of the external surface. One company that manufactures roll compactors is Fitzpatrick-mpt. Examples of their roll compacter can be seen on their website:

[0086] Grinding and / or Fracturing During Transfer

[0087]

[0083] In one embodiment the seeds are ground during transfer of the pomace from the delivery vehicle to the OS-Fermenter. In this embodiment the pomace is transferred from the pomace container used to bring the pomace to the winery via a conveyor to the grinder, wherein the seeds are ground in a manner that will make the pomace easier to pump into the OS-Fermenter.

[0088]

[0084] Technologies appropriate for this process include the hammer mill, the screw grinder, or the roller mill.

[0089]

[0085] The completion of grinding and / or fracturing the seeds can be tracked according to measuring the free lipid content in the ground pomace by biochemical analysis. The process is determined to be complete when the free lipid content remains constant. Another option is to examine the ground pomace microscopically to observe the broken and unbroken seeds. In this embodiment, the process is considered complete when there are no remaining unbroken seeds. The test would be conducted after the pomace exits the grinder and if it fails the test, then the pomace would be pumped back to the incoming pomace stream, using a positive displacement pump such as a flexible vane pump or a progressive cavity pump.

[0086] After being ground and / or fractured to completion pomace can be transferred to the OS- Fermenter by a positive displacement pump.

[0090] Grinding and / or Fracturing After Transfer

[0091]

[0087] In one embodiment, the pomace comprising the seeds will be transferred to the OS- Fermenter and will be ground while in the OS-Fermenter. One example of this embodiment is shown in FIG. 6. In this embodiment, the pomace will be continuously recycled from the bottom of the OS-Fermenter through either a pump-grinder, or as shown in FIG 6 through a must pump and then through a shearing grinder, and returned back into the top of the OS- Fermenter until either biochemical analysis and / or microscopic analysis indicates that the seeds have been appropriately ground to completion. The process is considered adequate when the free lipid content remains constant as assessed biochemically. Alternatively, the process is considered adequate when microscopic analysis indicates that there are no remaining unbroken seeds remaining.

[0092]

[0088] The pomace can optionally be pumped into a grinder in a continuous flow. One could use, for example, a peristaltic pump, a progressive cavity pump, a centrifugal pump, or a flexible impeller pump. A peristaltic pump is a flexible tube with rollers that compress the tube. A progressive cavity pump is a long skinny tube with a screw in the middle. One manufacturer of a progressive cavity pump is North Ridge Pumps and an example of their progressive cavity pump can be viewed at h . Another example of a company that manufactures a progressive cavity pump is NOV (totps: / / www. Their website states that some of the advantages of a progressive cavity pump is that they provide gentle pumping action for solids handling such as moving suspended solids with minimal damage (e.g., diced fruits). They can handle different viscosities including viscous slurries over l,000,000cps (e.g., peanut butter). A flexible impeller pump is a pump with an off- centered cavity in which a series of flexible rubber vanes rotates such that the vanes are alternately compressed and extended while rotating though the open and compressed position of the pump cavity. One example of a company that sells sanitary flexible impeller pumps, which are appropriate for the food industry is Jabsco, which invented the flexible impeller pump over 60 years ago. Jabsco is a subsidiary of Xylem. The website shows an impeller pump:

[0089] One example of a company that manufactures a centrifugal pump is CPE Systems Inc. and an example of their centrifugal pump can be viewed at:

[0093] Step II: Stabilize the Pomace (Preserve its Integrity)

[0094]

[0090] In one embodiment, pomace 102 is stabilized prior to fermentation as an industrial-scale bioconversion process will typically be carried out in batches and, as a result, it may be desirable to store pomace for a period of time prior to commencing the fermentation processes, so that it is readily available to be streamed into the fermentation processes as batches of fermented pomace 220 are streamed into subsequent steps of the General Process 100. This allows for processing continuity and efficiencies that characterize an industrial-scale process.

[0095]

[0091] The pomace 102 may be stored in a container or vessel that seals (e.g. a holding / storage tank) and then transferred to an OS-Fermenter 214, or may be directly stored in the OS- Fermenter 214 to avoid unnecessary additional handling that could compromise the integrity of the pomace 102. In either case, it is necessary to stabilize the the pomace 102 in a container or vessel 202 using one or more stabilization media 204 and a monitoring subsystem 206 (e.g. including a temperature and dissolved oxygen sensors, sampling and equipment for analysing the pomace to monitor the stability of its pH, titrable acidity, Brix and ethanol and data processing means, each of which is understood to be a monitoring means) to preserve its integrity (e.g. to preserve its phenolic content) and to prevent spoilage. Using the monitoring subsystem 206 allows for adjustments to the stabilization approach taken (e.g. by adding additional or alternative stabilization media 204) to preserve the integrity of the pomace 102 while being held or stored prior to fermentation. For example, the detection of a change in the headspace atmosphere above the pomace in a holding container 202 may signal a break in the integrity of the holding container’s seal remedied by fixing the seal and exchanging the gas above the pomace 102 with more inert gas. A change in pomace characteristics may signal potential microbial metabolic activity eroding the integrity of the pomace remedied by adding microbial metabolic blockers or bacteriocins. If the holding / storage container 202 is also an OS-Fermenter 214, the same monitoring subsystem 206 can be configured for monitoring fermentation processes 110 and 114. If the necessary water level above settled pomace drops due to a leak or evaporation this remedied by addressing the breach to the holding container 202 and then topping up the water levels accordingly. It is understood that the monitoring subsystem 206 may be used to carry out one or more of the PCPs 105 illustrated in FIG. 1A and comprises one or more monitoring means for managing one or more selected process control point (PCP) tests during the operation of the system (that can each be implemented independently of being configured as part of a monitoring subsystem) to carry out the bioconversion of the pomace into the acidic pomace that can be further processed into a product for incorporation into food. It is also understood that the generalized labelliing of the PCPs 105 illustrated in FIG. 1 A is in no way intended to suggest that all of the PCPs are the same type of process control point; some PCPs may denote the application of the same type of test measurement protocol and other PCPs may denote the application of different test measurement protocols, depending on selected benchmarks, KPIs and HACCP set for the management and control of the General Process progress and outputs.

[0096]

[0092] Stabilization media 204 that perform various functions can be selected to perform the stabilization step 104. In one embodiment, a short term strategy for suppressing the growth of aerobic microorganisms is to immerse pomace under an approximately equal volume of water (the water being the stabilization medium 204). Quality assurance requires measurement of the dissolved oxygen in the water and calculation of how much oxygen will likely be transferred to the pomace. The inverse relationship between temperature and oxygen solubility is an important part of the calculation. Anaerobic shelf-life depends upon dissolved oxygen transfer and must be determined according to oxygen analysis. When it is time to start grinding and fermenting the pomace, the water can be decanted from the top of the container, because the pomace usually settles to the bottom of the container.

[0097]

[0093] In one embodiment, a strategy for the stabilization of stored pomace is to dry the pomace down to less than 10% moisture in order to comply with Kosher standards. In this instance the stabilization medium 204 is heat. This process is beneficial because the low water activity inhibits microbial spoilage. In this instance, rehydration of the pomace 102 would be done prior to fermentation (see Step III).

[0098]

[0094] In one embodiment, a strategy for stabilization of the stored pomace 102 could entail maintaining an anaerobic surface in a containment headspace using an inert gas such as argon, nitrogen, carbon dioxide or some combination thereof (the gas or gases selected being the stabilization medium) that will displace, remove, or exclude oxygen from a container. FIGs. 4A, 4B, 5 and 6 show the pomace 102 being stored in the OS-Fermenter 214 with the use of nitrogen.

[0099]

[0095] In one embodiment, a strategy for stabilization of the stored pomace could entail the employment of various species of lactic acid bacteria (LAB stabilization medium) in an anaerobic environment to deplete the pomace of microbiologically supportive metabolites. This approach may be considered if it is intended to conduct a fermentation 110 of the pomace 102 in the General Process using (fermentation) microbials 212 comprising LAB as well.

[0100]

[0096] In one embodiment, a strategy for stabilization of the stored pomace 102 could entail the employment of bacteriocins (stabilization medium) to be used to kill and or inhibit susceptible spoilage microorganisms. Bactericins can be deployed either by adding commercially available bacteriocins to the pomace, or by adding one or more bacterioacin-competent bacterial strains. Step III: Optionally Store Pomace until Ready to Ferment

[0101]

[0097] Depending upon which stabilization strategy is employed, the pomace 102 can be stored for a short term (e.g. one month) up until about one year. The storage step 106 is optional and employed dependent on the availability of pomace 102 and desired efficiencies and processing flow using the General Process and General Process System. The water storage strategy could work for a period of time up to about six months , depending upon the temperature of the environment. The drying technology, the inert gas, the LAB and the bacteriocin strategies could work for up to one year, depending upon the temperature of the environment.

[0102]

[0098] If the pomace 102 has been stored in a dry state, it must be re-hydrated to not less than 100% (double the volume) prior to preparing the pomace to be fermented. This can be achieved by soaking the pomace in enough water for 24 to 48 hours. In one embodiment the pomace is soaked for 24 hours, tested for its hydration level and then soaked for an additional 24 hours if required.

[0103] Step IV: Add Microbials and Optional Additives

[0104]

[0099] There are a number of pathways to generate the final fermented pomace 219 which will be at a pH below 4.0 (e.g. between 3.5-4.0), by using a cocktail of microbes 212 to among other things generate and then oxidize ethanol. The microbial cocktails used are prepared using microbial starters 208 propagated in a propagation vessel (tank) 210. At a high level, embodiments of the pathways represent a combination of conducting a fermentation using an anaerobic microbial culture and a fermentation using a bacterial culture (which may be an anaerobic bacterial culture or an aerobic bacterial culture). In an embodiment, the fermentations may be done concurrently if both are anaerobic. In another embodiment the fermentations are done sequentially. The end result of the fermentations is an acidic pomace 219.

[0105]

[0100] Microbial culture material 212 is added to an OS-Fermenter 214 to carry out the following fermentation pathways: 1) a yeast-acetic acid bacteria pathway (Yeast-AAB-Pathway); 2) a yeast-lactic acid bacteria pathway (Yeast-LAB-Pathway) and 3) a yeast- lactic acid bacteria- acetic acid bacteria pathway (Yeast-LAB-AAB Pathway). Each pathway may be implemented using one or more OS-Fermenters 214 to either conduct all fermentations in a single OS- Fermenter 214 for optimal processing efficiency, or the fermentation steps 110 and 114 can be conducted in two or more OS-Fermenters 214 to accommodate processing preferences for the quality of the product output, dependent on an Industrial-Scale Winery’s configuration and layout constraints, so as to ensure wine production at the facility is not compromised.

[0106]

[0101] The manner in which it is determined that the fermentations 110 and 114 have been completed entails monitoring the levels of the substrates and the metabolites produced by the microbials 212 using the monitoring subsystem 206 or by was of independently applied monitoring means. For example the Brix levels will be monitored. The pH will be monitored / tracked (for example as a safety factor), as it can vary because of the composition of the pomace, some of which can buffer the pH. Factors such as the type and amount of minerals present in the pomace, the quality of the water, the temperature can affect the pH. For ease of discussion of the overview of the processes herein, the pH will be referred to as a factor.

[0107] The Yeast-AAB-Pathway

[0108]

[0102] One pathway entails first fermenting the pomace using yeast to generate ethanol and then using AAB to generate the acetic acid which lowers the pH in the pomace to below 4.0, and in one embodiment to between 3.5-4.0. For this pathway, in order to determine whether yeast nutrient must be added to meet the yeast available nitrogen and carbon requirements, the pomace must be tested for these components. Yeast available nitrogen and sugar requirements are tested using techniques which are standard in the winery industry.

[0109]

[0103] In one embodiment of the Yeast-AAB-pathway, the yeast will be added on the surface of the pomace / water mixture at a rate of approximately 1 liter of actively growing yeast culture per 1,000 liters pomace. In one embodiment, the yeast culture will be provided in its entirety. In one embodiment, a starter culture will be sent to the fermentation site and grown in a propagation tank to generate an appropriate amount of actively fermenting yeast. In one embodiment, it is one liter of this culture per 1,000 liters pomace which will be added to the pomace in the OS-Fermenter. In one embodiment, the inoculation will be conducted by adding approximately 200 mg cells / L The Yeast-LAB-Pathway

[0110]

[0104] Another pathway entails first fermenting the pomace using yeast at a scale that grows the number of yeast cells, but minimizes the amount of ethanol, such that after the yeast die, their cells provide nutrients throughout the pomace required by the LAB to lower the pH in the pomace to below 4.0 (Acidic Pomace 219), and in one embodiment to between 3.5 - 4.0.

[0111] Hence, this will be termed the Yeast-LAB-Pathway. Lactic acid bacteria have more complex nutrient requirements than fermentation yeasts and may require completion of a yeast fermentation or nutrient supplementation in order to proceed with LAB fermentation of yeast metabolites due to competition for the same nutrients (e.g. sugars). It is possible, however, to manage microbial growth conditions such that the LAB fermentation is initiated before the yeast fermentation, which tends to proceed at a faster rate than a LAB fermentation if not managed properly. This may be a consideration due to the natural presence of yeasts in pomace without inoculation, especially if the pomace is obtained and fermented immediately after being pressed from harvested grapes.

[0112]

[0105] For the Yeast-LAB-pathway the pomace would initially be tested for amino-nitrogen and sugar content, using tests that are standard in the winery industry. For this pathway where the objective is to grow the yeast, but not produce as much alcohol in contrast to what would be the case if there is to be an AAB fermentation as part of the pathway, the target objectives for these g nutrients would be sufficient to grow the yeast cells to a population of approximately 10 / ml as determined by standard plate counts or direct microscopic examination using, for example, a hemocytometer. In one embodiment, the sugar requirement will be approximately 20 g / liter and the amino-nitrogen requirement will be approximately 1 g / liter.

[0113] Yeast-LAB-AAB Pathway

[0114]

[0106] In one embodiment, as illustrated in FIGS. 8 and 9, one fermentation will be conducted anaerobically in an OS-Fermenter using yeast and LAB concurrently, to generate sufficient alcohol for the AAB conversion into acetic acid in order to teach the target sourness. When fermenting the yeast and the LAB together, according to one embodiment approximately half of the sugar will be converted to lactic acid and half to ethanol. The Brix is monitored and when the Brix levels are stable, then it is determined that half of the sugar has been converted to ethanol and half to lactic acid.

[0115]

[0107] After transfer of the fermented pomace to a fermenter or other appropriate container located outside of the wine cellar, the fermented pomace will be inoculated with AAB and the remaining ethanol will be converted to acetic acid.

[0116] Nutrient Additives

[0117]

[0108] If it is determined that yeast, LAB and or AAB nutrients need to be added to conduct the appropriate fermentation, then commercial nutrients would most likely be used to ensure reproducibility and the process. In one embodiment, first rack lees can be added to supplement available nitrogen and available sugar requirements

[0118] Optional Microbial Propagation and Inoculation Step

[0119]

[0109] Depending on the source and age of the pomace (freshly pressed versus stored for a period of time, there may already be sufficient yeast present to conduct the first anaerobic fermentation step of the General Process. For example, freshly obtained pomace may ferment when sealed in a holding tank, and testing would be done to determine how to ensure that this fermentation is completed to specifications before processing the second fermentation to generate an acidic pomace. In other instances, pomace stabilized to preserve its integrity for storage purposes may require the addition of yeast culture to conduct an anaerobic fermentation and obtain an ethanolic pomace. Additionally, in the case of grape pomace, to conduct any kind of bacterial fermentation it will generally be necessary to inoculate the pomace, whether or not the bacterial fermentation is done concurrently with the anaerobic fermentation (as may or may not be the case using LAB) or sequentially with the anaerobic fermentation (as would be the case using AAB).

[0120] [HO] With reference to embodiments shown in FIGs. 7A and 7B, it may be necessary for the Industrial-Scale Winery to propagate one or more of the microbes required in one or more propagation tanks. In other embodiments there are two or more, three or more or four or more propagation tanks 210. In still other embodiments, a propagation tank 210 may be operatively- associated with, or otherwise used to provide microbials 212 to one or more pomace processing bioreactors (fermenters, i.e. OS-Fermenters 214). In other embodiments, the propagation tanks are off-site of the winery and the microbial cultures for inoculating pomace are delivered to the winery. In still other embodiments, the microbial cultures generated from propagation may be added to the fermenter manually. The sequence and timing for the propagation and inoculation of microbes is managed according to the available propagation equipment, its location and the process progression so that the necessary microbes can be available to inoculate the pomace for the stage of progression of fermentation.

