Casein-Based Filaments for Pet Chew Tensile Strength
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Solution Overview
Problem
Current methods for producing protein-based fibers and filaments are not suitable for the pet food and treat industry, as they focus on textile applications and do not utilize edible, flexible, and high tensile strength materials needed for long-lasting chew products.
Innovation Solution
Development of protein-based flexible filaments using casein-based proteins like milk protein concentrate, calcium caseinate, and sodium caseinate, combined with plasticizers, processed through a twin-screw extruder to achieve high tensile strength and suitable diameters for pet food applications without the need for spinneret processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wet-spinning process is used to produce protein fibers, then fibers can be formed with desired shape and structure, but the process requires complex chemical treatments including acid baths, formaldehyde hardening, and crosslinking which are not suitable for edible applications
Solution Approach 1:
The patent extracts and removes the harmful chemical treatment steps (acid baths, formaldehyde hardening, crosslinking) from the traditional wet-spinning process, retaining only the essential fiber formation capability while making the process suitable for edible applications
Solution Approach 2:
The patent changes the process parameters from chemical-intensive to physical-based processing, using extrusion and mechanical drawing instead of chemical treatments, thereby simplifying the process and making it suitable for food applications
2Strength
If traditional protein fiber processing is used, then fibers achieve sufficient strength for textile applications, but the fibers become brittle and lack the flexibility needed for pet chew products
Solution Approach 1:
The patent changes the processing parameters including extrusion temperature, drawdown ratio, and plasticizer content to optimize the balance between tensile strength and flexibility, producing filaments suitable for pet chew applications
Solution Approach 2:
The patent uses composite formulations combining casein-based proteins with plasticizers and other edible ingredients to achieve the desired combination of strength and flexibility in the final filament product
3Productivity
If spinneret processing is used to produce filaments, then continuous fibers can be formed, but the process is complex and not suitable for the pet food industry
Solution Approach 1:
The patent removes the spinneret component entirely from the process, using direct extrusion through a die instead, which simplifies the equipment while maintaining continuous production capability
Solution Approach 2:
The patent replaces the complex spinneret mechanical system with a simpler extrusion-drawdown system, achieving continuous filament production through mechanical extrusion and conveyor-based drawdown
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 resulting filaments exhibit non-brittle, high tensile strength, and suitable mechanical properties, making them suitable for reinforcing long-lasting pet chew products, with tensile strengths ranging from 30 MPa to 80 MPa and diameters from 80 to 2,000 microns.
Implementation Method 1
processed through a twin-screw extruder to achieve high tensile strength and suitable diameters for pet food applications
Data Source
AI summary
Edible casein-based flexible filaments with high tensile strength are disclosed. Filaments are formed by extruding compositions comprising about 30 to 60 wt. % milk proteins and about 40 to 65 wt. % of plasticizer. Casein sources include MPC, CaC, or NaC. Plasticizers include water, glycerol, lactose and mixtures thereof. Ingredients to improve material properties may be used to form flexible filaments with higher tensile strength. Ingredients include gelatin or soy protein isolates (about 0.75-5 wt. %), xanthan gum (about 0.1-0.35 wt. %), and cellulose (about 0.5-4.95 wt. %). Filaments may be crosslinked by multivalent ions such as calcium to form networks to strengthen the filaments. Filaments of high tensile strength are provided with diameters ranging from about 80 to 2,000 microns. Filaments can be used as single filaments, strands of multiple filaments, or combinations of threads or braids, or shaped into configurations such as weaves, sheets, tubes, and rods.