Multi-Step Filtration for Nitrate-Rich Fermentation Liquids
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Solution Overview
Problem
Existing methods for processing celery powder and similar nitrate-rich food products fail to significantly improve product color, purity, and flavor, which are critical for consumer acceptance and quality.
Innovation Solution
A multi-step filtration method involving a ceramic membrane for initial filtration to separate bacteria and solids, followed by ultrafiltration, and optional high-temperature spray drying to produce a clear, high-purity product with enhanced color and flavor, maintaining nutritional and flavor profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional filtration methods are used for fermentation liquids, then the processing is simple, but the product color, purity, and flavor are insufficient
Solution Approach 1:
The filtration process is divided into multiple sequential stages: initial filtration to remove large particles, ceramic membrane filtration for bacteria and fine solids, and ultrafiltration for macromolecules. Each stage targets specific contaminants, progressively improving product purity and color without overwhelming complexity at any single step.
Solution Approach 2:
The fermentation liquid undergoes preliminary treatment including settling and initial filtration before entering the ceramic membrane and ultrafiltration stages. This preliminary action removes bulk contaminants early, reducing the burden on subsequent filtration stages and improving overall efficiency.
2Illumination intensity
If fiber content is not reduced in the fermentation liquid, then the processing is straightforward, but the cured color quality deteriorates with grey and brown appearance
Solution Approach 1:
Ceramic membranes with specific pore sizes are employed to selectively remove fiber particles and solids from the fermentation liquid. The porous structure allows passage of beneficial fermentation products while blocking fiber contaminants, improving cured color quality without requiring complex mechanical removal methods.
3Shape
If the fermentation liquid is not spray dried, then the flavor profile is preserved, but the particle size is large and dispersibility is poor
Solution Approach 1:
The spray drying process utilizes phase transition from liquid to aerosol to powder form. The fermentation liquid is atomized into fine droplets that rapidly evaporate, producing uniform powder particles with excellent dispersibility. This phase transition approach efficiently reduces particle size while maintaining flavor profile through controlled processing parameters.
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 method results in a product with improved color, purity, and flavor, reducing particle size and moisture content, making it suitable for injection into meats and other food products, enhancing dispersibility and reducing clogging risks without altering the nutritional or flavor profiles.
Implementation Method 1
passing the food product through a first filter... passing the food product through a second filter
Implementation Method 2
passing the food product through a second filter... ultrafiltration
Implementation Method 3
optionally controllably spray drying the food product at high-temperature
Implementation Method 4
spray drying is critical for homogenization and reduction of particle size
Data Source
AI summary
A method for filtering a food product, including the steps of: (a) providing a food product, wherein the food product comprises a fermentation liquid derived from an edible nitrate containing plant; (b) passing the food product through a first filter; (c) passing the food product through a second filter; and (d) optionally controllably spray drying the food product at high-temperature.