Gluten Shearing Unit for Starch Separation
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Solution Overview
Problem
Conventional methods for increasing the protein content of gluten during production are costly and only achieve a small increase, limiting the quality and value of the final product.
Innovation Solution
A shearing unit with a two-shaft design, where disc-shaped shearing tools on rotating shafts create gaps to apply shear stresses to the gluten-starch mixture, preventing cutting stress and allowing for efficient separation of starch and gluten, thereby increasing protein content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If rotor-stator devices are used to increase protein content, then the protein content of gluten increases slightly, but the cost increases significantly
Solution Approach 1:
The patent replaces expensive rotor-stator mechanical systems with a less complex shearing device that uses a drum rotating in a liquid medium, achieving similar or better protein content increase at lower cost
Solution Approach 2:
The patent changes the operating parameters by rotating the drum at specific speeds (5-50 rpm) and controlling the liquid medium flow, achieving effective starch removal and protein concentration without expensive equipment
2Manufacturing precision
If conventional washing methods are used, then the process is simple, but the protein content of gluten remains below 75%
Solution Approach 1:
The patent introduces a liquid medium (water or salt solution) as an intermediary to wash and remove starch from the gluten mixture, enabling effective separation without complex equipment
Solution Approach 2:
The patent employs periodic rotation of the drum and continuous flow of liquid medium, creating cyclic washing action that progressively removes starch while concentrating protein
3Manufacturing precision
If high protein content gluten is produced, then the quality and price increase, but the extraction process becomes more complex
Solution Approach 1:
The patent designs a multi-functional system where the drum serves as both mixing and washing element, and the liquid medium performs both washing and separation functions, reducing overall process complexity
Solution Approach 2:
The patent uses dynamic rotation of the drum at controlled speeds to achieve both mixing and washing functions, allowing flexible adjustment of process parameters to optimize protein content
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 shearing unit effectively increases the protein content of gluten, enhancing its quality and value by efficiently separating starch and gluten, making the gluten more suitable for food use.
Implementation Method 1
apply shear stresses to the gluten-starch mixture, preventing cutting stress and allowing for efficient separation of starch and gluten
Data Source
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AI summary
The invention relates to a cutting unit for recovering gluten from a mixture containing starch and gluten, having a housing (10) in which is formed a cutting chamber (16) having an inlet (18) and an outlet (20). A first shaft, which is mounted in a rotatable manner in the housing (10), has a multiplicity of first disc-like cutting tools (24), which are fitted in a rotationally fixed manner on the first shaft, wherein in each case two adjacent cutting tools of the multiplicity of first cutting tools (24) are spaced apart from one another axially to form an interspace. A second shaft, which is mounted in a rotatable manner in the housing (10) is arranged parallel to the first shaft and has a multiplicity of second disc-like cutting tools (28), which are fitted in a rotationally fixed manner on the second shaft, wherein in each case two adjacent cutting tools of the multiplicity of second cutting tools (28) are spaced apart from one another axially to form a further interspace. The first and second cutting tools (24, 28) are arranged in the cutting chamber (16), wherein the first and the second shafts are spaced apart from one another radially, and the multiplicity of first cutting tools (24) are offset axially relative to the multiplicity of second cutting tools (28), such that at least one portion of one of the multiplicity of second cutting tools (28) engages in an interspace. A respective gap having a width of at least 0.3mm is formed in the axial direction between the at least one engaging portion and the two adjacent, interspace-forming first cutting tools (24).