Hydrolysis Tank Circulation Loop for Enzyme Control
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Solution Overview
Problem
Current hydrolyzate production processes lack versatility and often require adaptation for each raw material, leading to reduced productivity and yield, along with increased costs and energy consumption due to inefficient handling and mixing processes.
Innovation Solution
A process involving a circulation loop between the hydrolysis tank and preparation unit for gradual and continuous enrichment of the raw material in an aqueous phase, with controlled enzyme addition to optimize hydrolysis, allowing for the production of a more homogeneous and concentrated hydrolyzate with improved sweetening power and reduced water requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional hydrolyzate production processes are used, then processing can be performed with conventional equipment, but the processes lack versatility and require adaptation for each raw material, reducing productivity and yield
Solution Approach 1:
The patent applies universality by designing a single hydrolysis process and equipment configuration that can handle multiple different raw materials (starches, fibers, proteins, lipids) without requiring process adaptation. The circulation loop system and controlled enzyme addition methodology work universally across different substrate types, eliminating the need for separate optimized processes for each material type while maintaining high productivity.
2Device complexity
If raw material is introduced suddenly into the hydrolysis tank, then the process is simpler, but it causes viscosity issues and inefficient handling
Solution Approach 1:
The patent applies preliminary action by pre-mixing the raw material with water in a preparation unit before introducing it to the hydrolysis tank. This preliminary mixing step creates a slurry with optimized consistency that prevents viscosity problems during subsequent hydrolysis, while the automated circulation system handles the transfer efficiently without requiring complex manual intervention.
Solution Approach 2:
The patent uses water as an intermediary substance that mediates between the raw material and the hydrolysis process. By introducing raw material as a water-based slurry rather than dry powder, the system achieves smooth flow characteristics and efficient mixing in the hydrolysis tank, eliminating handling issues while maintaining process simplicity.
3Device complexity
If enzyme addition is not controlled, then the hydrolysis process is simpler, but it reduces the quality and consistency of the hydrolyzate
Solution Approach 1:
The patent applies feedback by implementing a controlled enzyme addition system that responds to process conditions. The circulation loop allows continuous monitoring of hydrolysis progress, and enzyme can be added at optimized stages based on substrate conversion levels. This feedback-controlled approach ensures consistent hydrolyzate quality and dextrose equivalent while managing process complexity through automated control mechanisms.
4Use of energy by moving object
If conventional hydrolysis processes are used, then energy consumption is lower, but productivity and yield are reduced due to inefficient handling
Solution Approach 1:
The patent applies continuity by implementing a circulation loop system where the hydrolysis mixture continuously circulates between the preparation unit and hydrolysis tank. This continuous circulation eliminates idle time, ensures constant mixing and heat distribution, and maintains optimal reaction conditions throughout the process. The system operates continuously at high efficiency, improving productivity and yield while managing energy consumption through optimized circulation patterns and heat recovery.
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 enhances productivity and yield by avoiding sudden raw material introduction, reducing viscosity issues, and enabling controlled hydrolysis, resulting in a more efficient and adaptable process for various raw materials with improved hydrolyzate quality and energy savings.
Implementation Method 1
at least a first progressive and continuous entrainment during a first predetermined period of time, in a circulation circuit, of the raw material by the aqueous phase to progressively and continuously form a first mixture of raw material in the aqueous phase
Implementation Method 2
at least a first progressive and continuous entrainment during a first predetermined period of time, in a circulation circuit, of the raw material by the aqueous phase
Implementation Method 3
at least a second progressive and continuous entrainment during a second predetermined period of time, in the circulation circuit, of the raw material by the mixture of raw material in the aqueous phase and at least one enzyme
Implementation Method 4
Enzymatic hydrolysis is a process in which hydrolase enzymes cleave a substrate into reaction products through the action of a water molecule
Implementation Method 5
at least a first step of adding at least one enzyme into the hydrolysis tank which takes place between said first predetermined time period and said second predetermined time period
Data Source
AI summary
The present invention relates to a process for producing a hydrolysate, to the hydrolysate obtained by the process according to the invention and finally to the use of such a hydrolysate for the preparation of an intermediate product and/or a final product, for example a syrup, a dehydrated syrup/powder, a base for vegetable or dairy products, fruit juice, concentrated fruit juice or even a food product.