Eggshell Membrane Separation Using Cavitation for Continuous Recovery
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Solution Overview
Problem
The high cost and inefficiency of landfill disposal of eggshell membranes, the need for elemental calcium, and the waste of valuable materials like collagen and hyaluronic acid in eggshell membranes, along with contamination and lack of continuous processing methods in hatcheries, hinder the commercial extraction and utilization of these materials.
Innovation Solution
A method and system for continuous separation of eggshell membranes from eggshells using cavitation in a fluid mixture, followed by drying and extraction of high-value polypeptides like collagen and hyaluronic acid, which includes infrared drying to preserve the materials and reduce contamination, and recirculation of the fluid mixture for efficient processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If eggshell membranes are disposed of in landfills, then disposal costs are incurred and environmental harm is caused, but the high-value materials (collagen, hyaluronic acid) contained in the membranes are wasted
Solution Approach 1:
The patent applies extraction by separating eggshell membranes from eggshells using a fluid mixture and cavitation, then extracting high-value materials (collagen, hyaluronic acid) from the membranes through chemical processing. This transforms the waste disposal problem into a resource recovery process, eliminating landfill costs while capturing valuable substances.
Solution Approach 2:
The patent employs parameter changes by altering the physical and chemical state of the eggshell membrane system. Cavitation uses intense mechanical energy to separate membranes, while subsequent chemical extraction processes change the molecular state of embedded materials, enabling their recovery in usable forms.
2Productivity
If traditional separation methods are used, then eggshell membranes can be separated, but the process is not continuous and sanitation is compromised in hatchery environments
Solution Approach 1:
The patent implements continuous processing by designing a system where eggshells are continuously fed into a fluid mixture tank, subjected to cavitation, and separated into membranes and shells in an uninterrupted flow. This eliminates batch processing interruptions and maintains consistent sanitation conditions throughout the operation.
Solution Approach 2:
The patent uses a fluid mixture as an intermediary medium that facilitates both separation and sanitation. The fluid acts as a carrier for cavitation energy to separate membranes while simultaneously providing a controlled environment that prevents contamination and maintains hygiene standards during continuous processing.
3Quantity of substance
If high-value materials are extracted from eggshell membranes, then new revenue streams are created, but the processing complexity and cost increase
Solution Approach 1:
The patent applies segmentation by dividing the processing system into distinct functional modules: a cavitation separation stage that isolates membranes from shells, a drying stage that prepares membranes for extraction, and an extraction stage that recovers high-value materials. This modular approach manages complexity while enabling comprehensive material recovery.
Solution Approach 2:
The patent employs preliminary action by performing cavitation-based membrane separation and drying before the extraction of high-value materials. This preparatory processing simplifies the subsequent extraction step by providing clean, pre-treated membrane material, thereby reducing the overall processing complexity despite the multiple stages involved.
4Loss of substance
If eggshell membranes are dried using conventional methods, then moisture is removed, but heat-sensitive materials like collagen may be denatured
Solution Approach 1:
The patent applies parameter changes by using infrared radiation to dry eggshell membranes at controlled temperatures that remove moisture while preserving heat-sensitive materials like collagen. The infrared heating method allows precise temperature management that prevents denaturation unlike conventional high-heat drying methods.
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
Enables the efficient and cost-effective separation and extraction of high-value materials from eggshell membranes, reducing waste, pathogens, and odor, while allowing for continuous processing and preservation of materials for storage or transport, thereby creating new revenue streams for hatcheries.
Implementation Method 1
applying cavitation to thereby separate the egg shell membranes from the egg shells
Implementation Method 2
The step of drying is performed at a temperature which preserves the at least one polypeptide
Data Source
AI summary
A method for processing unseparated egg shells is provided. The method includes placing the unseparated egg shells in a fluid tank containing a fluid mixture, applying cavitation to the fluid mixture to thereby assist in separating the egg shell membranes from the egg shells, and recovering the egg shell membranes. Preferably, the fluid mixture is recirculated to thereby provide for continuous processing of unseparated egg shells. The method may further include drying the egg shell membranes to produce dried egg shell membranes which may then be vacuum packaged for storage and/or transport. The dried egg shell membranes may then be subjected to an extraction process for extracting at least one type of polypeptide from the egg shell membranes. Collagen, hyaluronic acid, or amino acids of interest may be extracted from the egg shell membrane and purified for numerous uses.