[0121]

[0111] One manufacturer of propagation tanks is Cedarstone Industry. Such tanks can be seen on their website: ht ps: / / cedarstouesnd»sixy. com / prod»ct--category / mixing-xtorage--tanksZmixing--

[0122]

[0112] With reference to FIGs. 7A and 7B in one propagation tank 210, two or more microbial starters 208 may be propagated in a sequence determined according to the growing conditions for a given microbial starter 208 and the efficient implementation of a substantially continuous General Process 100 that is to carried out at an Industrial-Scale Winery (facility). It is be understood that each of the possible microbial starters 208 contemplated herein, namely a yeast starter, a LAB starter and an AAB starter may comprise one or more microbial species selected to perform efficiently during the fermentation steps 110 and 114, to be readily manageable in terms of propagation, in transition between fermentation steps 110 and 114 and to provide for a desired product profile at the end of the General Process 100.

[0123] Step V : Conduct F ermentation

[0124]

[0113] Wherever possible, the yeast and / or anaerobic bacterial fermentation step 110 should be carried out under optimal conditions of temperature and nutrient supply. The OS-Fermenter 214 used can be in or external to a wine cellar of an Industrial -Scale Winerry. Appropriate nutrient content is assessed according to standard methods for yeast available nitrogen (YAN) and optimal fermentation temperature such as 25 degrees Celsius + / 1 five degrees. Typical YAN from pomace plus supplements should be in the range of 200 to 350 mg / L. The monitoring subsystem 206 or independently implemented monitoring means can be used to facilitate the assessment of the progress of fermentation and its completion. In one embodiment, the decision to move from an ethanolic fermentation step 110 to an aerobic fermentation step 114 is a process control decision point that requires testing to determine if the Brix is stable and the conversion of the total sugars content to ethanol is at least 49% on a weight by weight basis.

[0125] Step VI: Optionally Transfer Pomace to an OS-Fermenter External to a Wine Cellar for AAB Fermentation 1

[0114] Configurations for the location of OS-Fermenters 214 used for anaerobic and aerobic fermentation, as well as holding (storage) containers 202 of a General Process System 200 are illustrated in FIGs. 19A-19H. Illustrated are also embodiments where the same vessel is used as a holding (storage) container and OS-Fermenter 202 / 214 (see FIGs. 19C, 19D and 19H). The location of this equipment of a General Process System 200 is delineated with reference to an Industrial-Scale Winery 20, and a wine cellar 15 or wine cellar area 17 isolated from an aerobic fermentation area 16 within the original wine cellar of the facility prior to its adaptation to carry out a General Process 100. OS Fermenters available after wine fermentation, will often not be physically separated from the other tanks in a cellar still producing wine. In order to minimize cross contamination, the such out of service tanks should be physically separated or isolated and sanitation standards can be enhanced (e.g. to 3 A standards as would be known to one skilled in the art) including regular (e.g. daily) surface disinfection and any other steps or mechanisms implemented in order to assure that there is no mixing of winery products with (re)processed pomace intermediates and products.

[0126]

[0115] In embodiments where the Yeast-Pathway or the Yeast-LAB-Pathway are followed, the entire process may be carried out within an OS-Fermenter in a wine cellar 15 (or wine cellar area 17).

[0127]

[0116] It is also contemplated that a single LAB fermentation may be done to obtain an acidic pomace according to the present disclosure.

[0128]

[0117] If the AAB-pathway or the Yeast-LAB-AAB-pathway is to be employed, the yeast fermentation step 110 is conducted in the OS-Fermenter 214 until sufficient ethanol levels have been attained. The yeast cells will grow to a maximum population and maintain that population until they run out of sugar, which is when they will die. Before starting the fermentation, one needs to calculate how much acetic acid or lactic acid it is desired to produce in the aerobic fermentation step 112 using AAB. For example, one needs to provide the exact amount of sugar prior to initiating the anaerobic fermentation 110 knowing that when the yeast cells run out of sugar they will die leaving behind the amount of ethanol needed for the AAB to produce the desired amount of acetic acid and pH for the Acetic Acid Pomace (also referred to generically herein as an Acidic Pomace) and subsequently following shearing, the Raw Puree 220. In an example where yeast and LAB are used, the nutrient supply is managed so that these microbes can work concurrently in a fermentation process. The choice to also conduct an AAB fermentation will depend on the desired specifications for the final product and to ensure that the desired product acidity is achieved for the Acidic Pomace 219 that is sheared to become a Raw Puree 220 and then a final product 225 after further processing by the processing subsystem 224.

[0129]

[0118] In embodiments where the AAB cannot be used within OS-Fermenters 214 located within a wine cellar because there is too great of a risk of contamination by the AAB within the cellar. This would place the normal wine fermentation activities at great risk of crosscontamination resulting in wine spoilage. Thus, the yeast-fermented pomace must be transferred to an OS-Fermenter 214 that is located outside the wine cellar (i.e. essentially in an area in a winery isolated from the area in a winery where wine production is undertaken, including, for example, the fermentation and / or aging process) prior to adding the AAB to the pomace. For example, if an isolated room is used, the room may be vacated, sealed, and all surfaces sanitized by filling the room with an ozone mist. A vacated room may also be disinfected by Ultraviolet light. Makeup air in a room may be disinfected by ultraviolet light in air ducts.

[0130]

[0119] Some wineries have fermenters located within a wine cellar and others located outside a wine cellar, but still on the winery premises. Alternatively, in one embodiment, the starting pomace or partially bioconverted pomace might need to be transferred to OS-Fermenters 214 (repurposed winemaking fermenters) located at another property or facility completely offsite to the winery (step 112). In another embodiment, the AAB fermentation 114 will be conducted in a fermenter that is not a repurposed winemaking fermenter, but another type of fermenter. References to such other types of fermenters herein are also understood to be references to OS- Fermenters 214 if used as part of a General Process 100, as defined herein.

[0131]

[0120] In one embodiment, pomace (partially) processed by fermentation can be removed by using a positive displacement pump to pump it from the bottom drain valve of the red wine fermenter according to the viscosity of the fermented pomace. If the viscosity approximates or is less than the viscosity of a ketchup, then this method can be used.

[0132]

[0121] Alternatively, if the viscosity exceeds that of a ketchup, then the pomace (partially) processed by fermentation could be removed via an outward opening manway located at the bottom of the OS-Fermenter 214. If the floor of the tank is at a 45-degree angle and the manway is opened, the contents of the OS-Fermenter 214 will fall onto the solids conveyor, which can then transport the pomace (partially) processed by fermentation to the applicable next step of the General Process 100.

[0122] In one embodiment, as shown in FIG. 9, the pomace that was partially processed by fermentation 110 in the OS-Fermenter 214 is transferred (pumped via piping) to an appropriate fermenter 214 located outside of the wine cellar (step 112).

[0133] Step VII: Add Acetic Acid Bacteria and Ferment until pH < 4,0

[0134]

[0123] In one embodiment employing the AAB-Pathway, acetic acid bacteria 212 are added to the pomace partially processed by anaerobic fermentation, which is aerated and fermented until the pH lowers to less than 4.0, and in one embodiment to between 3.5-4.0 (step 114). At this point, all of the ethanol should have been consumed by the AAB.

[0135]

[0124] In one embodiment 10-20 liters of AAB per 1,000 liters pomace which will be added to the pomace in the OS-Fermenter, or other type of fermenter. In one embodiment, the inoculation will be conducted by adding approximately 200 mg yeast cells / L. The AAB 212 can be added 114 to the top of the OS-Fermenter 214 or other fermentation tank.

[0136] Aeration Means

[0137]

[0125] The OS-Fermenter or other type of fermenter 214 is provided with means to aerate 216 the fermenting pomace. The objective is to provide sufficient oxygen to force aerobic fermentation and not allow anaerobic fermentation to occur. The rate of fermentation affects the flavor of the finished product.

[0138]

[0126] There are at least two options: 1) pump the fermenting pomace from the bottom drain valve up to the headspace containing air; 2) introduce air through a port located at the bottom of the OS-Fermenter via a wand which is fitted with gas emission nozzles along its length. Another embodiment comprises having gas emission nozzles, which are mounted within the tank at approximately one third of the distance from the bottom to the top (normally used for mixing the must and breaking apart the “cap,” which forms when fermenting red wine on the crushed berries and skins). If this system is combined with pump-over the whole tank would be aerated.

[0139]

[0127] Air normally comprises approximately 20% oxygen. The air located in the headspace of an OS-Fermenter 214 will comprise less than 20% oxygen because the oxygen will be taken up by the AAB during the conversion of ethanol to acetic acid. When the headspace oxygen returns to 20% the reaction should be complete. Terminating the Fermentation Process

[0140]

[0128] The fermentation process is terminated when the levels of acetic acid and / or / lactic acid reach a pre-determined composition within the bioreactor (OS-Fermenter 214) vessel. One fermentation termination means 218 is by sealing the bioreactor vessel in a manner such that no oxygen can enter the bioreactor vessel. In one embodiment, the process is terminated by using a sparger 218 for (additionally) sparging with nitrogen, argon, carbon dioxide or a combination thereof.

[0141] Step VIII: Process for Consumer Use

[0142]

[0129] When the AAB or the LAB fermentation is considered complete the fermented pomace is an Acidic Pomace 219 that may be sheared to provide a Raw Puree 220 will be transferred out of the OS-Fermenter or other fermenter 214 to transfer appropriate container (holding tank or hopper) 222 for transfer to a further processing area or facility off-site of the winery to produce the final (merchantable) consumer product (step 118). In embodiments, part of the further processing of Raw Puree 220 is conducted at the winery. In other embodiments, all of the further processing is conducted as a facility separate from the winery. The further processing of Raw Puree 220 is done as needed using one or more processing mechanisms of a processing subsystem 224 as further described below. An exemplary processing subsystem including hypershearing, pasteurization (heat treatment) for processing into powder and puree products is shown in FIG. 10. Other embodiments of processing subsystems are illustrated in FIGs. 15C and 16C.

[0143]

[0130] The next step, according to one embodiment is to fine grind (e.g. 80 mesh) the fermented pomace. The particle size to be created from grinding must match or exceed standards according to the food product in which the pomace product will be incorporated.

[0144]

[0131] This step can be done at the winery or the pomace can be transferred to a processing facility and conduct the fine grind there. The fermented pomace can be fine ground either wet or dry. There are a number of commercially available grinders that may be used, including a hammer mill, a colloid mill, a roller mill, or for dry material, a flour mill (see below).

[0145]

[0132] One embodiment for conducting the fine grind at the winery is to remove the fermented pomace from the OS-Fermenter using a positive displacement pump through a grinder such as a hammer mill and transfer the ground pomace to a clean tank or an appropriate container for transfer to the further processing site.

[0133] One embodiment for conducting the fine grind at a processing facility would entail removal of the fermented pomace from the OS-Fermenter by pumping from the drain valve located at the bottom of the OS-Fermenter an appropriate container for transfer to the further processing site. When at the processing site, the fermented pomace could be transferred from the transfer container using a positive displacement pump through a grinder such as a hammer mill and transfer the ground pomace to a clean tank.

[0146]

[0134] Alternatively, if the fermented pomace is to be dried, which would most likely occur at a third party drying facility, the transport container containing the fermented pomace would be delivered to the third party drying facility. The pomace would be dried according the preferred method (See below for examples of some appropriate drying technologies). Once dried the dried fermented pomace could be ground using a grinder such as a flour mill (see below).

[0147]

[0135] There are multiple options for the particular adjustments (e.g. with optional additives) that can be made to the pomace as it is being converted throughout the process, wherein the objective is to transform a variable fruit biomass generated during the process of winemaking with an initial biochemical composition to a “final” product 225 with a commercially specified biochemical composition (standardized output) in a stepwise targeted process optimized manner, in order to meet commercial specifications for a product, while maintaining appropriate sanitary conditions (e.g., cGMP)

[0148] Adjust to Commercial Specifications

[0149]

[0136] There are a number of possible adjustments that can be performed at this stage in order to bring the characteristics of the commuted, fermented pomace in line with commercial specifications and / or desired characteristics. Ingredients can be combined with the ground, fermented pomace in order to refine it in a manner to conform to commercial specifications.

[0150] (Note that in general, it would be preferable to make adjustments by blending, but if that cannot be accomplished, then this could be done by adding ingredients).

[0151]

[0137] One method for changing the flavor is changing the acidity and the astringency. Changing the acidity simply involves adding acid to it to make the fermented product more sour (acidity equates to sourness). Astringency relates to the phenolic compounds; to change astringency, one can add phenolics - or one could lower phenolics by using a fining agent such as gelatin or the vegan approach of using pea protein to bind some of the phenolics (protein-tannin binding) - a proteinaceous binding agent.

[0138] The material may be analyzed for pH, concentration of phenolics, color, acetic acid content, and / or other organic acids, optimized ratio of protein / phenolics, depending on the nature of the protein. It may be desirable to adjust the pH, for example by adding acetic acid.

[0152]

[0139] In some embodiments, non-fermented comminuted pomace can be added and blended in order to achieve target composition: polyphenolics, lactic acid and malic acid profile. It may also be desirable to blend the finely ground fermented pomace with another finely ground fermented pomace (e.g., 80 mesh finely ground pomace).

[0153]

[0140] In some embodiments, it may be appropriate to apply product specific processing to conduct a controlled Maillard reaction. For example, if the product objective is to prepare a sauce such as a Worcestershire sauce, soy sauce, chocolate, or coffee, for example.

[0154] Prepare for Packaging

[0155]

[0141] In order to prepare the product for packaging, it may be desirable to terminate the microbes using a process that minimizes damage to the phenolics.

[0156]

[0142] There are applications for both a pasteurized puree (with no bioactive materials) and a probiotic puree. High-pressure pasteurization technology may optionally be used to create a pasteurized nutrient-rich product, although other current or future heat-treatment / pasteurization techniques may be employed. The bioactive puree will have been fermented to an approved pH level for sealed storage at room temperature, refrigerated temperature, and / or frozen.

[0157]

[0143] In some embodiments, it may be desirable to change the state of the product from a slurry to a paste or a powder.

[0158]

[0144] In some embodiments, it may be desirable to conduct a drying step to reduce the amount of water present in the final product. There are a number of methods of drying known in the art, which include, for example, vacuum drying, microwave-assisted drying, ultrasonic-assisted drying, spray-drying, drum drying, freeze drying, solar drying, etc. Another method that is used in winemaking to remove yeast and bacteria is tangential flow filtration. In some embodiments, if tangential flow filtration is conducted before drying to reduce the amount of water content, it will reduce the energy required to dry the product to a powder.

[0159] Fine Grind Technologies and Methods

[0160] Hammer Mill for Wet Fine Grinding

[0161]

[0145] The difference between a coarse grind and a fine grind is the mesh size of the screen that the ground product must pass through. A Fitzpatrick mill has interchangeable screens, so the user makes a decision as to how fine they want to grind the material at that point in the processing will determine which screen to use. The blades come close to the screen and scrape any material that does not fit through the screen. What will happen is the rate at which the product passes through will decline as the screen size becomes a smaller screen. The hammer-mill may have a screen at the exit of the device such that no unbroken seeds will be able to pass through the device. Examples of their hammer-mills can be seen on their website: ht ps: / / www.fi tzpatnck-mpt.com / producte / hammer-mdls--m5a--d6a Centrifugal Impact Mill (CIM) or Pin Mill for Dry Fine Grinding

[0162]

[0146] If the fermented pomace product has been dried, a Centrifugal Impact Mill that is typically used for grinding dry powder (such as making chocolate powder) to a particle size that is not perceived as "gritty" on the teeth could be used to grind the fermented dried products into a powder. This technology is a type of grinder that uses centrifugal force and impact to reduce the size of materials from a coarse to a fine grind.

[0163]

[0147] A CIM comprises a rotor, which is a spinning drum or cylinder with blades or combs attached to its surface, and a stator, which is a stationary housing or chamber that surrounds the rotor. The bulk material is fed into the central inlet of the stationary disk and lands on the rotor moving at a high-speed rotation creating a centrifugal force, whereby it is pre-crushed on impact. The centrifugal force then throws the material against the stator causing it to be finely ground into a fine powder through shearing effects. One company that sells CIM / Pin Mills is Munson Machinery Co. One example can be seen on their website at: hup:;..

