Insect Pulp Acidification for Fat-Solid Separation
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Solution Overview
Problem
Current processes for fractionating insect pulp to produce food and feed products are either expensive and labor-intensive or result in insufficient degreasing of the solid fraction, leading to poor further processing capabilities.
Innovation Solution
A process involving the crushing of insects to form a pulp, followed by pH adjustment to an acidic range using an acid and malaxation for at least 45 minutes, and subsequent fractionation into a solid fraction and a fat phase, allowing for improved separation efficiency and reduced residual fat content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If presses are used to press off fat from solids, then the process is simple, but the residual fat content in the solid fraction is too high for good further processing
Solution Approach 1:
The patent applies parameter changes by adjusting the pH of the insect pulp to an acidic range (pH 2-4) before fractionation. This chemical parameter modification enables much more effective separation of fat from solids, achieving residual fat content below 15% w/w, which resolves the contradiction between process simplicity and low residual fat content.
2Loss of substance
If aqueous fractionation process is used to obtain high protein content solid, then residual fat content is lower, but the process is more complex and labor-intensive
Solution Approach 1:
The patent applies preliminary action by adjusting the pH to acidic range before the fractionation step. This pre-treatment prepares the insect pulp for more efficient fat-solids separation, enabling the aqueous fractionation process to achieve low residual fat content while reducing the complexity of subsequent processing steps.
3Device complexity
If enzyme-free fractionation process is used, then the process is simpler and cheaper, but brown discoloration occurs within very short time after comminution
Solution Approach 1:
The patent applies preliminary action by adjusting the pH to acidic range immediately after comminution and before fractionation. This pre-treatment with acid prevents the brown discoloration that occurs in enzyme-free processes, while maintaining process simplicity and avoiding the use of expensive enzymes.
Solution Approach 2:
The patent converts the harmful browning effect into a benefit by using the acidic pH condition. The acid treatment not only prevents discoloration but also improves the separation efficiency of fat from solids, turning a potential quality issue into a process advantage.
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 process achieves a significantly better separation efficiency of fat from solids, with over 20% higher efficiency compared to existing methods, and produces a solid fraction with low residual fat content, suitable for use as animal feed or in sports nutrition.
Implementation Method 1
shifting the pH of the insect pulp to an acidic range by adding an acid
Implementation Method 2
The pulp is then heated to temperatures of 70-100° C. and finally separated into three phases
Implementation Method 3
malaxing the insect pulp for a period of at least 45 minutes
Implementation Method 4
Fractionation of the insect pulp into at least two fractions i. a solid fraction, ii. one fat phase
Data Source
AI summary
A method for obtaining products for the food industry and/or feed industry from insects at the larval stage involves: a) comminuting the insects to form an insect pulp; b) shifting the pH-value of the insect pulp to an acid range by adding an acid and malaxing the insect pulp for a period of at least 45 minutes; and c) fractioning the insect pulp using centrifugal treatment into at least two fractions i) a solid fraction, ii) a fatty phase; and a fat-reduced solid phase.