Continuous High-Shear Processing for Protein Fibrous Products
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Solution Overview
Problem
Existing extrusion processes for producing fibrous meat-like products are complex, difficult to scale up, require high mechanical energy, and involve significant capital and operational expenses, making it challenging to achieve consistent texture and structure in plant-based meat analogues.
Innovation Solution
A continuous process and system that includes a transport stage with controlled pressure difference, a high shear stage with adjustable mechanical energy and temperature, and a forming stage to produce a fibrous structure from protein-based materials, allowing independent control of various processing phenomena.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional extrusion processes are used to produce fibrous meat-like products, then the characteristic texture and structure can be achieved, but the process complexity and capital expenses increase significantly
Solution Approach 1:
The continuous extrusion process is segmented into three distinct stages (mixing, extrusion, cooling) with dedicated functional elements for each stage, allowing independent optimization and control of each process step while maintaining overall system simplicity
Solution Approach 2:
The extruder design integrates multiple functions into unified components: the screw elements simultaneously perform conveying, mixing, and heating functions, while the die assembly combines shaping with cooling, reducing the number of separate devices needed
2Manufacturing precision
If traditional extrusion processes are used to produce fibrous meat-like products, then the desired fibrous structure can be obtained, but the energy consumption and mechanical requirements increase
Solution Approach 1:
The process utilizes phase transitions of water (liquid to vapor) through controlled heating and pressure changes during extrusion, which facilitates protein denaturation and fibrous structure formation without requiring excessive mechanical energy input
Solution Approach 2:
The extrusion process exploits thermal expansion and pressure-induced volume changes of the protein-water mixture to generate the necessary expansion and fibrous morphology, reducing reliance on high mechanical shear forces
3Manufacturing precision
If traditional extrusion processes are used to produce fibrous meat-like products, then the characteristic texture can be achieved, but the scalability and operational flexibility are reduced
Solution Approach 1:
The extrusion system incorporates dynamically adjustable parameters including screw rotation speed, feed rate, heating power, and die geometry, allowing the process to be easily scaled and adapted to different production volumes and product specifications
Solution Approach 2:
The process achieves scalability through systematic parameter changes: adjusting the ratio of mixing time to extrusion time, modifying heating temperature profiles, and changing die opening dimensions allows the same equipment to produce different product types at various production scales
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 and system enable the production of fibrous products with controlled texture and structure, reducing energy consumption and simplifying scalability, while overcoming the limitations of traditional extrusion methods.
Implementation Method 1
wherein the base material is sheared between a wall of the container and the high shear tool
Implementation Method 2
a temperature control system configured for controlling a shear stage temperature of the base material in the container
Implementation Method 3
transporting the base material through the container is based on a pressure difference between a feeding pressure provided to an inlet port of the container and a discharge pressure at a discharge port of the container
Data Source
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AI summary
The invention provides continuous process for production of a product (90) comprising a fibrous structure from a base material (1), wherein the base material (1) is a protein-comprising material (5), the process comprising a transport stage, a high shear stage and a forming stage, wherein the transport stage comprises: (i) providing the base material (1) with a feeding pressure (Pf) into a container (121) (ii) transporting the base material (10) in a transport direction (125) through the container (121) and (iii) discharging treated base material (1) from the container (121), wherein transporting the base material (1) and discharging the treated base material (1) is based on a pressure difference between the feeding pressure (Pf) and a discharge pressure (Pd), wherein a flow of the base material (1) in the container (121) is controlled by controlling the pressure difference between the feeding pressure (Pf) and a discharge pressure (Pd); the high shear stage comprises: while transporting the base material (1) through the container (121) (i) controlling a shear stage temperature (Ts) of the base material (1) in the container (121) and (ii) providing a specific mechanical energy (SME) to the base material (1) to treat the base material (1) in the container (121), wherein the specific mechanical energy provided to the base material (1) is selected from the range of Whr – 800 Whr per kg of base material (1), wherein the specific mechanical energy is controlled by controlling a shear force provided to the base material (1) as a function of the flow of the base material (1); and the forming stage comprises: guiding the base material (1) from the container (121) through a forming system (130) while controlling a forming temperature (Tf) of the treated base material (1) in the forming system (130), to provide the product (90) at an exit (139) of the forming system (130).