Feather Washing with Sinking-Zone Separation and Turbulent Cleaning
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Solution Overview
Problem
The keratinaceous materials from slaughterhouses vary in quality due to foreign materials and microbial spoilage, leading to inefficiencies and reduced quality in hydrolyzed products and down industry applications, as existing methods are inadequate for removing denser contaminants and biogenic amines effectively.
Innovation Solution
A continuous washing system for keratinaceous materials, featuring an infeed device, washing space with a sinking zone for denser material separation, and a recycling system for the washing liquid, which includes turbulence-inducing structures and a filter to remove contaminants and biogenic amines, ensuring efficient processing and quality improvement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional washing methods are used for keratinaceous material, then processing can be performed, but foreign materials and biogenic amines cannot be effectively removed, resulting in reduced product quality
Solution Approach 1:
The washing system is divided into multiple treatment chambers (first chamber, second chamber, third chamber) that perform different functions sequentially. Each chamber addresses specific contaminants: the first chamber removes foreign materials through filtration, the second chamber removes biogenic amines through chemical treatment, and the third chamber performs final rinsing. This segmented approach allows targeted removal of different harmful factors without compromising product quality.
Solution Approach 2:
The system performs preliminary washing and contaminant removal before the main hydrolysis process. By pre-removing foreign materials and biogenic amines through the multi-chamber washing system, the subsequent hydrolysis process operates on cleaner material, ensuring higher final product quality and preventing contamination from affecting the hydrolysis reaction.
2Productivity
If batch processing methods are used for feather washing, then treatment can be performed, but processing efficiency is low and cannot handle large volumes effectively
Solution Approach 1:
The washing system is designed for continuous processing where keratinaceous material flows continuously through multiple treatment chambers. The material enters the first chamber, proceeds to the second chamber, then to the third chamber, and exits the system without interruption. This continuous flow eliminates the downtime associated with batch processing, significantly improving productivity while maintaining effective contaminant removal through each stage.
Solution Approach 2:
The continuous processing system is segmented into multiple specialized chambers that work in sequence. Each chamber is optimized for a specific washing function (filtration, chemical treatment, rinsing), allowing the system to handle large volumes efficiently while maintaining control over the washing process. The modular chamber structure manages complexity by dividing the overall washing task into manageable, specialized units.
3Reliability
If hydrolysis is performed on contaminated keratinaceous material, then protein digestion can be improved, but the presence of foreign materials and biogenic amines reduces overall process efficiency and final product quality
Solution Approach 1:
The system performs preliminary cleaning of keratinaceous material by removing foreign materials and biogenic amines through the multi-chamber washing system before the hydrolysis process begins. This preliminary action ensures that the hydrolysis reaction operates on clean material, maximizing protein digestion efficiency and preventing contaminants from interfering with the hydrolysis reaction or reducing overall process efficiency.
Solution Approach 2:
The washing system extracts and removes harmful contaminants (foreign materials and biogenic amines) from the keratinaceous material before hydrolysis. By taking out these contaminants in advance through filtration, chemical treatment, and rinsing stages, the system ensures that only clean keratinaceous material undergoes hydrolysis, thereby improving both the reliability of protein digestion and the efficiency of the overall 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
The system effectively removes unwanted denser particles and biogenic amines, enhancing the quality and efficiency of keratinaceous material processing, resulting in improved hydrolyzed products suitable for animal feed and down industry uses.
Implementation Method 1
the washing space comprises a sinking zone wherein material with a density higher than the washing liquid sinks below the keratinaceous material
Implementation Method 2
at least one washing structure that sloshes the washing liquid and/or causes turbulence in the washing liquid present in the washing space
Data Source
AI summary
Washing system (1) suitable for continuous processing, for the pre-treatment of keratinaceous material, preferably feathers, hair or wool. The washing system (1) comprises an infeed device (2) for feeding the keratinaceous material to the washing system (1) and a washing space (3) for washing the keratinaceous material with an aqueous washing liquid. A washing liquid system for supplying and extracting the washing liquid to and from the washing space (3) is comprised in the washing system (1). The washing space (3) comprises a sinking zone wherein material with a higher density than the washing fiquid sinks below the keratinaccous material. An extracting system (8) is placed at the bottom of the sinking zone (6) for extracting the material with a higher density than the washing liquid. Furthermore, at least one washing structure (4) that sloshes the washing liquid and/or causes turbulence in the washing liquid is present in the washing space (3). Finally, an outfeed device (9) is provided for extracting the keratinaceous material from the washing system (1).