[0164] Drying Technologies and Methodologies

[0165]

[0148] There are a number of technologies known in the field for effectively drying a product into a powder. For example, descriptions and instructions for various technologies and techniques can be found in one or more books / reference manuals, such as, for example, “Advanced Drying Technologies for Foods,” Edited by Arjun S. Mujumdar and Hong-Wei Xaio, CRC Press, 2020, ISBN 13: 978-1-138-58490-7.

[0166]

[0149] In general the choice of a drying technology depends on the solids composition, the viscosity, and the texture of the substance. For a liquid that can be easily pumped, such as any homogeneous liquid between the viscosity of milk to catsup, the most appropriate drying technology is spray drying, where droplets of product pass down through an upward moving dry air current. For a material that is still mostly liquid but which may contain large particles that would block a nozzle, a laminar flow drier is more appropriate, where dry air passes uniformly across the surface of the material For a material that can be fractured by bending or grinding but still has a water content that would enable fungal growth, the most appropriate method is fluidized bed drying, where dry air passes vertically between particles

[0167] Spray-Drying

[0168]

[0150] Spray-drying is an established technology that is widely used in the food and dairy industry. Spray drying technology is a method of producing a dry powder from a liquid or slurry by pumping the same through a spray nozzle or spinning disk in order to atomize the liquid or slurry into droplets, which are then introduced into a drying chamber to be rapidly dried into a powder with consistent particle sizes by the hot air stream. There are a number of manufacturers of Spray Dryers located in the US, Europe and large milk producing countries such as New Zealand, which use the technology to produce dried milk powder (see Tetra Pak Australia and New Zealand: drying ). One example of a company is GEA, which sells industrial scale, pilot scale and test scale spray dryers. Their website is: htte / Ay^w.g£UCom4^ .

[0169]

[0151] Another example is SPX that sells the Triple- A® spray dryer, which combines a new spray dryer design with an integrated fluid bed and an optional external fluid bed. Their website is: https: / / www.spxflow.com / anhvdro / products / triple-a-sprav-drvers .

[0170] Fluidized Bed Dryer

[0171]

[0152] For partially dried product such as pomace that has been Kosher washed and drained, spray drying won't work. A fluidized bed dryer is better.

[0172]

[0153] A fluidized bed dryer, also known as a fluid bed dryer is a technology, which works on the principle of fluidization that allows for efficient heat transfer and mass transfer, where a powder or granular material is suspended and aerated by a gas stream. The fluidized bed dryer comprises a gas dispersion plate (perforated plate type) located at the bottom of the dryer. The hot air entering through the dispersion plate creates a powder-charged air, causing an effective mass and heat exchange, as well as good mixing of the powder, whereby the moisture content of the powder is picked up by the air flowing through and discharged via cyclone and filter. Details may be found in “Principles of Powder Technology”, page 124, Martin Rhodes et al, Wiley, 1990 and in “Introduction to Fludization,” Coco et al, AICHE, 2014.

[0173] Laminar Flow Drier

[0154] A laminar flow drier can be used to dry material that is too wet for a fluidized bed drier but too viscous for a spray drier. For example, this type of dryer is typically used to produce fruit leathers. It is also used for drying biological samples, such as cells, tissues, and biomaterials, to preserve their integrity and prevent contamination. This type of drying technology involves directing a stream of air through a duct or chamber in a way that creates a uniform velocity and direction throughout the flow thereby generating a laminar airflow pattern that will evenly distribute heated air across the drying surface, promoting uniform evaporation and drying of materials. The air molecules move in parallel layers, with minimal turbulence or mixing, in order to achieve a consistent drying effect, which results in consistent evaporation and drying rates that reduce the risk of hot spots, uneven drying, and contamination. The design thereby maintains a clean and sterile environment, while minimizing the risk of particle resuspension and contamination.

[0174]

[0155] One manufacturer of Laminar Flow Driers is WSI Machinery, whose website is

[0175] A Non-Thermal Process for Generating a Powder

[0176]

[0156] Another way to convert the pomace to a powder is by immobilizing it with an agent such as agar, protein or pectin. Once the solid has been created by the addition of one of these agents, the solid can be ground to a powder which then contains all the original aroma and acidity of the initial pomace puree.

[0177] THE PRODUCT

[0178]

[0157] According to some embodiments, the product 225 (See FIG. IB) can be used to improve the surface contact between the palatial sites of the tongue and food substances, thereby increasing the basic tastes: saltiness / sweetness / bitterness and sour, because they are sensed by the tongue. Without being bound by any theory, some of the polyphenols in the product form complexes with the proteins in the coating of the tongue, thereby “unmasking” the pellicle covering.

[0179]

[0158] Thus, the product can be used in food preparation, to, for example: a) reduce the amount of sodium in a food formula; b) reduce the amount of sugar in a food formula; c) preserve dairy, meat, condiment and cereal nutrient-rich products; d) enhance the flavour of fruits, vegetables, and spices within a food formula; e) provide significant nutrient value to a food formula; f) provide a source of yeast and other bacteria to cause the leavening of bread; g) provide a source of bacteria to cause the fermentation of dairy nutrient-rich products; and / or h) provide a source of bacteria to cause the fermentation of plant-based proteins. Through use and sensory testing relating the application of the product it has been found that when the pomace is processed to a titratable acidity of 2.5-2.7% or 2.5-3.0% a better performance in food applications is achieved. The higher titratable acidity also makes for a safer food product. The Table (FIG. 18) provides certain target benchmarks and key performance indicators (KPIs) for intermediates (partially processed pomace or Raw Pomace) and final products of a General Process (including embodiments thereof). Additional details of product characteristics are provided in the exemplary product Certificates of Analysis at FIGs. 12A and 12B; FIGs. 13A and 13B, FIGs. 20A and 20B; FIGs 21A and 22A; and FIGs. 22A and 22B.

[0180]

[0159] The product may also be used to provide a medium for extraction of nutrients for pharmaceutical use in addition to provide a medium for topical applications in cosmetics or skin therapy.

[0181]

[0160] It is contemplated that the resulting product may be used to address some of the key challenges in the food & beverage industry. Depending on the use case, some of the potential benefits include, for example: (a) significant sugar reduction (by 50%+); (b) substantial calorie reduction; (c) deep sodium reduction by as much as 80%; (d) natural shelf-life extension by 55%+; (e) effective masking of bitter notes and off flavors (e.g., pea protein); (f) improved texture and mouthfeel; (g) cost savings dependent on application; and (h) enriched nutritional value with phytonutrients and antioxidants.

[0182]

[0161] Use of the product (for example, in puree or powder form) as an ingredient in a number of different foods has demonstrated cross-functional impact across the board, such as: (a) flavor enhancement; (b) masking off notes; (c) deep sodium reduction; (d) significant sugar reduction and added fiber; (e) moisture & lipid binding; (f) improved texture and mouthfeel; (g) lipid oxidation prevention; and (h) natural shelf-life extension. The addition of the product (either in puree or powder form) as an ingredient to various food products has been validated in taste tests / sensory comparison tests, for a variety of use cases. Some examples of these test / studies are outlined below. The increased functionality is a result, in many cases, of the total phenolics (polyphenols) in the nutrient-rich product. It has been confirmed from testing of the red grape powder and white grape powder blends, for example, that polyphenols are present in high concentrations (resulting in increased antioxidant activity). Sugar Reduction

[0183]

[0162] The addition of a white grape puree / white grape powder blend (2%) to chocolate spread demonstrated that the puree delivers on some of the most important attributes of flavor, while allowing for significant improvements in nutrition. The chocolate spread formulation allowed for a 30% reduction in added sugar and provided substantial enhancement to flavor. Other benefits included contributing a velvety appearance and texture. Formulation highlights included: 30% reduction in sugar; 20 % reduction in carbohydrates; added polyphenols and antioxidants; and added calcium. .

[0184]

[0163] A similar study on the use of the puree in condiments and sauces also showed that it delivers on some of the most important attributes of flavor, while allowing for significant improvements in nutrition. Adding the while grape puree / white grape powder to a barbeque sauce allowed for a 32% reduction in sugar, 20% reduction in salt and provided a substantial enhancement in both flavor and spice. Other benefits included contributing a velvety appearance. Formulation highlights included: 32% reduction in added sugar; 20% reduction in added salt; 33% increase in calcium; 9.5% reduction in calories; 9% reduction in carbohydrate; added fiber.

[0185] Flavor Enhancement

[0186]

[0164] A study revealed that adding the puree to a plant-based burger patty resulted in a 2: 1 preference over the standard patty and significantly improved the taste, profile, texture and appearance. A 2:1 preference was demonstrated.

[0187] Off-Note Elimination

[0188]

[0165] The polyphenols in the red grape puree are generally hydrophilic. By incorporating the puree or powder upstream with the addition of water, polyphenols become easier to absorb. Base proteins are positively charged while polyphenols are negatively charged. This causes the polyphenols to bind to the protein compounds creating a reaction which denatures a protein base material to a flavorless substrate, significantly enhancing the flavor of the ingredients added to the formulation after the hydration step. This allows formulators to lower their use of bitter blockers or maskers and presents an opportunity for cost saving.

[0189] Sodium Reduction

[0190]

[0166] In a study carried out using consumer panelists, this indicated that a patty with red grape puree added and sodium reduced (at 40% less sodium) achieved higher results than a full sodium control patty. In other words, addition of the product (puree form) can provide for a sodium reduction of -40%.

[0191] Increasing Sweetness

[0192]

[0167] The puree contains a cocktail of acids with different sensory profiles & the result is a more complex sour than with use of industrial vinegars or citric acids. Fresh fruit and vegetables have a slightly tangy sensation that can disappear with age or cooking. The puree / powder is heavily concentrated with malic, lactic and tartaric acids, which work to bring fruit & vegetable ingredient flavors to the fore. The added sour freshness coupled with the additional Ionized Potassium based ‘Saltiness’ creates a strong and rounded sweetness which differs from artificial sweeteners. Applications tested have matched their controls level of perceived sweetness with sugar reduced by up to 50%.

[0193] Retain Succulence

[0194]

[0168] With a high concentration of functional phenolic compounds, the puree has also been shown to be an effective complementary ingredient for textured protein particularly due to its functionality in terms of water & fat retention. In addition to flavor enhancement, chew and succulence are also important attributes for meat-analogues to capture a meat like, fatty mouthfeel. Added fats escape plant-based products during production and once cooked. Phenolic compounds in the puree have been shown to work effectively for lipid binding & oils. This pulls and holds fats into the substrate to mimic real ground meat which adds to the additional “chew” that the puree brings to the textured protein. This improves texture & mouthfeel.

[0195] Lipid Oxidation Prevention

[0196]

[0169] Polyphenol levels are linked to Antioxidant Capacity. The use of a red grape puree blend with canola oil & soybean oil has been found to improve the oxidative stability index thereof Customer Validation. Natural Shelf Life Extension

[0197]

[0170] A particular pate formulations had a shelf life of 120 days. With the addition a white grape puree blend at a 2% application rate, resulted in the pate having an increased shelf-life of 185 days with no food safety or quality concerns. There are several aspects of the product that are believed to contribute to shelf-life extension. One of these is the low pH, which generally supresses oxidative degradation. Secondly, the phenolic compounds have a lot of double bonds in them, which are antioxidant - so the double bonds can be moved into single bonds and absorb the electrons that contribute to oxidation. Thirdly, phenolic compounds bind to protein, which can bind to critical proteins like contaminates - some of the binding sites on the cell surface or critical enzymes - if they have phenolics bound to them then they can stop the micro-organisms from doing their metabolism or from propagating. Thus, they can be antibacterial / antioxidant.

[0198] KOSHER CERTIFICATION

[0199]

[0171] Kosher food is defined in accordance with Jewish religious law, which is set down in the Torah, the centerpiece of the Jewish faith. The word kosher signifies everything that has been produced or prepared according to Jewish law. Kosher diet follows the rules of kashrut (Jewish dietary laws). In accordance with kashrut, only four-footed animals that chew their cud and have cloven hooves may be eaten. This excludes pigs or hares, for example. Poultry, by contrast, is kosher. Of fish, only those that have fins and scales may be eaten. The rules also include using separate pots, cutlery and dishes for these foods.

[0200]

[0172] Traditional rabbis prohibited any item of food that had been used in the service of an idol or had been consecrated to an idol. The kashrut laws state that if a wine might have been used for idolatry, it cannot be considered kosher. Yayin nesekh is the traditional term for the prohibition against drinking non-Jewish wine. Wine that has been heated, yayin mevushal, becomes unfit for idolatrous use so can be regarded as drinkable. Moreover, a number of wine producing countries now produce kosher wines, for example, Israel, the United States, France, Germany, Italy, South Africa, Chile, and Australia.

[0201]

[0173] There are a number of methods for processing a foodstuff so that it will meet the requirements for Kosher Certification. The design for rendering the production equipment and processes ready for Kosher Certification can be found in one or more books / reference manuals, such as, for example, “Kosher Food Production (second edition), Zushe Yosef Blech, Wiley- Blackwell, A John Wiley & Sons Ltd. Publication, 2008, ISBN 978-0-8138-2093-4.

[0202]

[0174] In some embodiments, the process will be performed in a manner such that the final product can be certified as being Kosher. Food ingredients can be classified into three groups with regard to Kosher products: ingredients that are considered to be inherently Kosher; ingredients which can be produced in a Kosher or non-Kosher manner; and ingredients which are not acceptable for use in Kosher products. If the process is followed to render the product as being Kosher certified, then all the processes and additives used in the process will be either certified as Kosher or not required to be certified Kosher, but will be verified as being appropriate for use in a Kosher product.

[0175] In some embodiments, the pomace bioconversion process is designed so that the product can be certified as Kosher. Some examples of modifications to the process for this purpose include kosherizing the processing equipment, supervision of the material handling by a Rabbi at one or more stages such as, for example, harvest, grape pressing, fermentation, finishing / processing; and drying of the product to a moisture level that is less than about 10%. Washing of the pomace to kosherize it is an optional step, or one that may only arise if necessary (e.g. up to seven times), in the event that there is any doubt or concern about the integrity of the kosherized pomace arising from the grape pressing stage.

[0203]

[0176] In one embodiment, the bioconversion of pomace to a product is certified as Kosher (e.g., quality for Kosher Certification) as illustrated in FIG. 14A. Kosher grapes 2 may be received at the winery and a Rabbi can be involved in initiating, inspecting and otherwise supervising various aspects of pomace processing. In embodiments, the Rabbi initiates the pressing process 601 for harvested fruit (grapes), and may then inspect the processing area to assure all materials and equipment are Kosherized 603. If deemed appropriate or necessary, the Rabbi will have hands on involved in the transfer and storage of pomace 605 and may optionally also initiate the processing of pomace according to the present disclosure, such as the fermentation of the pomace 607. In embodiments, the Rabbi will be responsible for the hands-on initiation of machinery (generally equipment that is automated to one degree or another) relevant to the Kosherization process including, as needed, the machinery for pressing, transferring and sealing the Kosher pomace in a storage container / vessel. These are all steps done before the fermentation of pomace. A Rabbi also inspects the winery, and in particular the areas of the winery where the General Process is implemented and the General Process System is set up, to ensure no non- kosher pomace is being processed in these areas to avoid cross contamination. In some embodiments, the Rabbi may also initiate one or more of the fermentation steps of the General Process by initiating the relevant equipment. See also FIGs. 16A-16C.

[0204]

[0177] In other embodiments the bioconversion of pomace to a product, that may be certified as Kosher (e.g., quality for Kosher Certification) using a Kosher washing step is described below with reference to FIGs 10 and 14B.

[0205]

[0178] In some embodiments, Kosher washing step uses, prior to fermentation, a Kosher Washing Station . With reference to FIG. 14B the washing station 701 comprises a wash bar 703A for washing pomace in a container 702. Each wash station is configured so that the pomace is thoroughly washed during each wash cycle. In some embodiments, the pomace is, optionally, washed with water, wherein the ratio of water: pomace is 7: 1 by volume (for example, for 250 L of pomace, 500 L of water can be sprayed over the pomace. The wash bar and wash container have been designed so that when the pomace exits the wash container, it is suitable to be Kosher certified.

[0206]

[0179] In some embodiments the wash is be conducted within 24 hours of pressing the fruit (i.e., crush).

[0207]

[0180] In some embodiments, the water used in the Kosher Wash System is potable water. In an embodiment, the water used in the Kosher Wash System has been filtered. In some embodiments, the water used in the Kosher Wash system has been pre-treated in some manner to render the pomace washing step sufficient to render the pomace Kosher certifiable upon exit of the Kosher Washing Station.

