Enzymatic Extraction of Bioactive Compounds from Brewers Stillage

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Solution Overview

Problem

Commercial-scale extraction of bioactive compounds such as polyphenols from ethanol brewers' stillage is challenging due to time-consuming processes and significant solvent waste generation.

Innovation Solution

A safe, cost-effective, and scalable method involving the addition of lyophilized enzymes and ethanol to the stillage, followed by mixing, extraction, and separation of bioactive compounds using distillation or evaporation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional extraction methods are used to extract bioactive compounds from brewers' stillage, then extraction capacity is achieved, but extraction time is excessive and solvent waste is substantial

Engineering Contradiction:

Improveextraction capacityVSAvoidextraction time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The method applies preliminary enzymatic treatment to the brewers' stillage before extraction. Enzymes such as cellulases, hemicellulases, and pectinases are added to pre-treat the material, breaking down cell walls and releasing bound polyphenols. This preliminary action prepares the matrix for more efficient subsequent extraction, reducing the time and solvent needed in the extraction step itself.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The extraction process is designed as a continuous operation where enzymatic treatment, extraction, and separation occur in sequence without complete interruption. The system maintains continuous flow of material through different processing stages, ensuring that the useful action of extracting bioactive compounds continues uninterrupted, thereby increasing overall productivity while reducing total processing time.

Inventive Principle:

Principle #20Continuity of useful action

2Productivity

If conventional extraction methods are used to extract bioactive compounds from brewers' stillage, then bioactive compounds are obtained, but solvent waste generation is substantial

Engineering Contradiction:

Improveextraction yieldVSAvoidsolvent waste

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The method changes the parameters of the extraction system by using enzyme pre-treatment to modify the physical and chemical structure of the stillage matrix. This makes the polyphenols more accessible and soluble, allowing for efficient extraction with reduced solvent volumes. The enzymatic modification of the matrix parameters enables higher extraction yields with less solvent.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The system is designed to recover and reuse extraction solvents through distillation and filtration processes. The spent solvent is separated from the extract, purified, and recycled back into the extraction process. This recovery approach minimizes solvent waste while maintaining continuous high-yield extraction operations.

Inventive Principle:

Principle #34Discarding and recovering

3Productivity

If enzymatic treatment is applied to stillage before extraction, then extraction efficiency is improved, but process complexity increases

Engineering Contradiction:

Improveextraction efficiencyVSAvoidprocess complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The overall process is segmented into distinct functional stages: enzymatic pre-treatment, extraction, separation, and solvent recovery. Each stage uses specific equipment and conditions optimized for that function. This segmentation allows for modular design where each unit operation can be independently controlled and optimized, making the overall complex process more manageable and scalable.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The extraction system is designed with multi-functional equipment that performs multiple operations. For example, the extraction vessel also serves as a reaction vessel for enzymatic treatment, and the separation system handles both solid-liquid separation and solvent recovery. This multi-functionality reduces the number of separate devices needed, thereby reducing overall process complexity while maintaining high extraction efficiency.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

This method efficiently produces a unique combination of bioactive compounds, including polyphenols, suitable for human or animal consumption, while minimizing waste and operational complexity.

Implementation Method 1

The addition of carbohydratases and/or proteases allowed for optimal results for removal of the flaxseed byproducts compared to conventional non enzymatic extraction

Methodology Applied

Scientific EffectEnzymatic hydrolysis: Hydrolysis

Implementation Method 2

Extraction methods include dioxan/ethanol, water/acetone, water/methanol, and water/ethanol

Methodology Applied

Scientific EffectSolvent extraction: Solvation

Implementation Method 3

separating the bioactive compounds from the extracted ethanol by distillation or evaporation of the ethanol

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 4

separating the bioactive compounds from the extracted ethanol by distillation or evaporation of the ethanol

Methodology Applied

Scientific EffectDistillation: Distillation

Data Source

PatentUS20250179538A1Apparatus and method for extracting bioactive compounds from ethanol brewers stillage or feed stock utilized in biochemical reactors

Publication Date: 2025.06.05 IMMORTAZYME CO LTD

AI summary

Extracting bioactive compounds from stillage produced by brewing ethanol or feedstock utilized in a biochemical reactor.