Microbial Protein Concentrate via A. pullulans Fermentation
Solution Overview
Problem
The existing methods for producing fish meal protein for aquaculture are unsustainable due to the depletion of wild fish stocks and the environmental issues associated with solvent extraction processes for soybean meal and soy protein concentrates, which are also limited by anti-nutritional factors and high costs.
Innovation Solution
A microbial-based process converts plant materials into a high-quality protein concentrate using A. pullulans fermentation, producing a protein concentrate with enhanced digestibility and reduced anti-nutritional factors, suitable for animal feeds and human consumption, while minimizing solvent use and environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If solvent extraction process is used to produce soy protein concentrate, then protein bioavailability is improved and anti-nutritional factors are removed, but environmental pollution increases and processing cost rises
Solution Approach 1:
The patent replaces the chemical solvent extraction process with a microbial fermentation process using A. pullulans. The microorganism naturally degrades anti-nutritional factors and converts plant proteins into high-quality protein concentrate through biological metabolism, eliminating the need for harmful chemical solvents like hexane and their associated environmental pollution.
Solution Approach 2:
The patent introduces A. pullulans (Aureobasidium pullulans) as an intermediary biological agent between the plant material and the final protein concentrate. This microorganism acts as a mediator that transforms the plant protein through fermentation, naturally removing anti-nutritional factors and enhancing protein quality without requiring harsh chemical extraction methods.
2Reliability
If thermal step is applied to inactivate antigenic factors, then protein quality is improved, but energy consumption increases
Solution Approach 1:
The patent substitutes the thermal inactivation method with a microbial fermentation process. A. pullulans naturally degrades antigenic factors and anti-nutritional factors through enzymatic activity during fermentation, eliminating the need for energy-intensive thermal processing steps while maintaining or improving protein quality.
3Productivity
If fish meal is used to meet aquaculture protein demand, then growth performance is improved, but sustainability is compromised due to wild fish stock depletion
Solution Approach 1:
The patent changes the source parameter of protein from animal-based (fish meal) to plant-based (fermented plant material). By using A. pullulans fermentation to convert plant proteins into high-quality protein concentrate with improved amino acid profile and digestibility, the system achieves sustainable protein production that can replace fish meal while maintaining animal growth performance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process achieves a protein concentrate with over 65% protein content, low ash and potassium content, and improved digestibility, allowing for up to 70% replacement of fish meal in aquaculture diets, enhancing feed efficiency and growth performance in fish and shrimp.
Implementation Method 1
A microbial-based process converts plant materials into a high-quality protein concentrate using A. pullulans fermentation
Implementation Method 2
The process achieves a protein concentrate with over 65% protein content, low ash and potassium content, and improved digestibility
Data Source
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AI summary
The invention relates to a method of treating plant-based material comprising: a) transferring said plant-based material to a first mix-tank (102(a)), wherein said plant-based material is mixed with one or more first solvents to produce a washed mash; b) separating the washed mash into at least one centrate and a washed cake; c) transferring said washed cake to one or more second mix-tanks (102(b)-102(d)), wherein one or more second solvents are mixed with said washed cake to produce a washed cake suspension; d) transferring said washed cake suspension to one or more fermenters (104), wherein said transferred washed cake suspension is inoculated with at least one microbe, and wherein said inoculated washed cake suspension is incubated for a sufficient time to produce a fermented mixture; e) optionally heating said fermented mixture for a time sufficient to achieve a degree of hydrolysis (DH) of at least 10% of the proteins therein; f) separating said fermented mixture into a fermented centrate and a fermented cake by hydrodynamic force; g) transferring the fermented centrate to: (i) a first mix-tank (102(a)) and/or (ii) one or more second mix-tanks (102(b)-102(d)), wherein a mix-tank comprises said plant-based material or said washed cake, and wherein steps (c)-(f) and h) are repeated at least one (1) time for sub-steps (i) or (ii); and h) drying said fermented cake, wherein the resulting dried fermented cake has higher protein content compared to said transferred plant-based material.