[0208]

[0181] In some embodiments, the Kosher Washing Station is located at a fermentation location. In some embodiments, the Kosher Washing Station is positioned on a truck or other vehicle, such that it is a mobile Kosher Washing Station. In some embodiments, the Kosher Washing Station is located at a central processing facility

[0209]

[0182] In some embodiments, the water that has been washed over the pomace is collected from the washing container and recycled for future use within the Kosher Washing Station. In some embodiments, the water used to wash the pomace must be drained from the pomace and can be recycled up to three times for the first 6 washes, but then clean water is used for the last wash (the 7th), and is allowed to drain prior to transferring to a Kosher Transfer Station.

[0210] Kosher Wash Station

[0211]

[0183] Water jets can be installed above a conveyor such as shown in FIGS 10 and 14B. Grapes pass under the jets and water are collected continuously in a reservoir located at the bottom. In one embodiment three rinses can be made with recycled water and the others must be made with clean or cleaned water.

[0212] Kosher Transfer Station

[0213]

[0184] In some embodiments, a Kosher Transfer Station comprises a hopper 706 (see FIG. 14B) for receiving pomace, a conveyor 708, and a water-spray system 703B. The Kosher Transfer Station comprises suitable conveyor, for example, a screw convey or / auger conveyor positioned within a trough. In an embodiment, the conveyor is a screw conveyor / auger conveyor. In some embodiments, the conveyor is inclined upwards so as to elevate and deliver the contents by gravity to another container located below the end of the conveyor that is opposite to the hopper. A Kosher Transfer Station 704 may include a second wash step following the first wash at the Kosher Wash Station 701. After the second wash by the water-sprayer 703B, the pomace is transferred to a holding tank or fermenter 214. The washed pomace may be manually transferred from the container 702 of the Kosher Wash Station 701 to the hopper 706 of the Kosher Transfer Station 704.

[0214]

[0185] In an alternative embodiment, FIG. 10 illustrates a wash bar 703B that sits over a conveyor 708 to wash the pomace 102 as it is being transferred.

[0215]

[0186] A water spray system is located above the conveyor (e.g., trough), comprising a plurality of spray jets, linearly disposed and aligned with the conveyor trough so as to spray the pomace as it is transported along the conveyor.

[0216]

[0187] In some embodiments, the washed pomace is delivered from the conveyor into a kosher- process bioreactor 214, which has been kosherized, for fermentation. When the fermentation has been completed, the fermented pomace will be tested for quality approval and transferred to the processing area.

[0217]

[0188] According to some embodiments wherein the final product is to be certified as Kosher, Kosher grapes derived from a Kosher certified vineyard can be used.

[0218] INDUSTRIAL-SCALE QUALITY ANALYSIS AND FOOD SAFETY PROCESSES

[0219]

[0189] The industrial-scale biotransformation (also referred to herein as bioconversation) process seeks to optimize the conversion of the biochemical composition of the winery-derived fruit pomace into the biochemical composition of the final product, in which the optimized process is designed to minimize the number of adjustments to the composition (to as few steps as possible). The objective of each step is to achieve the largest adjustments possible towards the final target composition, with the highest conversion efficiency possible, in each step, in order to minimize the cost of production (time, energy, risk management, waste, people resources, etc.).

[0220]

[0190] In some embodiments, the objective is to achieve the largest adjustments early in the process, to attain an “intermediate” product, which can then be refined into a product that meets specifications. In laymen’s terms, in order to achieve a cost effective and high yield output, the design of the process is to front-load the efforts - so you don’t have to back-load more effort, with loss of control and efficiency.

[0191] One critical distinction between small-scale-commercial production and industrial production may entail the “granularity” of each biochemical analysis process. For example, the small-scale process generally might only measure a few variables such as pH and Brix, whereas an indusrial -scale production uses a set of chemical and biochemical markers to have greater insight into the biochemical conversion at each stage. Moreover, adherence to high standards of quality control is emphasized. This point is emphasized in FIGs. 1A and 10, which shows multiple process control points, PCP(s), all of which are alternatively referred to herein as Inspection Points, and some of which include Prevention Control (otherwise known as Hazard Analysis and Critical Control Points, abbreviated as “HACCP”), such as testing for microbes, toxins, metals, etc.

[0221] • Another critical distinction between small-scale and industrial-scale production entails the management of risk of loss.

[0222] • According to some embodiments, an industrial-scale process would be expected to have the following features / considerations:

[0223] • Standardized ingredients / additives for use with the pomace

[0224] • The generation and adherence to Standard Operating Procedures (SOP)

[0225] • Regular testing throughout (e.g., PCP including HACCP points)

[0226] • Independence from fluctuations of annual agricultural conditions (e.g. blending multiple sources of pomace)

[0227] • Identify and control all the steps that can fail

[0228] • Minimizing risk

[0229] • Everything is documented and recorded, variation in results also documented (success, failure and error)

[0230] • Documented in a manner that all the source ingredients are recorded (e.g., easy to identify tracking to source)

[0231] • Searchable records, for if / when a regulatory inspector wants to review records to determine compliance with regulatory standards - Extensive, organized and accessible documentation

[0232] • Optimized processes - efficient and effective as possible.

[0233]

[0192] The manner for conducting various PCP tests may vary. In embodiments, a conventional laboratory uses a pH meter for pH measurements and determining end points of various titrations. In other embodiments, a refractometer is used to determine sugars. In still other embodiments, titration is used to determine titratable acidity. In yet other embodiments, a Cash is used to determine volatile acidity. In further embodiments, an ebulliometer is used to determine ethanol. Paper chromatography is used to determine completion of a malolactic fermentation. In an alternative embodiment, all of these analyses can be performed on a single sample with an Oenofoss analyzer. Such an analyzer may understood as a multi-monitoring means and optionally incoroporated as part of a monitoring subsystem.

[0234]

[0193] In some embodiments, the process will be performed in a manner such that the final product can be certified as being Kosher.

[0235]

[0194] Quality Analysis can be conducted at any stage and / or step in the process as deemed appropriate. In general, at least the pH and the levels of lactic acid and / or acetic acid will be measured. If sensors are used as part of a monitoring subsystem, this can be more continuous monitoring. In another embodiment, a continuous flow instrumental analysis can replace a wide range of sampling and bench analyses and enable concise, automated process control either on site or remotely Additional points of analysis can include: in the headspace, ethanol and acetic acid could be monitored using appropriate monitoring means (in or outside of a monitoring subsystem). Other parameters or categories of molecules that could be similarly monitored: aldehydes, such as acetaldehyde; esters, such as ethyl acetate; pH; minerals, such as potassium, sodium, calcium, magnesium; microbial content, yeast, mold and bacteria content and possibly subsets thereof (not species - it will likely be general levels, not specific species, unless a commercial specification indicates a coliform test); organic acids, such as tartaric acid, malic acid, lactic acid and acetic acid. There can also be trace amounts of other organic acids.

[0236]

[0195] The Global Food Safety Initiative (GFSI) provides a platform for collaboration between food safety experts associated with the food supply chain, international organizations, academia, and government. GFSI’s work in benchmarking and harmonisation fosters mutual acceptance of GFSI-recognised certification programmes across the industry and enables a simplified “once certified, recognised everywhere approach, The GFSI Benchmarking process is now the most- widely recognised in the food industry worldwide.

[0237]

[0196] SQFI is a division of the Food Industry Association (FMI), SQF is a GFSI recognized standard (benchmark) thatindustrial scale food manufacturers would be aware of and follow to ensure food safety. Details of procedures and processes can be found in SQF Food Safety Code: Food Manufacturing, Edition 9, 2020 and the SQF Quality Code, Edition 9, edition 2020.

[0238]

[0197] In general, the pomace, the fermented pomace, the puree, and the powder will be sampled and analyzed at various points throughout the process to ensure that appropriate standards of food safety are met. For example, upon receipt of the pomace from the wineries, a visual inspection will be conducted to ensure that there are no pests, mold, and foreign material present, in addition to taking a sample and analyzing for heavy metals, mycotoxins, and pesticides. If these types of toxic substances exceed a regulatory threshold, then the batch of pomace will likely be rejected. Samples will also be taken at appropriate spots throughout processing and prior to shipping the product to customers to ensure that the biomass has not been contaminated or adulterated. In embodiments, a PCP test may be conducted hourly with respect to the processing of pomace (e.g. fermentation). In other embodiments, a PCP test may be conducted daily when the pomace is being stored prior to fermentation. In another embodiment, a PCT test maybe conducted weekly in adjacent winemaking areas (if any).

[0239] Instrumental Analysis

[0240]

[0198] According to embodiments, the analytical parameters used to monitor the performance of the fermentation process and the quality of the final products are analyzed by analytical methodologies such as gas chromatography for ethanol and UV-visible spectrometry for carbohydrates, nitrogen nutrients, organic and phenolic acids, and titration for the total acids content. However, a faster methodology has been developed to analyze all the parameters using a Fourier transform infra-red approach calibrated for wines and supplied by Foss and other manufacturers of FTIR analysis, companies, for example an OenoFoss. This device analyzes for organic acids, (acetic acid, lactic acid, tartaric acid, citric acid, malic acid), reducing sugars. It calculates pH and titratable acid, etc. When testing for sugar, the typical test is for reducing sugar, either glucose or fructose. It can be corrected with sucrose, which is not a reducing sugar. The methodologies will be adjusted and validated for the products and processes to ensure a faster and accurate analytical control that can be used in small- or large-scale processes. For example, an alternative method to monitor sugars, ethanol and organic acids is high performance liquid chromatography (HPLC) (e.g. as can be sourced from the Neogen Corporation).

[0241]

[0199] Microbial Analysis

[0200] When surfaces become contaminated with bacteria, fungi, yeasts, viruses, or other microorganisms, or "microbes," sickness (morbidity) and, sometimes, death (mortality) may result. This is particularly true when surfaces in food processing become contaminated with microorganisms.

[0242]

[0201] In food processing plants, surfaces (e.g., solid surfaces, equipment surfaces, protective clothing, etc.) may become contaminated. Such contamination may be caused by or transferred to meat or other foods. Once a surface becomes contaminated with microbes, contact with the contaminated surface may easily and readily transfer microbes to other locations, such as another surface, an individual, equipment, food, or the like.

[0243]

[0202] As is well known, microbial contamination and transfer in certain environments may pose significant health risks. For example, the food that leaves a contaminated food processing plant will subsequently be eaten, and may cause sickness and, possibly, death. Microorganisms such as Listeria monocytogenes, Salmonella enteritis, and Escherichia coli O157:H7 are of particular concern.

[0244]

[0203] Conventionally, environmental microbial testing includes obtaining a sample from a surface. This is typically done by contacting (e.g., wiping, swiping, etc.) the surface with a sterile sampling appliance, such as a swab or a sponge. Surfaces that are tested in this manner are usually visually quite clean; thus, the number of microorganisms that are picked up by the sampling appliance is typically quite low. Due to the small number of microorganisms, any microbes that are on (e.g., picked up by) the sampling appliance typically must be reproduced, or "grown" or "cultured," to provide a sufficient number of organisms for further analysis.

[0245]

[0204] A number of “rapid techniques” for conducting microbiological analysis have been developed over the years and have been reviewed by H.M. Hungaro, et al., “Overview of Microbiological Methods for Food Analysis,” Encyclopedia of Agriculture and Food Systems, 2014, herein incorporated by reference.

[0246]

[0205] The microbiological analysis has been conducted in-house using plating techniques and microscopy. It is the growth of the sample in a specific culture medium and selective conditions with subsequent colorimetric and morphological identification with the aid of an optical microscope. The final product is analyzed for pathogenic bacteria, in accredited third laboratories, regarding the limits and microorganisms stipulated in the current food law.

[0206] The genetic analysis are performed, when necessary, to characterize the proprietary inoculum. Such analysis is carried out in partnership with third party laboratories and / or universities and research centers.

[0247] Pesticide Analysis

[0248]

[0207] Pesticide residues resulting from the use of plant protection products on crops that are used for food or feed production pose a risk factor for public health. A comprehensive legislative framework has been established in each country which defines rules for the approval of active substances used in plant protection products, like pesticides. These rules regulate the use of plant protection products and set maximum amounts of residues permitted in food. Residue definitions are set during the evaluation process of the active substance, which may include relevant metabolites and other transformation products. Food surveillance testing programs check for compliance with maximum residue limits (MRLs), assess dietary exposure, and check for use of unauthorized pesticides. The food industry also undertakes testing of ingredients and finished products for due diligence, or product release purposes.

[0249]

[0208] Pesticide analysis is carried out by accredited external laboratories as required by food law. The quality of the raw material is ensured throughout the processing on a small, medium or large scale by the internal regulations provided by the quality management, thus a rigorous control of sampling of the raw material and sending the samples to accredited laboratories, to guarantee traceability and safety of the final product, is part of the production and development operations at the current scale and must be adjusted for future scales considering the legal requirements and other requirements demanded by the different current and future legislations and certifications.

[0250]

[0209] In some embodiments, the process is provided in the form of software, wherein the user inputs information and data regarding the starting product and information and data regarding the commercial specification and the software provides an optimized process.

[0251]

[0210] In some embodiments of a software implementation, machine learning would assist in optimizing the programming, using the information and results of earlier fermentations.

[0252] Sensory Analysis

[0253]

[0211] In general, professional taste panels usually comprise a small group of people who have been trained to recognize specific traits. Consumer taste panels are large groups of untrained participants. For example, the wine industry VQA panelists are both screened and trained. They are screened to prove that in a blind tasting they can each recognize common wine flaws. Further to that, many wines contain these flaws to some degree but the panelists are expected to make a judgement decision to accept or disqualify a wine as merchantable quality in spite of the flaw they detect. The design for Sensory Analysis and process instruction can be found in one or more books / reference manuals, such as, for example, “The Sensory Analysis of Food, Statistical Methods and Procedures.” Michael Mahoney, Food Science and Technology, 16, 1986, ISBN 9780824773373; “Sensory Evaluation of Wines” Margaret Cliff & Marjorie King, Okanagan University College Winery Assistant Course, Revised Gary Strachan 2001. Ethanolic Fermentation

[0254]

[0212] When ethanolic fermentation is conducted, yeast is used to convert sugars, such as glucose, fructose and sucrose in the pomace into ethanol and carbon dioxide in an anaerobic process. This increases the level of ethanol present in the processing container. The ethanolic fermentation step can be particularly important, for example, where, according to some embodiments, the pomace has been washed in order to comply with Kosher certification requirement.

[0255]

[0213] Acetic Acid Fermentation

[0256]

[0214] In the acetic acid fermentation step, acetic acid bacteria, (genus Acetobacter or Gluconobacter) is used to oxidize sugars and / or ethanol in the pomace into acetic acid (e.g., vinegar) in an aerobic process.

[0257]

[0215] Lactic Acid Fermentation

[0258]

[0216] When a lactic acid fermentation is conducted, an appropriate LAB bacteria, will convert sugars, such as glucose, fructose and sucrose in the pomace into lactic acid in an anaerobic or micro aerobic fermentation.

[0259]

[0217] Terminating the Fermentation Process

[0260]

[0218] According to some embodiments, the fermentation process may be terminated when the levels of acetic acid and / or lactic acid reach a pre- determined concentration, considering the predicted stoichiometric yields and the stability of the concentration of the produced acids, within the fermenter vessel. In the case of a AAB fermentation, the termination of fermentation can be accomplished by sealing the vessel in a manner such that no oxygen can enter the bioreactor vessel. In some embodiments, the process is terminated by additionally sparging with nitrogen, argon, carbon dioxide or a combination thereof. In other cases, the depletion of fermentable sugars will terminate the fermentation.

[0261] Microbial Inoculum

[0262]

[0219] The microbial inoculum used for each fermentation can be a single species or a mixed culture (microbial consortium or microbial community), comprising two or more bacterial or microbial groups (e.g., yeast and bacteria). In an embodiment, a mixed culture inoculum comprises bacteria, fungi (including yeast). In an embodiment, a mixed culture inoculum comprises one or more strains of yeast (yeast are facultative aerobes, which means they can primarily grow in the presence of oxygen or survive using alternative metabolic pathway such as ethanolic fermentation in the absence of oxygen) and one or more strains of bacteria. In an embodiment, a mixed culture inoculum comprises one or more strains of yeast and one or more strains of bacteria and one or more strains of fungi.

[0263]

[0220] These three types of fermentation may be conducted in separate phases using different microorganisms, or they may be conducted using a mixed culture in a more simultaneous fashion.

