Collagen Concentrate for Edible Casings
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Solution Overview
Problem
Current collagen mass production for edible casings faces challenges such as high water content, microbiological instability, and high transport costs due to the need for refrigeration, which limits storage and transport duration and increases economic burdens.
Innovation Solution
A film-forming collagen concentrate with at least 18% collagen dry matter, which is insoluble in water but swellable in dilute acid, allowing for the production of a stable and transportable extrudable or coextrudable mass suitable for edible collagen skins, achieved through a process involving centrifugation and filtration to separate high-molecular weight collagen fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If aqueous collagen mass with high water content (3-6% dry matter) is used for production, then the collagen is readily dispersible and emulsion-stabilizing, but the transport costs increase and storage becomes complex requiring refrigeration
Solution Approach 1:
The patent changes the concentration parameter of collagen from 3-6% dry matter to 18-30% dry matter, transforming the physical state from aqueous mass to concentrate. This parameter change reduces water content while maintaining functional properties, enabling room temperature storage and reducing transport costs.
Solution Approach 2:
The patent performs preliminary concentration and stabilization of collagen before final application. By pre-concentrating the collagen to 18-30% dry matter and adding stabilizing agents, the product becomes suitable for extended storage and transport without refrigeration, while still maintaining dispersibility when needed.
2Ease of manufacture
If acidified aqueous collagen mass is used for production, then the collagen mass can be produced with suitable properties, but the acid attacks the collagen chemically destroying it over time
Solution Approach 1:
The patent performs preliminary neutralization or stabilization of the collagen mass before final product formation. By adjusting pH to neutral or slightly alkaline levels and adding stabilizing agents, the collagen is protected from acid attack while maintaining production suitability. The concentrate can be stored stably and only activated during final application.
Solution Approach 2:
The patent introduces stabilizing agents and pH modifiers as intermediary substances that protect collagen from chemical degradation. These additives act as mediators between the acidic environment needed for production and the neutral environment needed for stable storage, preventing direct chemical attack on the collagen.
3Duration of action of moving object
If collagen mass is stored for extended periods, then more production time is available, but microbiological breakdown increases and refrigeration is required
Solution Approach 1:
The patent changes key parameters including concentration (18-30% dry matter), pH level, and addition of preservatives to create a stable concentrate. These parameter changes raise the microbiological stability threshold, allowing extended storage at room temperature without significant bacterial growth or breakdown.
Solution Approach 2:
The patent converts the potential harm of high protein content (which attracts microbes) into a benefit by using concentrated collagen (18-30% dry matter) with added stabilizers and preservatives. The concentration itself becomes a protective factor, reducing water activity and creating an environment less favorable for microbial growth while maintaining product functionality.
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 concentrate is microbiologically stable for at least 6 months at room temperature, reducing transport costs and enabling efficient production of edible casings with improved mechanical stability and reduced water content.
Implementation Method 1
at least 50% by weight of the protein of a homogeneous suspension having a dry matter fraction of 0.5% by weight produced from the concentrate may be separated off as sediment by centrifugation
Implementation Method 2
The mass is then extruded through an annular die and the tubular casing formed is subsequently stabilized
Implementation Method 3
a film-forming collagen concentrate which is insoluble in water, but is swellable in dilute acid
Implementation Method 4
The mass is then extruded through an annular die and the tubular casing formed is subsequently stabilized
Data Source
AI summary
A film-forming collagen concentrate is provided containing at least 18% by weight dry matter. At least 50% by weight of the protein of a homogeneous suspension produced from the concentrate in a 0.15 molar aqueous sodium dihydrogenphosphate buffer having a pH of 7 and a calculated dry matter fraction of 0.5% by weight may be separated as sediment by 15 min centrifugation at 1780 RFC and 15° C. A process is also disclosed for producing a collagen-concentrate-containing food casing that includes (a) producing an aqueous collagen mass; (b) concentrating the aqueous collagen mass until it has a solids fraction of 18% by weight or more; (c) admixing the concentrate with dilute acid to obtain a (co)extrudable or castable collagen mass; (d) coextruding or casting the collagen mass to from a casing; (e) solidifying the casing and, optionally, (f) drying the casing.