Intermittent Infrared Drying for Brewery-Spent Grain Flour
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Solution Overview
Problem
Traditional dehydration methods for brewery-spent grain (BSG) are energy-intensive and expensive, resulting in only a small percentage of usable product for human consumption, and BSG is typically used as animal feed due to its high water content and instability.
Innovation Solution
An intermittent infrared (IR) heating and stirring protocol is applied to BSG, where the grain is spread on a conveyor belt and exposed to IR emitters followed by stirring, repeated multiple times to achieve a moisture content suitable for human consumption, enhancing the product's crispiness, aroma, and nutritional value.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional dehydration methods are used for BSG, then the process is simple and well-established, but energy consumption is high and the yield of usable product is low (5-10%)
Solution Approach 1:
The patent applies periodic action by using intermittent infrared heating cycles followed by stirring periods. The conveyor belt passes through heating zones and stirring zones in sequence, creating periodic heating-stirring-heating-stirring cycles. This periodic action allows efficient moisture removal while preventing energy waste, achieving both low energy consumption and high yield of usable dried product.
Solution Approach 2:
The patent replaces traditional mechanical dehydration systems with infrared radiation heating. Instead of using conventional hot air circulation or contact heating mechanisms, the system uses infrared emitters that directly radiate energy to the BSG, achieving faster and more efficient drying with lower energy consumption and higher productivity.
2Reliability
If traditional dehydration methods are used, then the process is straightforward, but the final product has high microbial load and is not safe for human consumption
Solution Approach 1:
The patent incorporates feedback mechanisms through moisture content monitoring during the drying process. The system adjusts heating intensity and stirring duration based on real-time moisture levels, ensuring the BSG reaches safe moisture content thresholds for human consumption. This feedback control guarantees product safety while maintaining manageable processing complexity.
Solution Approach 2:
The patent changes critical parameters including heating temperature, drying time, moisture content thresholds, and stirring frequency to achieve safe product conditions. By optimizing these parameters, the system transforms BSG from a high-microbial-load material into a safe human food product without requiring overly complex processing equipment.
3Ease of manufacture
If traditional dehydration methods are used, then the equipment is simple, but the product lacks desirable characteristics such as crispiness and pleasant aroma
Solution Approach 1:
The periodic heating and stirring cycles create optimal conditions for developing desirable product characteristics. The intermittent heating prevents excessive energy input while the stirring ensures uniform moisture distribution, resulting in crispy texture and pleasant aroma without requiring complex specialized equipment.
Solution Approach 2:
The patent utilizes phase transitions of water (liquid to vapor) during the infrared heating process. The controlled heating causes moisture evaporation from the BSG, and the subsequent cooling and stirring allow proper crystallization and texture formation, achieving crispy characteristics through natural phase changes rather than complex mechanical processing.
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 a safe, energy-efficient, and nutrient-dense BSG flour that can be used in human food products, reducing waste and providing a sustainable ingredient, with a moisture content below 10% and significantly reduced microbial load.
Implementation Method 1
IR emitters are positioned about 8 inches above the conveyor belt. As the conveyor belt advances at a consistent speed, the BSG passes under about three linear feet of IR emitters
Implementation Method 2
when the BSG is no longer under the IR emitters, the BSG is stirred for about three minutes
Data Source
AI summary
The system for processing brewery spent grains (BSG) includes a specific intermittent infrared (IR) heating and stirring protocol designed to produce a unique dried BSG product that can be used whole or ground up and used as a quality flour suitable for human consumption.