[0264]

[0221] The design for fermentation and process instruction can be found in one or more books / reference manuals, such as, for example, “Wine Microbiology”. By Fugelsang and Gump, “Food Microbiology,” “Food Fermentations,” “Indigenous Fermented Foods,” or “Food Microbiology: Fundamentals and Frontiers”, edited by Michael P. Doyle, Larry R. Beuchat, and Thomas J. Montville.

[0265] Acetic Acid Bacteria

[0266]

[0222] The steps of the derivative-conversion require inoculation of microbial formulation, comprising acetic acid bacteria. One skilled in the art of fermentation would know which one(s) to select from the family of family Acetobacteraceae.

[0267]

[0223] Acetic acid bacteria (AAB) are a group of rod-shaped, Gram-negative bacteria which aerobically oxidize sugars, sugar alcohols, or ethanol with the production of acetic acid as the major end nutrient- rich product. This special type of metabolism differentiates them from all other bacteria. The acetic acid bacteria consist of 10 genera in the family Acetobacteraceae, including Acetobacter. Species of Acetobacter include: A. aceti; A. cerevisiae; A. cibinongensis; A. estunensis; A. fabarum; A. farinalis; A. indonesiensis; A. lambici; A. liquefaciens; A. lovaniensis; A. malorum; A. musti; A. nitrogenifigens; A. oeni; A. okinawensis; A. orientalis; A. orleanensis; A. papaya; A. pasteurianus ; A. peroxydans; A. persici; A. pomorum; A. senegalensis; A. sicerae; A. suratthaniensis; A. syzygii;A. thailandicus; A. tropicalis; and A. xylinus. Several species of acetic acid bacteria are used in industry for production of certain foods and chemicals.

[0268]

[0224] The strains, which have been identified include: Acidibrevibacterium Acidicaldus Acidiphilium Acidisoma Acidisphaera Acidocella Acidomonas Ameyamaea Asaia Belnapia Bombella Caldovatus Commensalibacter Craurococcus Crenalkalicoccus; Dankookia Elioraea Endobacter Gluconacetobacter; Gluconobacter Granulibacter Humitalea Komagatabacter Komagataeibacter Kozakia Muricoccus Neoasaia Neokomagataea Nguyenibacter

[0269] P ar acr aurococcus; Parasaccharibacter. Although a variety of bacteria can produce acetic acid, mostly members of Acetobacter, Gluconacetobacter, and Gluconobacter are used in industry.

[0270] One skilled in the art would know which one(s) to choose for the fermentation processes depending on the final product they desire to generate.

[0271] Lactic Acid Bacteria

[0272]

[0225] Lactic acid bacteria (LAB) are an order of gram-positive, acid-tolerant, generally nonsporulating, non respiring, either rod-shaped (bacilli) or spherical (cocci) bacteria that belong to the order Lactobacillales and share common metabolic and physiological characteristics. Lactic acid bacteria are used in the food industry for a variety of reasons such as the production of cheese and yogurt nutrient-rich products. The genera that comprise the LAB are at its core Lactobacillus, Leuconostoc, Pediococcus, Lactococcus, and Streptococcus, as well as the more peripheral Aerococcus, Camobacterium, Enterococcus, Oenococcus, Sporolactobacillus, Tetragenococcus, Vagococcus, and Weissella.

[0273]

[0226] Yeasts

[0274]

[0227] Exemplary yeasts includes, but are not limited to Saccharomyces sp. (for example, from the genus Saccharomyces arboricolus, Saccharomyces eubayanus, Saccharomyces bayanus, Saccharomyces beticus, Saccharomyces cerevisiae, Saccharomyces fermentati, Saccharomyces kudriadzevii, Saccharomyces mikatae, Saccharomyces paradoxus, Saccharomyces pastorianus and Saccharomyces uvarum.), Brettanomyces sp. (Teleomorph Dekkera sp.), Candida (Teleomorphs for different species from several genera including Pichia sp., Metschnikowia sp., Issatchenkia sp., Torulaspora sp. and Kluyveromyces sp.), Kloeckera sp. (Teleomorph Hanseniaspora sp.), Saccharomycodes sp., Schizosaccharomyces sp. Yarrowia sp. (Yarrowia lipolytica) and Zygosaccharomyces sp. One exemplary strain is Saccharomyces cerevisiae, var. diastaticus.

[0275]

[0228] In some embodiments, the yeast cells can be from Saccharomyces sp., Brettanomyces sp., Candida, Kloeckera sp., Saccharomycodes sp., Schizosaccharomyces sp., Yarrowia sp. or Zygosaccharomyces sp. In still embodiments, the yeast cells are selected from the group consisting of Saccharomyces sp., Brettanomyces sp., Candida, Kloeckera sp., Saccharomycodes sp., Schizosaccharomyces sp., Yarrowia sp. and Zygosaccharomyces sp.

[0276]

[0229] In some embodiments, the yeast cells can be a Saccharomyces arboricolus, a Saccharomyces eubayanus, a Saccharomyces bayanus, a Saccharomyces beticus, a Saccharomyces cerevisiae, a Saccharomyces fermentati, a Saccharomyces kudriadzevii, a Saccharomyces mikatae, a Saccharomyces paradoxus, a Saccharomyces pastorianus or Saccharomyces uvarum. In further embodiments, the yeast cells are selected from the group consisting of Saccharomyces arboricolus, Saccharomyces eubayanus, Saccharomyces bayanus, Saccharomyces beticus, Saccharomyces cerevisiae, Saccharomyces fermentati, Saccharomyces kudriadzevii, Saccharomyces mikatae, Saccharomyces paradoxus, Saccharomyces pastorianus and Saccharomyces uvarum. In further embodiments, the yeast cells are a Saccharomyces cerevisiae.

[0277]

[0230] In some embodiments, the yeast cells can be from Dekkera sp. In still embodiments, the yeast cells can be from Pichia sp., Metschnikowia sp., Issatchenkia sp., Torulaspora sp. or Kluyveromyces sp. In yet further embodiments, the yeast cells are selected from the group consisting of Pichia sp., Metschnikowia sp., Issatchenkia sp., Torulaspora sp. and Kluyveromyces sp. In embodiments, the yeast cells can be from Hanseniaspora sp. In further embodiments, the yeast cells can be from Yarrowia sp. In still a further embodiment, the yeast cells can be a Yarrowia lipolytica.

[0278] PROCESS OVERVIEW - INDUSTRIALL-SCALE TECHNOLOGY

[0279]

[0231] An Industrial-Scale Winery is configured to process large volumes of fruit harvests to produce wine and there are many different configurations and layouts for doing so. Depending on an Industrial-Scale Winery’s configuration and layout the technology for the General Process leverages some of the equipment and spaces at the Industrial-Scale Winery. The General Process can be implemented, for example, by using winery fermenters, propagation tanks, holding tanks, conveyor and other materials transfer equipment. At the same time, there will additional equipment that must be brought on site to an Industrial-Scale Winery in order to carry out the General Process using such equipment and in areas of the Industrial-Scale Winery that are not in use for wine production during the “off-season” or that are otherwise temporarily or have been more permanently decommissioned. In some embodiments, the fermentation steps of the General Process are all implemented using fermenters onsite at an Industrial -Scale Winery. In other embodiments, the General Process a fermentation step is carried out onsite at an Industrial-Scale Winery (e.g. an anaerobic fermentation step) and another fermentation step is carried out off-site of the Industrial-Scale Winery (e.g. an aerobic fermentation step).

[0280] General Process System Configurations

[0281]

[0232] A General Process System may have various configurations of equipment adapted to work within an Industrial -Scale Winery’s configuration / layout, so as to not interfere with wine production and achieve a high throughput processing of pomace via various product intermediates (e.g. Ethanolic Pomace, Acetic Acid Pomace), into a (Blended) Raw Puree product that can then be further processed into a final puree or powder product. The one or more steps of the General Process relating to an aeorobic fermentation and subsequent processing steps to obtain a (Blended) Raw Puree and, subsequently, a final puree product of final dry powder product may be carried out at the winery, or off-site of the winery.

[0282]

[0233] To avoid acetic acid bacteria contamination in the winemaking process, a winery must designate a location for aerobic fermentation that allows for the implementation of isolation barriers such as air filters, physical space isolation through walls, and controlled-flow doors. Furthermore, cleaning protocols applying thermal and chemical decontamination must be evaluated, validated, and implemented. The personnel involved in wine production and pomace processing must work together to implement the barriers and protocols, ensuring that both industrial-scale bioconversion processes can operate with acceptable or optimized efficiencies and without losses caused by cross-contamination via air or processing lines.

[0283]

[0234] The manner in which efficiencies may be evaluated is with respect to production capacities, production demand and production costs. In embodiments, the propagation of microbials and the fermentation steps according to the General Process are configured to be done in batches. In other embodiments, the propagation of microbials and the fermentation steps according to the General Process are configured to be done in a continuous throughput manner. In still other embodiments, the propagation of microbials and the fermentation steps according to the General Process are replicated in whole or in part (using corresponding replicated aspects of the General Process System) to be carried out in parallel. In yet other embodiments, the propagation of microbials and fermentation steps according to the General Process are carried out using a General Process System that is adapted to switch between multiple fermenter and single fermenter configurations in accordance with winery capacity dependent on the need for fermenters to be used in wine production.

[0284]

[0235] In embodiments, there are two or more, three or more, or four or more pomace processing bioreactors for each fermentation step.

[0285]

[0236] FIGs. 19A-19H provides schematic representations of configurations of a General Process System configured to carry out the propagation and fermentation steps of the General Process.

[0286]

[0237] FIGS. 2 - 6, 8-10 and 17A-17B illustrate various technologies in which OS-fermenters can be used in various locations. The lines / arrows indicating material being transported in the Figures can indicate stainless steel tubing. One company that manufactures such tubing is Equinox Stainless Inc. Their website can be seen at: Clamps can be used to connect the tubing. Equinox Stainless Inc. also manufactures such connectors, which can be viewed on their website at ht ps: / / www.eqninoxsi.ai mess . co i 'iycjanip-'heavy-diqy~ss304-l 0300194(j75--gro;ip

[0287]

[0238] FIG. 2A is a process diagram, according to some embodiments, showing the technology and steps for making a red wine 9 that are typical for an Industrial-Scale Winery. A truck 1A delivers grapes 2 to a hopper 3A which then transfers the grapes 2 to a conveyor 4A which then runs the grapes 2 through a destemmer 5. The must 7 is delivered to the fermenter 8 by a must pump 6 and the fermenter produces wine 9. Pomace 102A is collected from the fermenter 8 using a conveyor 4B and is transferred to a press machine 10, after which the pressed pomace 102B is collected in a hopper 3B and loaded into a truck IB for transport off-site of the winery. The truck IB, takes the pomace 102B to either landfill, compost, to be included in animal feed and / or or to a company that would extract food supplements from the pomace. Note that the (pressed) pomace 102A and 102B is never delivered back to a fermenter located within the Industrial-Scale Winery.

[0288]

[0239] In a white wine production process the grapes 2 would be run through a press 10A after being run through a destemmer 5 and the juice 13 is separated and delivered to a white wine fermenter 8B using a pump 11C. The pomace 102C would be transferred away off-site of the winery, as in the case of red wine production. These wine production pathways leading to the collection of pomace, can be redirected to a General Process System 200 for processing the pomace itself is illustrated in FIG. 2B. More particularly, FIG. 2B is a process diagram, according to embodiments, showing the technology and steps for redirecting pomace stream 102B from red wine production and pomace stream 102C from white wine production to a General Process System 200 (see FIG. IB) using a conveyor 4C after going through the press 10A, to be processed according to the General Process 100 of the present disclosure (see FIG. 1A).

[0289]

[0240] FIG. 3 is a process diagram, according to some embodiments, showing the technology and steps for adapting the Industrial-Scale Winery during the off season, or if decommissioned, in order to accomplish the storage and processing of the pomace into a food product. The technology that is from the winery is the fermenter 214, which is designated as an OS-Fermenter when out of service (e.g. during the offseason). A must pump 6 is used to circulate pomace for coarse shearing 219. and an optional ozonation subsystem is illustrated including a water tank 22, a water pump 21A to pump water to the ozonation machine 20 and then another water pump 21B to transfer ozonated water to the storage / fermenter tank 214. The additional technology illustrated is portable or mobile when possible to allow for the modular configuring of a General Process System and for the efficient removal or storing away of equipment from the winery, or isolation outside of a wine cellar area for the winery to resume their normal operations during the season of crush / winemaking (production). Water from a tank 22 is moved by a water pump 21A to an ozonation machine 20 and ozonated water is moved to the OS-Fermenter 214 which acts as a storage tank prior to fermentation, Nitrogen gas is used as an additional stabilization means (stabilization medium 204; see FIG. IB) to maintain the integrity of the pomace. The must pump 6 and shearing mechanism 23 are used to shear the pomace.

[0290]

[0241] FIG. 4A is a process diagram, according to some embodiments, showing the steps for how an Industrial-Scale Winery could transfer the pomace, after all the wine has been extracted, back into a Fermenter during the “off season,” such that the fermenter is now an OS-Fermenter. FIG. 4A also shows processes for optionally pre-milling, optionally ozonating prior to transfer into the OS-Fermenter 214 and shearing the pomace 102 while in the OS-Fermenter 214 and stored under an inert gas 24 such as nitrogen. As indicated in FIG. 4A, this example of an Industrial-Scale Winery has a grinding mill 23 on site. This is not normally used during winemaking, but if the Industrial-Scale Winery plans to use the pomace 102 to extract food supplements from the pomace 102, then it would likely have a grinding mill 23 present to grind the pomace 102 as it is being transferred using a converyor 4. See FIG. 11 illustrating an embodiment of milled pomace. Although FIG. 4A shows the water being ozonated and fed into the pomace 102 in the storage / fermenter tank 214 after the pre-milling step, it is to be understood that the ozonated water could be added during the pre-milling step and / or after. The ozonated water would be added to bring the moisture content of the pomace 102 up to a total of about 88% moisture. The amount of water required to be added depends on how dry the pomace is and the kind of milling machine that is being used. Ozonation is a strategy (stabilization means) for the temporary suppression of microbiological spoilage. FIG. 4B illustrates the configuration of the system and process steps if the ozonation and pre-milling equipment and steps are omitted, thereby eliminating the water tank, water pumps, ozonation machine and pre-milling equipment shown in FIG. 4A.

[0291]

[0242] FIG. 5 is a process diagram (similar to FIG. 3), according to some embodiments, showing the technology and steps for adapting the Industrial-Scale Winery during the off season in order to accomplish the storage and processing of the pomace into a food product. The pomace is delivered to the OS-Fermenter 214 using a must pump 6A for storage. The technology that is from the winery is the fermenter, which is designated as an OS-Fermenter during the offseason. The additional technology is portable or mobile when possible to allow for the modular configuring of a General Process System and for the efficient removal or storing away of equipment from the winery, or isolation outside of a wine cellar area for the winery to resume normal operations during the season of crush / winemaking.

[0292]

[0243] FIG. 6 is a process diagram, according to some embodiments, showing the steps for an alternate to the FIG. 4A and 4B processes, incorporating the embodiment of FIG. 5. In this embodiment, the pomace 102 is transferred from a red wine fermenter 8 using a conveyor 4A to a pomace press 10 and then transported to another area outside of the wine cellar to where the General Process System is set up to conduct the General Process. The pomace 102 is not premilled prior to transfer into the OS-Fermenter 214. Rather, it is ozonated prior to transfer into the OS-Fermenter, sheared while in the OS-Fermenter and stored under an inert gas such as nitrogen 24. In order for the must pumps 6A and 6B to be able to pump the pomace 102, (optionally ozonated) water 25 must be added to reduce the viscosity to an appropriate level where it will be fluid enough to be pumped.

[0293]

[0244] FIG. 7A is a process diagram, according to some embodiments, showing the technology and steps for how the microbial starters 208 could be propagated in a tank 210 to the amount required by Industrial-Scale Fermenters. A single propagation tank 201 can be used for the propagation of all the different types of microbials needed to carry out of the fermentation pathways (yeast / LAB; yeast / AAB and yeast / LAB / AAB). Alternatively, a separate propagation tank can be used for each type of microbial needed for the fermentation of pomace.

[0294] Micronutrients (minerals and vitamins) 207 and macronutrients (sugars, proteins) 209 are added to support the microbial propagation. The propagation tank 210 may be configured as a jacket stirred tank with controls for temperature, aeration (dissolved oxygen), pH, rotation, cell density. Providing for a stirring means 211 allows for a relatively efficient propagation timeline. In contrast the propagation vessel design of FIG. 7B that does not have a stirring means...

