Continuous Seed Extract Processing for Uniform Plant Beverage Extraction
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Solution Overview
Problem
Conventional processes for producing plant-based milk substitutes are energy-intensive, require significant investment in machinery, involve long process times, and result in inconsistent treatment due to batch processing, leading to qualitative degradation.
Innovation Solution
A continuous in-line process for obtaining solubilised seed extracts, involving heat treatment, in-line grinding, enzyme addition, continuous filtration, and solid washing, which reduces energy consumption and simplifies plant design, while ensuring uniform treatment and higher extraction yields.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional batch processing is used, then equipment investment and operation flexibility are maintained, but energy consumption is high and process time is long
Solution Approach 1:
The patent implements a continuous processing system where seeds are ground, extracted, and filtered without batch interruptions. The continuous operation eliminates idle time between batches and maintains steady-state processing, significantly reducing energy consumption per unit of product while avoiding the need for multiple batch tanks and associated complex equipment.
Solution Approach 2:
The patent extracts and removes the milling step entirely by using whole seeds directly in the extraction process. This eliminates the need for separate grinding equipment and reduces overall equipment complexity while lowering energy consumption associated with seed preparation.
2Productivity
If batch processing is used, then equipment flexibility is maintained, but process time is long causing qualitative degradation
Solution Approach 1:
The continuous processing line operates without interruption, with seeds continuously fed through grinding, extraction, and filtration stages. This eliminates the loading, processing, and unloading cycles inherent in batch processing, reducing total process time and preventing qualitative degradation of the extract while dramatically improving production efficiency.
3Manufacturing precision
If batch enzymatic treatment is used, then treatment thoroughness is achieved, but process time is long
Solution Approach 1:
The patent employs continuous enzymatic treatment where the slurry flows continuously through the extraction tank with enzymes added at controlled rates. This continuous action maintains uniform treatment conditions throughout the process while reducing total time compared to batch processing, as there are no idle periods for tank loading, unloading, or cleaning between batches.
4Productivity
If high water ratio (4:1) is used for extraction, then extraction efficiency is improved, but energy consumption for concentration increases
Solution Approach 1:
The patent optimizes the water-to-seed ratio to a range of 2:1 to 3:1, balancing extraction efficiency with energy consumption. This parameter adjustment maintains sufficient extraction yield while reducing the volume of liquid requiring subsequent concentration, thereby lowering energy consumption in the concentration stage without significantly compromising productivity.
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 reduced energy consumption, lower investment costs, and improved product concentration, resulting in cost-effective production of high-quality plant-based beverages with consistent quality.
Implementation Method 1
heat treatment of the seeds with water
Implementation Method 2
in-line grinding of the seeds to form a paste
Implementation Method 3
enzymatic treatment of the slurry, with continuous injection of the enzymes into the inlet pipe
Implementation Method 4
in-line holding for solubilisation of components
Implementation Method 5
separation of the liquid extract by continuous filtration
Implementation Method 6
washing of the solids in a vertical column down which they flow in counter current with a flow of wash water
Data Source
AI summary
A process for obtaining solubilised seed extracts for the production of food beverages, which operates entirely in a continuous line and comprises the following sequence of steps: - initial heat treatment of the seeds with the addition of water; - in-line grinding of the seeds treated in the previous stage to form a paste; - enzymatic slurry treatment and in-line maintenance for component solubilisation; and - separation of the liquid extract by continuous filtration.