Extrusion Process for Liquid Protein Concentrate
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Solution Overview
Problem
The existing processes for producing protein-containing products, such as meat alternatives, are costly, energy-intensive, and environmentally detrimental due to the high energy consumption and CO2 emissions associated with spray drying, which also degrades protein quality and poses operational risks.
Innovation Solution
A process that involves preparing a slurry from a protein source without spray drying, followed by direct extrusion to produce a protein-containing product, thereby reducing or eliminating the need for spray drying and associated costs and risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If spray-drying is used to produce protein powder, then the protein material can be stored and transported easily, but the energy consumption and CO2 emissions increase significantly
Solution Approach 1:
The invention extracts the harmful spray-drying step from the conventional protein processing sequence. By taking out the drying step entirely and proceeding directly from protein extraction to extrusion processing, the patent eliminates the major source of energy consumption and CO2 emissions while still achieving the desired product form through the extrusion process
Solution Approach 2:
The invention changes the physical state parameter of the protein material from dried powder to slurry form. By maintaining the protein in slurry form and processing it directly through extrusion, the patent achieves both ease of manufacture (the slurry can be pumped and processed) and dramatically reduced energy consumption (no drying required)
2Manufacturing precision
If spray-drying is used to concentrate protein, then the protein can be purified and stored, but the protein quality degrades due to high temperatures
Solution Approach 1:
The invention performs preliminary protein extraction and concentration to obtain a protein-rich slurry before proceeding to extrusion. By completing the purification step while the protein is in slurry form and avoiding subsequent high-temperature drying, the patent preserves protein quality while still achieving purification
Solution Approach 2:
The invention converts what would traditionally be considered a disadvantage (processing with high moisture content) into a benefit. The slurry form, which would normally require energy-intensive drying, is instead processed directly through extrusion, thereby protecting the protein from thermal degradation while maintaining purification effectiveness
3Productivity
If spray-drying towers are installed for protein processing, then large-scale production is enabled, but the infrastructure cost and operational risk increase
Solution Approach 1:
The invention merges the protein concentration and final product formation steps into a single continuous extrusion process. By combining these operations and eliminating the separate spray-drying infrastructure, the patent enables large-scale production while dramatically reducing device complexity and eliminating the need for tall spray-drying towers
Solution Approach 2:
The invention inverts the conventional sequence by processing protein in slurry form directly to final product through extrusion, rather than drying to powder first and then rehydrating. This reversal eliminates the need for complex spray-drying infrastructure while maintaining production scalability through the extrusion process
4Adaptability or versatility
If spray-drying is used to prepare protein powder, then the product can be rehydrated for processing, but the operational risk and safety concerns increase
Solution Approach 1:
The invention extracts the hazardous spray-drying operation from the process flow. By removing this step entirely and processing protein slurry directly through extrusion, the patent eliminates the explosion risks and safety concerns associated with spray-drying while maintaining product versatility through the extrusion process
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 approach significantly reduces energy consumption, CO2 emissions, and operational risks while maintaining the quality of the protein-containing product, offering a more sustainable and cost-effective method for producing protein-based food products.
Implementation Method 1
performing an extrusion process so as to obtain said protein-containing product
Data Source
AI summary
A process for producing a protein-containing product, comprising the steps of preparing a slurry comprising a protein from a protein source, wherein said slurry preparation does not involve a spray-drying step, inserting said slurry from step a) into an extruder, or into a pre-conditioner from which the slurry is transferred into an extruder, and performing an extrusion so as to obtain said protein-containing product. The present invention is furthermore related to a system for performing said process.