[0295]

[0245] FIG. 8 is a process diagram, according to some embodiments, showing the technology and steps for conducting an initial yeast and LAB (anaerobic microbial) fermentation using a the microbes as cocktail of fermentation microbials 212 on the pomace located in an OS-Fermenter 214„ which may be in a wine cellar. FIG. 8 shows the must pump 6 and the shearing grinder / pump 219 separately, but they can be combined into a singly pump-grinder unit. In this embodiment, the OS-Fermenter has a jacket-stirred configuration with controls for temperature and pH.

[0296]

[0246] FIG. 9 is a process diagram, according to some embodiments, showing the technology and steps for conducting an AAB (bacterial) fermentation on the yeast / LAB fermented pomace using AAB as the fermentation microbials 212 in an appropriate fermenter located outside of a winery cellar. In some embodiments, this fermenter external to a wine cellar could be located on the winery premises, or it can be located at a distance on another site. In this embodiment, the anaerobic fermentation was done in a different fermenter 214A (in or outside of a wine cellar or wine cellar area) than the second fermentation using AAB which is conducted in an appropriate fermenter 214B located outside of a winery cellar or wine cellar area. In this embodiment the distance between the two fermenters is such that a must pump 6 can be used to transfer the partially processed pomace from fermenter 214A to fermenter 214B. Also shown in this figure is also the supply of nutrients 215 and air / oxygen 217 needed for the AAB fermentation.

[0247] FIG. 10 is a process diagram, according to some embodiments, showing the technology and steps at a high level for conducting the conversion of winery derivatives into a product including a Kosher wash step. It also illustrates an embodiment of a processing subsystem and sets out various PCPs applicable in a Kosher and non-Kosher processing pathways.

[0297]

[0248] FIG. 17A illustrates, a according to some embodiments, showing the technology and steps for conducting both yeast and LAB fermentation (Yeast-LAB Pathway) steps in the same OS-Fermenter, which could be done inside of a wine cellar. FIG. 17B illustrates, according to some embodiments, the technology and steps for conducting an ethanolic (yeast) and AAB fermentation (Yeast-AAB Pathway) in the same OS-Fermenter, which would be done outside of a wine cellar. FIG. 17C illustrates, according to some embodiments, showing the technology and steps for conducting both yeast and LAB fermentation (Yeast-LAB-AAB Ppathway) steps in the same OS-Fermenter, which could be done inside of a wine cellar.

[0298]

[0249] Winery Conveyor Systems

[0299]

[0250] Industrial scale wineries often employ conveyor and pump systems which can be deployed as part of a material transfer subsystem for a General Process System together with pumps and piping. Conveyors can be positioned to be either horizontal or inclined, though once they are positioned as such, they tend to stay that way. Conveyors can be linked to one another so as to create a transport system throughout an industrial scale winery.

[0300]

[0251] Some conveyors such as belt conveyors are oriented in a horizontal position and typically comprise cleats located at appropriate intervals to stop the contents from sliding backwards and are used to transport the contents from one location to another. Other conveyors such as screw conveyors can be positioned to transport the contents from a lower position to a higher position up an appropriate incline.

[0301]

[0252] Examples of a conveyor systems used for short distance transfer are manufactured by pfi conveyers whose website: htt ^Z / w ^fi^ shows a number of different types of conveyers, including belt conveyors, lift conveyers, curve conveyers, horizontal motion conveyors, bucket and incline conveyers, dumpers and vibratory conveyers and feeders. Thus, in one embodiment, a short belt conveyor system can be used to transport crushed grapes to the top of an industrial fermenter where they can be introduced into the fermenter.

[0302]

[0253] KWS Conveying Solutions manufactures a number of different types of conveyor systems whose website is : https, / / wwv / . kwsmfg. com . For example, they sell a number of different types of screw conveyers, including horizontal screw conveyers, inclined screw conveyers, shaftless screw conveyers, and vertical screw conveyers

[0303] Their website explains that horizontal screw conveyers are used to transport bulk materials from one part of a process to another and are the most widely used.

[0304]

[0254] A European company located in the UK sells conveyor systems for the winery industry as shown on their website: https: / / www.vigoltd.com / Catalogue / Conveyoring / Conveyor-systems.

[0305]

[0255] Some industrial scale wineries have an extensive conveyor system to transport either whole grapes, crushed grapes or pomace.

[0306]

[0256] In one embodiment a material transfer subsystem comprises predominantly conveyors for the transfer of pomace in and out of fermenters. In another embodiment, a material transfer subsystem comprises a combination of conveyors and pumps, such as must pumps, and all related piping needed for the transfer of pomace in and out of OS -fermenters. In yet another embodiment, a material transfer subsystem comprises predominantly must-pumps and all related piping needed for the transfer of pomace in and out of OS-fermenter. Grapes can be either hand- picked or harvested by a machine. Grapes destined to become premium wines tend to be hand- picked whereas non-premium wines are often machine harvested. Premium wine grapes need to be crushed prior to entering the fermenter, which is almost always done on site. Non-premium grapes are somewhat crushed by the harvesting machine, but still need to go through a crusher prior to either juice extraction or introduction into a fermenter.

[0307]

[0257] When a transport vehicle arrives at an industrial sized winery, the contents of either premium grapes or machine-harvested grapes are usually transferred to a destemmer / crusher. The premium grapes tend to arrive in picking bins. The machine-harvested grapes tend to arrive either by a tanker or a gondola, wherein the contents are immediately transferred to a destemmer / crusher. After destemming the premium-grapes are also partially crushed grapes and like the machine harvested grapes are usually pumped either to a press or to a fermenter.

[0308]

[0258] A destemmer / roller crusher comprise two components: one designed to remove the stems from the grapes after which the berries are fed through a roller crusher. The destemmer is a rotating drum with high speed beaters, which remove the stems from a grape cluster. The berries are partially broken by this process and are then transferred to roller crushers which are part of the same machine. Berries are broken through the rollers are then transferred to a progressive cavity pump, which will transfer the crushed berries, suspended in juice either into a red wine fermenter or a white wine press. The juice exiting the white wine press is pumped into the white wine fermenter, whereas the white wine pomace is placed in some kind of appropriate storage container. One manufacturer of destemmers and destemmer / crusher’s is Sraml. One example of a destemmer that comprises an inline sliding crusher, is the Sraml DS-type destemmer series, which can be seen at Sraml’ s website: https: / / sra l. co / product-

[0309]

[0259] The surfaces of these conveyor systems are sanitized in a manner similar as one would expect for the surfaces of a food production facility and / or a restaurant.

[0310] INDUSTRIAL-SCALE OS-FERMENTERS, OTHER EQUIPMENT AND POSSIBLE MODIFICATIONS THEREOF

[0311]

[0260] The selection of an Industrial-Scale Fermenter designed for wine production to adapt for the fermentation of pomace will depend on a number of factors. Fermenters used for industrialscale red wine production are designed to receive and for the removal of pomace (see FIG. 2A). As a result, compared to fermenters used for white wine production fewer adaptations are needed to configure an industrial red wine fermenter for use to ferment and process pomace according to the present disclosure. Features such as a pomace dump door and sampling ports in the lower region of the industrial red wine fermenter are features useful for the fermentation of grape pomace on an industrial-scale.

[0312]

[0261] In one embodiment, an OS-Fermenter is an industrial-scale red wine fermenter adapted (configured) for the anaerobic fermentation of pomace to provide an ethanolic pomace. In another embodiment, an OS-Fermenter is an industrial-scale red wine fermenter adapted (configured) for the fermentation of an ethanolic pomace to provide an acidic pomace. In yet another embodiment, an OS-Fermenter is an industrial-scale red wine fermenter adapted (configured) for the aerobic fermentation of an ethanolic pomace to provide an acidic pomace.

[0313]

[0262] Industrial scale red wine fermenters comprise a closed top, wherein the top of the tank is an off-centre cone. One example of this type of a fermenter is sold by Propspero and can be viewed at https: / / prosperoequipment.eom / winerv-gallery / #group. The dimpled surface shown in the image is a heat exchanger for circulating glycol coolant. There are two dimple sections, one for the upper and the other for the lower section. The lower section is used for heating and can cause convection currents that move upward. The upper dimple section is used for cooling and can cause convection currents that move downward. These take advantage of the changes in liquid density by change in temperature.

[0314]

[0263] The tank is elevated so that pomace can be dumped onto a conveyor or pomace removal container. Note that the dump door slides upward in a frame and does not open inward as a white fermenter does. The control panel for each tank is mounted to the side. Note the hand crank to open the door.

[0315]

[0264] There is a racking valve mounted above the conical bottom of the tank. This used for the removal of liquid prior to opening the access door at the bottom of the cone. There are two other ports with no valves. These are probably ports for a Guth agitator. A Guth port has a hinged flapper valve inside the tank. An agitator with hinged paddles can be inserted through the port and the paddles become open by centrifugal force.

[0316]

[0265] Alternatively, a sparging wand can be inserted. No wine is spilled during insertion or withdrawal because the device has a sealed cap on the insertion rod that forms a part of the device. There is also a small valve somewhere for sample removal for analyses, and blind port for insertion of a thermometer. The wine can be sparged with any gas: oxygen to accelerate yeast growth or oxidative flavour changes, nitrogen to remove oxygen, argon to blanket or remove oxygen, or carbon dioxide to sparge and give short term protection against oxygen uptake, Commercial blends of these gasses are also used

[0317]

[0266] A variation on the dual purpose fermenter that can be used for whites or reds. One example of this type of a fermenter is sold by Propspero and can be viewed at https: / / prosperoequipment.eom / winerv-gallery / #group. The oval manway shown in the image on the left opens inward. This tank has a sloping bottom instead of conical. Same configuration of dimple sections. Dimple sections are created when a light weight sheet of stainless steel is spot welded to a heavy sheet. When compressed air is applied between the sheets, the light weight sheet expands slightly and creates passage ways for coolant to circulate.

[0318]

[0267] The vertical pipe on the right side is to enable a conventional "pump over" in which wine is removed from the bottom and periodically pumped to the top of the tank, thus submerging the skins. Skins are swept to the top of the tank by escaping carbon dioxide, but settle to bottom when fermentation stops. The tanks typically are not filled greater than about 75% in order to allow for foam and cap expansion of contents. The volume above the contents is referred to as headspace or ullage. After the fermentation is complete, the wine is removed from the sediment (lees) and the tanks are filled close to capacity in order to minimize ullage, which can contain air and lead to spoilage. White wine tanks or storage tanks often have a conical top with a chimney on top. The tank is filled to the bottom of the chimney and the volume of the chimney is equal to the wine expansion that would occur if the temperature of the contents rose by ten degrees Celsius.

[0319] Modifications to a Red Wine Fermenter

[0320]

[0268] During the fermentation of red wines a “cap” starts to form above the liquid as soon as fermentation starts after filling the fermenter with crushed red grapes and initiating the fermentation process. The skins separate from the liquid and are pushed up to the top by the CO2 released by the yeast forming a semi-solid “cap” over the liquid, which traps valuable components such as polyphenols. There are a number of different methodologies known in the field for breaking apart this “cap.”

[0321]

[0269] In general, winemakers desire to mix the must (wine, the berry flesh, skins, and seeds) while sparging to ensure that the wine fermentation is being conducted anaerobically. The sparging process using an inert gas (nitrogen, carbon dioxide, argon or some combination thereof) causes the mixing and oxygen removal of the fermentation materials. There are three reasons why a winemaker will mix a red wine tank: 1) to enhance extraction of anthocyanins and phenolic compounds from the pulp and skin, 2) to remove oxygen and 3) to break up the cap. In white wine, it is mixed only to remove oxygen.

[0322]

[0270] There are a number of ways to mix the wine producing mixture known in the field. One example is provided by the company, Parsec, which is described on their website: https: / / parsecsrl.net / en / air-mixing / . They developed a new technique to decompact the cap which forms at the top of the fermenter when fermenting red wines with the crushed berries and skin which involves sequential modulated injection of compressed air or gas. Their patented technologies comprises multiple injectors placed around the tank, approximately 1 / 3 from the bottom of the tank. The design creates a wave-like movement in the liquid inside the tank due to the combined and synergistic sequences of pauses and small jets. The cap is completely decompacted within a few seconds by inundating it with the wave-like fluid movement.

[0323]

[0271] In one embodiment, the more conventional technology is that the sparging is conducted at the bottom of the tank using a sparging port or nozzles located at that level. The availability of such features allows for the mixing of pomace and maintenance of an anaerobic environment when processing pomace to produce an ethanolic pomace or an acidic pomace, e.g. when fermenting with lactic acid bacteria.

[0324]

[0272] By contrast, an industrial-scale red wine fermenter must be adapted for use to conduct an aerobic fermentation of pomace. Adaptations needed may include providing for an aeration means, such as sparging with air or oxygen, to be able to be able to change out the atmospheric environment in the fermenter between anaerobic and aerobic conditions. This would be the case, for example, if the industrial red wine fermenter is to be used for both types of pomace fermentations according to the present disclosure. Other adaptions may include providing for the ability to circulate (pump) and coarsely shear the pomace as illustrated in the present disclosure, (e.g. see FIGs. 3 and 5).

[0325]

[0273] Additional considerations regarding the adaptation of red wine fermenters is when it may be used for extended storage. Most red fermenters have a dimple jacket for heating on the lower third of the tank, assuming that convection currents will circulate the contents upward. Longer term storage requires that cooling be on the upper third of the tank and convection currents will cool the lower part. Some tanks have two dimple sections and can be used either for storage or fermentation.

[0326] Modifications to a White Wine Fermenter

[0327]

[0274] The types of modifications described for industrial red wine fermenters will generally also have to be made to industrial white wine fermenters, taking into account differences in respective tank size and shape designs and temperature control features. Additionally, industrial white wine fermenters will require modification to provide a stirring means within the tank and to provide for the efficient removal of pomace from the white wine fermentation tank in order to transfer to another fermenter or removal for further processing. These modifications are needed because pomace is not part of the white wine fermentation process and is separated out away from the grape juices that are streamed into an industrial white wine fermenter.

[0328]

[0275] The other issue between white and red fermentation tanks is drainage which needs to be considered for the adaptation of white wine fermenters. White wine fermenter tanks are designed on the assumption that there will be no intact grape skins. There is a racking valve incorporated into the tank, just below an inward opening manway. This enables the contents to be mostly removed but leaves sediment in the bottom of the tank (such as lees). After the contents have been lowered to the level of the racking valve, the manway can be opened and the contents can be visually inspected to determine the exact level to remove clear liquid but leave the sediment intact. The racking valve and drain valve are typically butterfly valves which rotate on a central pivot. They are not suited for a tank which contains skins because the skins accumulate and plug a butterfly valve. Red tanks have a large gate valve that opens to a clean bore and will not plug. The manway opens outward or upward so that the contents will be accessible, even if there is pressure against the manway.

[0329]

[0276] In the case of using ozonation as shown in FIGs. 3 and 4A, it is noted that ozonation must be carefully controlled. Ozone can damage a stainless steel tank, which are what is typically used for wine fermentation. Fermenters at wineries are typically 304 stainless steel, however, a more resistant 316 steel tank construction could be brought on site and used (e.g sourced from In the alternative to using steel tanks, ozone resistant HDPE tanks custom made or adapted for fermentation may be brought on-site to a winery.

[0330] Other Equipment Modifications

[0331]

[0277] Additional modifications or changes in operating procedures may be required to assure proper maintenance and cleaning in order to assure there is no cross-contamination. For example, conveyors could be swapped or adapted to become sanitary conveyer systems (as is used in the food industry) that are continuously sanitized while being used. Pumps, transfer hoses, valves, sampling ports and various processing equipment used in the dairy industry are designed to be sanitized daily and are designed to avoid areas that can avoid sanitation and trap contaminants. The wine industry does not generally use 3A sanitation standards. Most equipment traps sediments which may include unwanted contaminants, however, equipment may be seldom disassembled and is not designed for easy disassembly. In one embodiment pumps, piping and / or conveyors of a winery are adapted to be readily sanitized or serviced for the removal of sediments and contaminants.

[0332]

[0278] Pomace usually requires a conveyor to remove it, unless it is suspended in a large amount of liquid. A liquid with suspended solids can be conveyed by a piston pump such as a Manzini or a progressive cavity pump such as a Moyno.

