Devitalized Wheat Gluten for Aqua Feed Processability

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Solution Overview

Problem

The aqua feed industry faces challenges in finding cost-effective, locally sourced, sustainable alternatives to soybean meal and aquatic animal-based meal ingredients that are easily transportable, digestible, and have the right amino acid profile.

Innovation Solution

A process for preparing a coarse devitalized wheat gluten composition by heating a vital wheat gluten composition, reducing its particle size, and drying it to a low water content, resulting in a product with high protein content and improved processability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If vital wheat gluten is used in aqua feed, then processability and binding properties are improved, but the content can be increased only up to 20 wt % due to difficulty in processing

Engineering Contradiction:

ImproveprocessabilityVSAvoidwheat protein content

Core Design Contradiction:

Ease of manufactureVSQuantity of substance

Solution Approach 1:

The patent applies parameter changes by transforming vital wheat gluten into devitalized wheat gluten through heating, which alters the physical and chemical properties of the protein. This devitalization process reduces viscoelasticity and improves processability, enabling higher wheat protein content in aqua feed formulations without compromising manufacturing feasibility.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent utilizes devitalized wheat gluten as a cost-effective alternative to vital wheat gluten. The devitalized form maintains protein content while reducing processing difficulties, serving as a disposable or single-use ingredient in feed formulations that balances cost, nutrition, and processability.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Ease of manufacture

If devitalized wheat gluten powder is used, then processability is improved, but it is expensive and has high carbon footprint

Engineering Contradiction:

ImproveprocessabilityVSAvoidcarbon footprint

Core Design Contradiction:

Ease of manufactureVSUse of energy by moving object

Solution Approach 1:

The patent transforms vital wheat gluten into devitalized wheat gluten through controlled heating, changing its physical properties to improve processability. This in-house devitalization process eliminates the need to purchase expensive commercial devitalized powder, reducing both cost and carbon footprint while maintaining the desired processability benefits.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent extracts the devitalization function from external commercial products and integrates it into the internal processing workflow. By performing devitalization in-house through heating, the system eliminates dependency on expensive external devitalized wheat gluten products, thereby reducing costs and environmental impact.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If devitalized wheat gluten is used, then digestibility is maintained, but it lacks viscoelastic binding properties

Engineering Contradiction:

ImprovedigestibilityVSAvoidbinding properties

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent merges devitalized wheat gluten with vital wheat gluten in composite feed formulations. The devitalized component provides digestibility and protein content, while the vital component contributes binding properties and pellet integrity. This combination allows the system to achieve both digestibility and binding functionality that neither ingredient provides alone.

Inventive Principle:

Principle #5Merging (Combining)

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 coarse devitalized wheat gluten composition can be easily incorporated into aqua feed, maintaining digestibility and processability, while reducing energy consumption and carbon footprint, and allowing for increased wheat protein content in aqua feed pellets.

Implementation Method 1

Heating (optionally with agitation) a vital wheat gluten composition to obtain a devitalized wheat gluten composition

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

Drying the wet coarse devitalized wheat gluten composition down to a water content of at most 14 wt %

Methodology Applied

Scientific EffectDrying: Desiccation

Data Source

PatentUS20250089740A1Process for preparing a coarse devitalized wheat gluten product

Publication Date: 2025.03.20 CARGILL INC

AI summary

The invention relates to the field of plant-based proteins, in particular wheat proteins, used in the aqua feed industry. The invention covers a process for preparing a coarse devitalized wheat gluten composition and the product obtained therefrom. The invention also covers an aquafeed product comprising the coarse devitalized wheat gluten composition of the invention and its use. The invention also covers the use of the coarse devitalized wheat gluten composition to at least partially replace other proteins in an aqua feed product, whilst maintaining the overall digestibility.