Insect Flour Spray Drying for Uniform Particle Size
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Solution Overview
Problem
Current techniques for processing insects into flour result in a product with non-uniform particle size and visible insect parts, making it difficult to use in cooking, as they often produce a mix of fine grain particulars and large fragments.
Innovation Solution
A method involving the use of low-shear and high-shear mixers to create a fine slurry from whole insects, followed by pasteurization and spray drying using a rotary atomizer, which separates particles to achieve a uniform particle size of less than 100 Microns, and subsequent filtration to remove larger particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional roasting and grinding techniques are used to process insects into flour, then the processing is simple and quick, but the resulting flour has non-uniform particle size with visible insect parts
Solution Approach 1:
The patent divides the particle size control into multiple stages: spray drying creates initial uniform particles, cyclone separation divides particles by size, and filtration removes larger fragments. This multi-stage segmentation approach achieves uniform particle size that cannot be obtained through single-step grinding.
Solution Approach 2:
The patent transitions from mechanical grinding (one-dimensional size reduction) to spray drying followed by cyclone separation (introducing aerodynamic classification in a different dimension). This dimensional change enables precise particle size control based on airflow dynamics rather than mechanical force.
2Manufacturing precision
If spray drying is used to reduce particle size, then smaller and more uniform particles are achieved, but conventional spray drying approaches fail to achieve consistent particle size distribution
Solution Approach 1:
The patent implements a feedback loop where cyclone-separated particles are recirculated back to the spray dryer inlet. This feedback mechanism allows continuous adjustment and refinement of particle size distribution, ensuring consistent uniformity while maintaining drying efficiency through optimized recirculation rates.
Solution Approach 2:
The patent optimizes multiple parameters including spray drying temperature, atomization pressure, and cyclone separation cutoff points to achieve the desired particle size distribution. By carefully controlling these parameters, the system maintains high drying efficiency while producing uniform particles.
3Manufacturing precision
If multiple processing steps including filtration are added to remove large particles, then uniform fine particle flour is produced, but the process complexity and time increase
Solution Approach 1:
The patent performs preliminary particle size classification through spray drying and cyclone separation before final filtration. This preliminary action removes the bulk of oversized particles early in the process, making the subsequent filtration step more efficient and reducing overall processing time compared to filtering alone.
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 produces insect flour with a uniform particle size, improving its usability and consistency in cooking applications by eliminating visible insect parts and ensuring a high-quality protein substitute.
Implementation Method 1
a rotary atomizer, which disperses the slurry into a drying chamber
Implementation Method 2
a drying chamber, which applies heat to evaporate water from the slurry before the slurry impacts the walls of the drying chamber
Implementation Method 3
one or more cyclones to separate any particles greater than a third particle size from particles less than the third particle size
Implementation Method 4
subsequent filtration to remove larger particles
Data Source
AI summary
In some examples, a system may be configured to generating flour having a uniform particle size of less than 100 Microns from whole insects. For example, the may include generating a slurry from whole insects by adding water while blending the whole insects using one or more mixers to generate an insect slurry. In some cases, the water is added to the insect parts to reduce the viscosity and to assist in separating the whole insects into parts. In some cases, the insect slurry may be filtered.