[0333]

[0279] Liquids can be transferred by either a centrifugal pump such as used in the dairy industry or a positive displacement pump such as a Ladish, Waukeshaw, or Jabsco. Centrifugal pumps can only be used if they are situated below the base of a tank because they cannot pump if there is an air pocket in the pump. This can occur during the final stages of drainage. Centrifugal pumps grind skins and seeds by shear forces and can create a thick suspension that may not be acceptable. An alternative to this may then be the use of must pumps.

[0334] EXAMPLES

[0335] EXAMPLE I; Ethanolic and Acetic Acid Fermentation without Kosher Washing

[0336]

[0280] FIGS. 15A-15C show a flow diagram for ethanolic and acetic acid fermentation without Kosher processing. As described in FIG. 15A, the pomace is transferred to a transport container and at step 906, the container is shipped (e.g. by truck) to for the pomace to be received at an Industrial Scale Winery. Alternatively, the pomace may be prepared and collected from grapes (white winemaking process) or collected from a winemaking fermenter (red winemaking process) at the winery and would generally be transferred using conveyors and must pumps to the initial holding container / fermentor of a system according to the present disclosure..

[0337]

[0281] Inspection Point 907 entails a visual inspection of the pomace, looking for pests, foreign matter and visible mold, etc. A sample (e.g., 200 ml) will be taken to conduct a laboratory analysis for moisture, total polyphenols, titratable acidity, ethanol, sugars, yeast and mold counts. On arrival the pomace tends to be in the pH range below 4.0, and the moisture is approximately 40%. A sample (e.g. 200 ml) will also be sent out to a third-party laboratory to analyze for pesticides according to the regulatory standards relevant to the jurisdiction in which the product will be produced (e.g., Health Canada Standards determine the tolerance levels for pesticides, which is currently on the order of 50 different pesticides). Analysis will also be conducted for pathogenic microorganisms, which will also be typically performed by DNA testing (PCR), rather than plating.

[0338]

[0282] At step 908 the pomace is accepted or rejected for further processing. If the pomace is to be milled, the milling will be done until at least 90% of the seeds are cracked, according to embodiments. A sample (e.g., 200 ml) will be collected 909 and inspected for broken seeds and moisture content. At step 910 the pomace, will be transferred to an anaerobic fermenter and there may be an additional Inspection Point 911 to test for molds and moisture content levels. The process continues at step 913 to 913 in FIG. 15B.

[0339]

[0283] At step 912, the pomace is inoculated with yeast and optional adjustments to the chemical composition may be made for fermentable sugars and nutrients. In some embodiments, the inoculation will be conducted by adding approximately 200 mg yeast cells / L.

[0340]

[0284] In some embodiments, the target for the Acetic Acid Pomace 923 is a titratable acidity of around 2.2%. In other embodiments the target titratable acidity is 2.5-2.7%. If the Acetic Acid Pomace 923 is destined to be dried and become a powder product, the titratable acidity might be in the range of 2.2-5% or in other embodiments may be in the range of 2.5-5%. This can be controlled by measuring the input material (e.g., ethanol, sugars, and yeast nutrients) and adding enough fermentable sugar and yeast nutrients to produce sufficient ethanol to be converted during the acetic acid fermentation to result in a titratable acidity of 2.2 - 5% in the Acetic Acid Pomace 923 or in other embodiments a titratable acidity of 2.5-5%. The acidity can be measured by titration, and a device such as an OenoFoss machine may be used to determine the amount of sugars and ethanol.

[0285] At 913, the process continues in FIG. 15B. At step 914, the pomace is fermented to generate ethanol. In general, a sample will be withdrawn the day after initiating the fermentation to ensure that the fermentation has started. If there is no activity, it might be necessary to reinoculate the pomace.

[0341]

[0286] At Inspection Point 915, a sample will be withdrawn and tested for yeast activity and ethanol to ensure that the fermentation is complete. This composition is referred to as Ethanolic Pomace 916.

[0342]

[0287] At step 917 the Ethanolic Pomace 916 is transferred to an aerobic fermenter, depending on the winery set up or the on-site capability to conduct the second fermentation in the same fermentation vessel as the first fermentation of FIG. 15A without affecting wine production. It may be desirable to blend varietals of Ethanolic Pomace 916 to stay within the limits of composition standards to ensure the pH is below 4.0 and the titratable acidity is below 8 grams / L. At the Inspection Point 919 the most important parameter is the concentration of ethanol. Accordingly, the Ethanolic Pomace 916 will be analyzed to determine the amount of ethanol in addition to determine that the composition of the Ethanolic Pomace appropriate for Acetic Acid Bacteria. At step 921 the Ethanolic Pomace 916 is fermented to produce acetic acid.

[0343]

[0288] In some embodiments, it may be desirable to calculate and meter the amount of oxygen delivered to the aerobic fermenter. For example, assuming that the efficiency of oxygen mass transfer between sparging air and pomace would depend on the air flow rate and bubble size. This transfer rate would have to be measured, but is on the order of 50%. Using the estimation that air comprises approximately 20% oxygen, the amount of air required for a 1,000 L fermentation tank would be calculated using an equation such as (liquid volume in the tank) X (% alcohol / weight / 100) X 250 Litres of air. The smaller the bubble size and the slower the rate of delivery, the greater the rate of conversion from ethanol to acetic acid.

[0344]

[0289] In some embodiments, the fermentation can be monitored using in-line analyzers for Brix, ethanol, dissolved oxygen and temperature. At Inspection Point 922 analysis will be conducted in order to determine that the stoichiometric conversion of ethanol to acetic acid is complete, (i.e., that no ethanol remains), and optionally to measure the titratable acids to ensure that they are in the range of 2.2-5%, or in other embodiments in the range of 2.5-5%. In one embodiment the measure of titratable acids is done to ensure they are in the range of 2.5-2.7%. At that point the aerobic fermentation should be discontinued by ceasing the aeration. This composition is referred to as Acetic Acid Pomace 923.

[0345]

[0290] At step 924 the Acetic Acid Pomace is sheared to create a puree, and the composition is termed Raw Puree 925.

[0346]

[0291] At 926, the process continues in FIG. 15C.

[0347]

[0292] In some embodiments, Raw Puree (also referred to herein as Raw Pomace) 925 will be analyzed to determine whether the composition meets the KPI for the Raw Puree 925 which in some embodiments would be a total polyphenol content of 50-60 mg. gallic acid equivalent / g dried mass and a particle size of 92 - 93% passing through an 80-mesh screen. In FIG. 15C, this analysis is indicated at Inspection Point 929, which follows from an optional blending step 928, only if the blending step is conducted at step 928 to produce a Blended Raw Puree 930. Otherwise, this Inspection Point would be conducted on the Acetic Acid Pomace 923 at Inspection Point 922 as shown in FIG. 15B. Other embodiments are provided in Table 1 at FIG. 18.

[0348]

[0293] At step 932, the (Blended) Raw Pomace 925, 930 is subjected to a thermal or nonthermal stabilization step in order to reduce the count of viable microorganisms, according to embodiments. In some embodiments, the objective of the stabilization process is to lower the colony forming units (CFU) to under 2,000 - 3,000 CFU / gram, while minimizing the loss of volatile compounds and / or damaging some of the phenolic compounds. In some embodiments, the treated pomace will be under 1,000 CFU / gram.

[0349]

[0294] Examples of non-thermal stabilization process could include ultrasonic radiation or ultraviolet radiation. Examples of a thermal process could include ultra-high temperature (UHT) for a time period such as 1 second or less, or high temperature short time (HTST) for a short time period, and could include heating the puree in industrial kettles. In some embodiments, the puree is heated at 90° C for 30 minutes in an industrial kettle. In some embodiments, the puree is heated at 85° C for one hour in an industrial kettle.

[0350]

[0295] After the stabilization step 932, Inspection Point 933 will be conducted to determine if an appropriate CFU count has been attained in addition to measuring the pH, titratable acidity, total phenolics, and acetic acid. In some embodiments, a KPI for Inspection Point 933 is a particle size 95-99% passing through an 80-mesh screen.

[0296] If the product is to be a puree, then the Raw Pomace 925 will be subjected to wet processing techniques 934, in some embodiments. Inspection point, 938 could be performed in order to determine a particle size KPI, which could be in the general range of 94% - 100% of the particles passing through an 80-mesh screen, in some embodiments, depending on the desired product texture. See FIG. 18 for additional embodiments. Moreover, in order to determine whether the product meets product specifications, analysis will be conducted for final inspection, pre-packaging, and should include titratable acidity, pH, total phenolics, tartaric acid, malic acid, lactic acid, acetic acid. Moreover, appropriate analysis must be conducted to gather the information to be included in the Certificate of Analysis (CoA) for the product. Examples of CoAs are presented in FIGs. 12A and 12B; FIGs. 13A and 13B, FIGs. 20A and 20B; FIGs 21A and 22A; and FIGs. 22A and 22B. Each of these is representative of selected (targeted benchmarks or specifications for product, which in embodiments of the General Process are considered for monitoring the pomace storage and fermentation environments, other process step conditions and progression, intermediates, pomace characteristics, by-products and contaminants, and other factors relevant to achieving the desired specifications of product.

[0351]

[0297] In some embodiments the KPI for the puree product can be that the particle size is such that 95-99% of the product passes through an 80-mesh screen, the moisture content of the puree is 86 - 87%, the total polyphenols are 0.3% for the “gold puree” (based on a white grape blend) and 0.4% for the “ruby puree” (based on a red grape blend). In some embodiments, the quality safety requirements include that the aerobic plate count is <10,000 CFU / grams puree, the total coliforms are < 10 CFU / grams puree, yeast and mold are < 1,000 CFU / grams puree. Moreover, the puree product tests negative for E. coli, Listeria monocytogenes, Salmonella spp. and Staphylococcus aureus.

[0352]

[0298] At step 942, the puree product will be packaged. In some embodiments, the puree product will be hot-packed, in which the product is heated, for example to a pasteurization temperature of 90° C and dispensed into the package and sealed while the contents are still hot. The package comes in a sterile condition from the manufacturer.

[0353]

[0299] At Inspection Point 944, packages will be drawn randomly from the batch, and analyzed to confirm that the CoA for the product is valid, pre-shipment. This sampling would be conducted on an appropriate periodic basis throughout the storage period, and likely within a short period of sending to a customer. At step 945, the product is shipped to the customer.

[0300] If the product is to be a dry product, then the Raw Pomace 925 will be subjected to drying processing techniques 950. Examples of drying processes include freeze drying, spray drying, microwave vacuum drying, etc. or immobilization onto a solid substrate. For example, immobilization onto a solid substrate entails adding a substrate such as agar, pectin, protein, etc. to create a solid complex, which can be powdered by conducting a fine grind.

[0354]

[0301] In some embodiments, where a tail-form spray dryer is used, the puree is transferred into a holding tank, where it is introduced into the top of the spray tower via a high-pressure nozzle. The high-pressure nozzle produces droplets of puree that fall through the heated air in the nozzle tower (for example, a 50-foot drop). By the time the droplets reach the bottom of the dryer they are dry particles having a particle size (mean particle size) in the range of an 80-mesh screen, or 0.177 millimeters. In some such embodiments, it will not be necessary to conduct a fine grind (step 952) in order to reduce the particle size.

[0355]

[0302] There are several parameters that determine what the final particle size will be including nozzle design / orifice size, height of spray dryer, pump pressure, puree solids content, and temperature. One objective is to ensure that the rate of evaporation is slow enough that damage to the active compounds within the puree (e.g., polyphenols) is minimized. These parameters are typically determined by simple trials which can help determine the right size / type of equipment along with proper puree characteristics to consistently produce product that has a desired particle size in a very narrow particle size distribution in addition to minimal damage to the polyphenols. There are several ways to atomize or spray puree into spray dryers.

[0356]

[0303] In some embodiments, the puree which is to be spray dried has an approximately 87% moisture content and 13 % solids content. In some embodiments, the target objective is to generate a powder, which has between 7%-less than 9% moisture content. In some embodiments, the moisture content of the final powder is 8.5%. The objective to remain below 9% is to be compliant with GRAS, to minimize the microbe activity in addition to the water activity. The moisture content is not to be lowered below 7% to retain the activity of the compounds within the powder. In some embodiments the polyphenol retention in the powder will be between 96% and 100%, the acids and volatiles retention will be between 50% and 80%, the water activity will be below 0.85 and the particle size will be such that 100% of the powder passes through an 80- mesh screen.

[0304] At step 952, the dried powder will be subjected to a fine grind. In some embodiments where the product will be incorporated into a food that is sensitive to particle size (e.g., a smooth chocolate), the particle size of the product will be smaller, such as similar to that of cocoa powder.

[0357]

[0305] Inspection Point 954 will be to determine a particle size KPI, which could be 94% - 100% of the particles passing through an 80-mesh screen. In some embodiments, in order to determine whether the product meets specifications, analysis will be conducted for final inspection, pre-packaging, must include titratable acidity, pH, total phenolics, tartaric acid, malic acid, lactic acid, acetic acid.

[0358]

[0306] In some embodiments the KPI for the powder product can be that the powder yield is >95%, the particle size is such that 100% of the product passes through an 80-mesh screen, the moisture content of the powder is 7 - 9%, the total acidity is 15%, the total polyphenol retention is 96-98%. In some embodiments, the quality safety requirements are that the water activity is <0.85, the aerobic plate count is <10,000 CFU / grams powder, the total coliforms are < 10 CFU / grams powder, yeast and mold are < lOOCFU / grams powder. Moreover, the powder product tests negative for E. coli, Listeria monocytogenes, Salmonella spp. and Staphylococcus aureus.

[0359]

[0307] Moreover, appropriate analysis must be conducted to gather the information to be included in the Certificate of Analysis (CoA). Examples of CoAs are presented in FIGs. 12A and 12B; FIGs. 13A and 13B, FIGs. 20A and 20B; FIGs 21A and 22A; and FIGs. 22A and 22B. Each of these is representative of selected (targeted benchmarks or specifications for product, which in embodiments of the General Process are considered for monitoring the pomace storage and fermentation environments, other process step conditions and progression, intermediates, pomace characteristics, by-products and contaminants, and other factors relevant to achieving the desired specifications of product.

[0360]

[0308] At step 958, the powder will be packaged, using ambient temperature packaging techniques. The package comes in a sterile condition from the manufacturer.

[0361]

[0309] At Inspection Point 960, packages will be drawn randomly from the batch, and analyzed to confirm the CoA is valid, pre-shipment. This sampling would be conducted on an appropriate periodic basis throughout the storage period, and likely within a short period of sending to a customer. At step 962, the product is shipped to the customer. EXAMPLE II: Ethanolic and Acetic Acid Fermentation with Kosher Processing

[0362]

[0310] FIGS. 16A-16C illustrate a flow diagram for ethanolic and acetic acid fermentation with Kosher processing. As described in FIG. 16A, Kosher Pomace is transferred to a transport container and at step 1006, the container is shipped (e.g. by truck) to an Industrial Scale Winery. Alternatively, the pomace may be prepared from grapes at the winery and would generally be transferred using conveyors and must pumps to the initial holding container / fermentor of a system according to the present disclosure.

[0363]

[0311] At the inspection point 1007 starts with a visual inspection looking for pests, foreign matter visible mold. A sample (e.g., 200 ml) will be taken to conduct laboratory analysis for moisture, total polyphenols, titratable acidity, ethanol, sugars, yeast and mold counts. On arrival the pomace tends to be in the pH range below 4.0, and the moisture is approximately 40%. A sample (e.g. 200 ml) will also be sent out to a third-party laboratory to analyze for pesticides according to the regulatory standards (e.g, Health Canada Standards which is currently on the order of 50), pathogenic microorganisms, typically done by DNA testing (PCR), rather than plating.

[0364]

[0312] At step 1008, the Kosher Pomace accepted for processing is optionally transferred to a Kosher Washing Station under the supervision of a Rabbi, according to embodiments. In some embodiments, a Kosher certified facility may perform some and / or all of the washing steps. In most cases the Kosherization process can be achieved without washing the pomace, in which case the process would go from step 1008 when the pomace is accepted for further processing by way of fermentation to step 1018 when the yeast microbials and nutrients needed for anaerobic (ethanolic) fermentation are added to the pomace in a fermentation tank (bioreactor). See FIG.

[0365] 16C

[0366]

[0313] In some embodiments the pomace must be washed within 24 hours of the juice being expressed from the whole berries. The pomace is washed several times (e.g. seven) at 1010 until Kosherization is assured. In some embodiments the water may be re-used for some of the washes, and only fresh water can be used for the final wash. The pomace is Kosher -Washed Pomace 1011.

