Method and apparatus for the washing of feathers and removing of extraneous material
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Solution Overview
Problem
The keratinaceous materials obtained from slaughterhouses vary in quality due to foreign materials and microbial spoilage, leading to inefficiencies and reduced quality in hydrolyzed products, particularly in the down industry, where biogenic amines and dense contaminants are not effectively removed by existing methods.
Innovation Solution
A continuous washing system for keratinaceous materials, featuring a sinking zone for denser contaminants, turbulence-inducing washing structures, and a recycling system to efficiently remove unwanted particles and biogenic amines, ensuring the keratinaceous material meets predetermined purity thresholds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional washing methods are used for keratinaceous material, then the washing process is simple, but foreign materials and biogenic amines are not effectively removed
Solution Approach 1:
The washing system is divided into multiple functional zones: a sinking zone for density-based separation of contaminants, a washing zone with turbulence-inducing structures for mechanical cleaning, and a floating zone for buoyancy-based separation. This segmentation allows each zone to target specific types of impurities, achieving high purification effectiveness without requiring overly complex equipment in any single section.
Solution Approach 2:
Washing liquid is introduced as an intermediary medium that facilitates the separation and removal of foreign materials and biogenic amines. The liquid enables density-based separation in the sinking zone, provides a medium for turbulence-induced cleaning in the washing zone, and allows buoyancy-based separation in the floating zone, thereby achieving comprehensive purification through a single integrated system.
2Productivity
If batch processing is used for washing feathers, then equipment complexity is reduced, but productivity is significantly lowered
Solution Approach 1:
The system enables continuous processing by maintaining constant water flow through all zones and allowing material to move continuously from the sinking zone through the washing zone to the floating zone. This continuous operation eliminates the need for batch processing cycles, significantly increasing productivity while the modular zone structure keeps individual components relatively simple.
Solution Approach 2:
The washing liquid serves multiple functions simultaneously: it acts as a separation medium in the sinking zone, a cleaning medium in the washing zone, and a buoyancy medium in the floating zone. This multi-functionality allows a single integrated system to handle multiple purification tasks, increasing productivity without proportionally increasing device complexity.
3Manufacturing precision
If density-based separation is used for removing contaminants, then separation effectiveness is improved, but the system cannot remove less dense organic contaminants
Solution Approach 1:
The system segments the purification process into three distinct zones, each targeting different types of contaminants: the sinking zone removes dense inorganic contaminants through density-based separation, the washing zone removes organic contaminants through turbulence-induced mechanical action, and the floating zone removes less dense organic contaminants through buoyancy-based separation. This segmentation allows the system to handle a wide range of contaminant types effectively.
Solution Approach 2:
The system changes the physical parameters of the washing liquid and processing conditions across different zones: in the sinking zone, high water flow creates strong downward current for dense particle removal; in the washing zone, turbulence-inducing structures create chaotic flow patterns for mechanical cleaning; in the floating zone, reduced flow velocity allows buoyancy to dominate for light contaminant removal. These parameter changes enable versatile contaminant removal across different density ranges.
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 system effectively reduces the amount of unwanted particles and biogenic amines, enhancing the quality and process efficiency of hydrolyzed keratinaceous materials and down products by continuously processing large quantities with improved separation and purification.
Implementation Method 1
a sinking zone wherein material with a density higher than the washing liquid sinks below the keratinaceous material
Implementation Method 2
at least one washing structure that sloshes the washing liquid and/or causes turbulence in the washing liquid present in the washing space
Data Source
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AI summary
This invention relates to a washing system suitable for continuous processing, for the pretreatment of keratinaceous material, preferably feathers, hair or wool. The washing system comprises an infeed device for feeding the keratinaceous material to the washing system and a washing space for washing the keratinaceous material with an aqueous washing liquid. A washing liquid system for supplying and extracting the washing liquid to and from the washing space is comprised in the washing system. The washing space comprises a sinking zone wherein material with a higher density than the washing liquid sinks below the keratinaceous material. An extracting system is placed at the bottom of the sinking zone for extracting the material with a higher density than the washing liquid. Furthermore, at least one washing structure that sloshes the washing liquid and/or causes turbulence in the washing liquid is present in the washing space. Finally, an outfeed device is provided for extracting the keratinaceous material from the washing system.