High-Shear Pump Comminution for Grain Stillage Bacterial Control
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Solution Overview
Problem
Existing methods for comminuting grain stillage do not effectively control bacterial load, leading to varying germ counts and reduced shelf life of fermented products.
Innovation Solution
A high-shear pump is used to crush grain stillage, achieving a specific particle size distribution (d90 between 500 µm and 1200 µm and d10 between 50 µm and 200 µm) that results in a lower bacterial load, specifically below 600 non-acid formers per gram, thereby improving storage properties and shelf life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If grain stillage is comminuted using conventional methods (stone disk mills, ball agitator mills, ultrasound, or high-pressure homogenizers), then the grain stillage is reduced to smaller particles, but the bacterial load increases significantly (typically 1900 non-acid-forming substances per gram)
Solution Approach 1:
The patent changes the key parameter of shear rate in the comminution process, using a high-shear pump to achieve intense mixing and particle size reduction. This parameter change enables achieving the desired particle size distribution (d90 between 500-1200 μm, d10 between 50-200 μm) while maintaining a significantly lower bacterial load (below 600 non-acid formers per gram) compared to conventional methods
2Manufacturing precision
If grain stillage particles are made too small (average particle size 40 μm or smaller), then the material is well-comminuted, but the feeling of satiety is not achieved and digestive properties are compromised
Solution Approach 1:
The patent applies local quality by creating a specific particle size distribution where different particle sizes serve different functions. The d90 between 500-1200 μm provides satiety and digestive benefits, while the d10 between 50-200 μm ensures good comminution. This distribution approach allows the material to have both adequate fineness and functional particle sizes for health benefits
3Object-generated harmful factors
If grain stillage particles are made too large, then the bacterial load may be lower, but the mouthfeel becomes unpleasant and satiety effects are reduced
Solution Approach 1:
The patent optimizes the particle size distribution parameters to achieve a balance between mouthfeel quality and bacterial load control. The d90 between 500-1200 μm ensures particles are not too large for pleasant mouthfeel, while the intense high-shear comminution process maintains low bacterial load through rapid processing
4Ease of manufacture
If conventional comminution methods are used, then the process is simple and equipment is readily available, but the germ count remains high and shelf life is reduced
Solution Approach 1:
The patent replaces conventional mechanical comminution systems (stone disk mills, ball agitator mills, ultrasound, high-pressure homogenizers) with a high-shear pump system. This substitution provides more intense and controlled shear forces that achieve better particle size distribution while minimizing bacterial contamination, thereby extending shelf life of the fermented product
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 achieves a significantly lower bacterial load compared to other methods, such as stone disk mills, resulting in a less contaminated and longer-lasting fermented grain stillage with improved satiety and digestive properties.
Implementation Method 1
crushing the grain stillage using a high-shear pump until the crushed grain stillage has particles with a d90 particle size between 500 μm and 1200 μm and a d10 particle size between 50 μm and 200 μm
Data Source
AI summary
Method for producing a comminuted distillers grain comprising the following steps: - preparation of a distillers grain and - comminutation of the distillers grain by means of a high-shear pump until the comminuted particles of distillers grain have a d90 particle size between 500 µm and 1200 µm and a d10 particle size between 50 µm and 200 µm in order to attain a comminuted distillers grain.