[0314] In some embodiments, it may be desirable to dry the Kosher -Washed Pomace 1011 below a threshold percentage such as less than 10% moisture content to be rendered Kosher throughout the rest of the processing without requiring supervision of a Rabbi.

[0367]

[0315] In embodiments, where the Kosher-Washed Pomace 1011 has not been dried, the Kosher Washed Pomace 1011 is optionally milled. In some embodiments, the result of the milling is such that at least 90% of the seeds are cracked. A sample (e.g., 200 ml) will be collected 1013 - inspection for broken seeds and moisture. At step 1014, the Kosher Washed Pomace 1011, will be transferred to an anaerobic fermenter. The process continues at step 1016 to 1016 in FIG16B.

[0368]

[0316] The Inspection Point at 1017 is conducted to assess the composition of the pomace. This requires analysis of pH, fermentable sugars, and yeast available nitrogen in order to determine the amount of fermentable sugars and nutrients to be added at step 1018.

[0369]

[0317] At step 1018, the Kosher-Washed Pomace 1011 is inoculated with yeast and optional adjustments to the chemical composition may be made for fermentable sugars and nutrients. Inoculation (200 mg yeast cells / L).

[0370]

[0318] The target for the Acetic Acid Pomace 1030 is a titratable acidity around 2.2%. In another embodiment, the target titratable acidity is 2.5-2.7%. If the Acetic Acid Pomace 1030 is destined to be dried and become a power product, the titratable acidity might be in the range of 2.2-5%. This can be controlled by measuring the input material (ethanol and sugars) and adding enough fermentable sugar and yeast nutrients to produce enough ethanol to be converted during the acetic acid fermentation to result in a titratable acidity of 2.2 - 5%. The acidity can be measured by titration, and a device such as an OenoFoss machine may be used to determine the amount of sugars and ethanol.

[0371]

[0319] At step 1020, the Kosher-Washed Pomace 1011 is fermented to generate ethanol and produce an Ethanolic Pomace 1022.

[0372]

[0320] In some embodiments, it may be desirable to calculate and meter the amount of oxygen delivered to the aerobic fermenter. For example, assuming that the efficiency of oxygen mass transfer between sparging air and pomace would depend on the air flow rate and bubble size. This transfer rate would have to be measured, but is on the order of 50%. Using the estimation that air comprises approximately 20% oxygen, the amount of air required for a 1,000 L fermentation tank would be calculated using an equation such as (liquid volume in the tank) X (% alcohol / weight / 100) X 250 Litres of air. The smaller the bubble size and the slower the rate of delivery, the greater the rate of conversion from ethanol to acetic acid.

[0373]

[0321] In general, a sample will be withdrawn the next day to ensure that the fermentation has started. If there is no activity, it might be necessary to re-inoculate the pomace.

[0374]

[0322] At Inspection Point 1021, a sample will be withdrawn and tested for yeast activity and ethanol to ensure that the fermentation is complete. This is referred to as Ethanolic Pomace 1022.

[0375]

[0323] At step 1024 the Ethanolic Pomace 1022 is transferred to an aerobic fermenter, depending on the winery set up or the on-site capability to conduct the second fermentation in the same fermentation vessel as the first fermentation of FIG. 16A without affecting wine production. It may be desirable to blend varietals of Ethanolic Pomace 1022 to stay within the limits of composition standards to ensure the pH is below 4.0 and the titratable acidity is below 8 grams / L. At the Inspection Point 1025 the most important parameter is the concentration of ethanol.

[0376]

[0324] Accordingly, the Ethanolic Pomace 1022 will be analyzed to determine the amount of ethanol in addition to determine that the composition of the Ethanolic Pomace appropriate for Acetic Acid Bacteria. At step 1028 the Ethanolic Pomace 1022 is fermented to produce acetic acid. At Inspection Point 1029 analysis will be conducted in order to determine that the stoichiometric conversion of ethanol to acetic acid is complete, (i.e., that no ethanol remains), and optionally to measure the titratable acids to ensure that they are in the range of 2.2-5%. At that point the aerobic fermentation should be discontinued by ceasing the aeration. This is referred to as Acetic Acid Pomace 1030.

[0377]

[0325] At step 1032 the Acetic Acid Pomace 1030 is sheared to create a puree, termed Raw Puree (or alternatively “Raw Pomace”) 1033.

[0378]

[0326] At 1034, the process continues in FIG. 16C.

[0379]

[0327] In some embodiments, Raw Puree 1033 will be analyzed to determine whether the composition meets the KPI for the Raw Puree 1033 which would be a total polyphenol content of 50-60 mg. gallic acid equivalent / g dried mass and a particle size of 92 - 93% passing through an 80-mesh screen. In FIG. 16C, this is indicated at Inspection Point 1037, which follows from an optional blending step 1036, only if the blending step is conducted to produce a Blended Raw Puree 1038. Otherwise, this Inspection Point would be conducted on the Acetic Acid Pomace 1030 at 1029.

[0328] At step 1040, the Raw Puree 1033 is subjected to a thermal or non-thermal stabilization step in order to reduce the count of viable microorganisms. In some embodiments, the puree is heated at 90° C for 30 minutes. In some embodiments, the puree is heated at 85° C for one hour. The objective of the stabilization process is to lower the colony forming units (CFU) to under 2,000 - 3,000 CFU / gram, while minimizing the loss of volatile compounds and / or damaging some of the phenolic compounds. In some embodiments, the treated pomace will be under 1,000 CFU / gram.

[0380]

[0329] After the stabilization step 1040, Inspection Point 1041 will be conducted to determine if an appropriate CFU count has been attained, pH, titratable acidity, total phenolics, acetic acid. A KPI for Inspection Point 1041 is a particle size 95-99% passing through an 80-mesh screen.

[0381]

[0330] If the product is to be a puree product, then the (Blended) Raw Puree 1033, 1038 will be subjected to wet processing techniques 1042. Inspection point 1046 will be to determine a particle size KPI, which could be in the general range of 94% - 100% of the particles passing through an 80-mesh screen,. depending on the desired product texture. See FIG. 18 for additional embodiments. Moreover, in order to determine whether the product meets specifications, analysis will be conducted for final inspection, pre-packaging, must include titratable acidity, pH, total phenolics, tartaric acid, malic acid, lactic acid, acetic acid. Moreover, appropriate analysis must be conducted to gather the information to be included in the Certificate of Analysis (CoA). Examples of CoAs are presented in FIGs. 12A and 12B; FIGs. 13A and 13B, FIGs. 20A and 20B; FIGs 21 A and 22A; and FIGs. 22 A and 22B. Each of these is representative of selected (targeted benchmarks or specifications for product, which in embodiments of the General Process are considered for monitoring the pomace storage and fermentation environments, other process step conditions and progression, intermediates, pomace characteristics, by-products and contaminants, and other factors relevant to achieving the desired specifications of product.

[0382]

[0331] In some embodiments the KPI for the puree product can be that the particle size is such that 95-99% of the product passes through an 80-mesh screen, the moisture content of the puree is 86 - 87%, the total polyphenols are 0.3% for the gold puree and 0.4% for the ruby puree. In some embodiments, the quality safety requirements include that the aerobic plate count is <10,000 CFU / grams puree, the total coliforms are < 10 CFU / grams puree, yeast and mold are < 1,000 CFU / grams puree. Moreover, the puree product tests negative for E. coli, Listeria monocytogenes, Salmonella spp. and Staphylococcus aureus.

[0383]

[0332] At step 1051, the puree product will be packaged. In some embodiments, the puree will be hot-packed, in which the product is heated such as a pasteurization temperature of 90° C and is dispensed into the package and sealed while the contents are still hot. The package comes in a sterile condition from the manufacturer.

[0384]

[0333] At Inspection Point 1050, packages will be drawn randomly from the batch, and analyzed to confirm the CoA is valid, pre-shipment. This sampling would be conducted on an appropriate periodic basis throughout the storage period, and likely within a short period of sending to a customer. At step 1052, the product is shipped to the customer.

[0385]

[0334] If the product is to be a dry product, then the (Blended) Raw Puree 1033, 1038 will be subjected to drying processing techniques 1056. (See above for the Ethanolic Acetic Acid Fermentation Non-Kosher section for examples and details)

[0386]

[0335] In some embodiments, the target objective is to generate a powder, which has between 7%-less than 9% moisture content. In some embodiments, the moisture content of the final powder is 8.5%. The objective to remain below 9% is to be compliant with GRAS, to minimize the microbe activity in addition to the water activity. The moisture content is not to be lowered below 7% to retain the activity of the compounds within the powder. In some embodiments the polyphenol retention in the powder will be between 96% and 100%, the acids and volatiles retention will be between 50% and 80%, the water activity will be below 0.85 and the particle size will be such that 100% of the powder passes through an 80-mesh screen.

[0387]

[0336] At step 1058, the dried powder will be subjected to a fine grind.

[0388]

[0337] Inspection point 1060 will be to determine a particle size KPI, which could be 94% - 100% of the particles passing through an 80-mesh screen. In some embodiments, in order to determine whether the product meets specifications, analysis will be conducted for final inspection, pre-packaging, must include titratable acidity, pH, total phenolics, tartaric acid, malic acid, lactic acid, acetic acid.

[0389]

[0338] In some embodiments the KPI for the powder product can be that the powder yield is >95%, the particle size is such that 100% of the product passes through an 80-mesh screen, the moisture content of the powder is 7 - 9%, the total acidity is 15%, the total polyphenol retention is 96-98%. In some embodiments, the quality safety requirements are that the water activity is <0.85, the aerobic plate count is <10,000 CFU / grams powder, the total coliforms are < 10 CFU / grams powder, yeast and mold are < lOOCFU / grams powder. Moreover, the powder product tests negative for E. coli, Listeria monocytogenes, Salmonella spp. and Staphylococcus aureus.

[0390]

[0339] Moreover, appropriate analysis must be conducted to gather the information to be included in the Certificate of Analysis (CoA). (for examples of CoAs are presented in FIGs. 12A and 12B; FIGs. 13A and 13B, FIGs. 20A and 20B; FIGs 21A and 22A; and FIGs. 22A and 22B )

[0391]

[0340] At step 1064, the powder will be packaged, using ambient temperature packaging techniques. The package comes in a sterile condition from the manufacturer.

[0392]

[0341] At Inspection Point 1065, packages will be drawn randomly from the batch, and analyzed to confirm the CoA is valid, pre-shipment. This sampling would be conducted on an appropriate periodic basis throughout the storage period, and likely within a short period of sending to a customer. At step 1066, the product is shipped to the customer.

Claims

CLAIMS1. A system for the bioconversion of pomace derived from grape wine production at an industrial-scale winery, comprising: a) a holding container for receiving and optionally storing pomace at the industrial-scale winery; b) a first industrial-scale winery fermenter located at the industrial-scale winery, not in use for winemaking, configured for use to anaerobically ferment the pomace to provide an ethanolic pomace, and, optionally, an acidic pomace derived from the further anaerobic fermentation of the ethanolic pomace; c) an optional second industrial-scale winery fermenter, not in use for winemaking, isolated from a wine cellar or wine cellar area and configured for use to aerobically ferment the ethanolic pomace to provide the acidic pomace; d) an industrial-scale material transfer subsystem for moving pomace through the system to carry out the bioconversion of the pomace; e) one or more propagation tanks for propagating sufficient microbial populations, as needed, to conduct fermentations in the first and optional second industrial-scale fermenters; and f) one or more monitoring means for managing one or more selected process control point (PCP) tests during the operation of the system to carry out the bioconversion of the pomace into the acidic pomace that can be further processed into a product for incorporation into food.

2. The system of claim 1, wherein the holding container is also the first industrial-scale fermenter.

3. The system of claim 1 or claim 2, wherein the first industrial-scale fermenter is isolated from the wine cellar or wine cellar area and also configured for use to aerobically ferment the ethanolic pomace to provide the acidic pomace.

4. The system of claim 3, wherein the first industrial-scale fermenter is used to perform one or more of a yeast fermentation, a lactic acid fermentation and a acetic acid fermentation.

5. The system of any one of claims 1-4, wherein the optional second industrial fermenter is used to perform an acetic acid fermentation.

6. The system according to any one of claims 1-5 further comprising a processing means to process the acidic pomace and provide a raw puree.

7. The system according to claim 6, further comprising a processing subsystem to process the raw puree into the product.

8. The system according any one of claims 1-7, wherein the optional second industrial-scale fermenter is located off-site of the industrial-scale winery.

9. A method of building a system for the bioconversion of pomace derived from grape wine production at an industrial-scale winery, comprising the steps of: a) designating a holding container at the industrial-scale winery for receiving and optionally storing pomace at industrial-scale winery; b) configuring a first industrial-scale winery fermenter located at the industrial-scale winery, not in use for winemaking, for use to anaerobically ferment the pomace to provide an ethanolic pomace and, optionally, an acidic pomace derived from the further anaerobic fermentation of the ethanolic pomace; c) optionally, configuring a second industrial-scale winery fermenter, not in use for winemaking and isolated from a wine cellar or wine cellar area, for use to aerobically ferment the ethanolic pomace to provide an acidic pomace; d) configuring an industrial-scale material transfer subsystem using equipment at the industrial-scale winery for moving pomace through the system to carry out the bioconversion of the pomace; and e) designating, or incorporating one or more propagation tanks at the industrial-scale winery for propagating sufficient microbial populations, as needed, to conduct fermentations in the first and optional second industrial-scale fermenters; and f) optionally, configuring one or more monitoring means as a monitoring subsystem for managing one or more selected process control point (PCP) tests during the operationof the system to carry out the bioconversion of the pomace into the acidic pomace that can be further processed to provide a product for incorporation into food.

10. The method of claim 9, wherein the first and second industrial-scale winery fermenters are industrial red wine fermenters.

11. The method of claim 9 or claim 10, wherein the first industrial-scale winery fermenter is configured for performing anaerobic and aerobic fermentations of pomace.

12. The method according to any one of claims 9-11, wherein one or more additional system components is portable.

13. An industrial-scale process for the bioconversion of pomace derived from grape wine production into a nutrient-rich product, comprising the steps of:(a) receiving or collecting the pomace at an industrial-scale winery;(b) conducting one or more PCP tests to accept or reject the pomace for processing;(c) using an industrial-scale material transfer system to move accepted pomace to a holding container and to one or more industrial-scale fermenters if any one of the one or more fermenters required to process the pomace is not the holding container;(d) optionally, stabilizing and storing the pomace in the holding container, or in a first industrial-scale fermenter, not in use for winemaking, located at the industrialscale winery for a period of time prior to fermenting the pomace;(e) propagating in a propagating tank at the industrial-scale winery, an anaerobic microbial culture, if there is insufficient yeast in the pomace, to inoculate the pomace with the anaerobic microbial culture;(f) fermenting the pomace in the first industrial-scale fermenter with the yeast in the pomace and supplementing with the anaerobic microbial culture, as needed, to provide an ethanolic pomace;(g) propagating a bacterial culture and inoculating the ethanolic pomace with the bacterial microbial culture;(h) fermenting the ethanolic pomace inoculated with the bacterial culture to provide an acidic pomace in the first industrial-scale fermenter, or in a second industrialscale fermenter outside of the wine cellar or wine cellar area by transferring the ethanolic pomace from the first industrial-scale fermenter to the second industrialscale fermenter prior to inoculating the ethanolic pomace;(i) processing the acidic pomace to generate a raw puree; and(j) conducting one or more selected process control point (PCP) tests throughout the process to ensure the raw puree meets selected specifications.

14. The process of claim 13, wherein the pomace is a Kosher pomace.

15. .The process of claim 13 or claim 14, wherein the holding container is also the first industrial-scale fermenter.

16. The process of any one of claims 13-15, wherein the first industrial-scale fermenter is isolated from the wine cellar or wine cellar area and also configured for use to aerobically ferment the ethanolic pomace to provide the acidic pomace.

17. The process of any one of claim 16, wherein the first industrial-scale fermenter is used to perform one or more of a yeast fermentation, a lactic acid fermentation and a acetic acid fermentation.

18. The process of any one of claims 13-17, wherein the optional second industrial fermenter is used to perform an acetic acid fermentation.

19. The process of any one of claims 13-18, wherein the acidic pomace has a titratable acidity between 2.2-5%.

20. The process of any one of claims 13-19, wherein the optional second industrial-scale fermenter is located off-site of the industrial-scale winery.

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