Counter-rotating Screw Larvae Separator for Chitin Recovery

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Solution Overview

Problem

Current methods for processing insect larvae biomass into chitin, fats, and proteins are energy-intensive, result in protein denaturation, and require additional costly steps, making them economically unattractive for large-scale processing.

Innovation Solution

A method involving grinding living insect larvae with counter-rotating screws and separating the biomass into pulp and liquid fractions using a mesh-equipped transport screw, which minimizes protein denaturation and allows for efficient separation of chitin-rich pulp and fat-protein rich liquid fractions in a single step.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If scalding is applied to kill insects prior to grinding, then the insects can be processed, but proteins are denatured and retained in the chitin pulp fraction requiring additional enzymatic hydrolysis steps

Engineering Contradiction:

Improvekilling of insectsVSAvoidprocess steps

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts the harmful effect of scalding-induced protein denaturation by eliminating the scalding step entirely. Instead, living insects are ground directly, and the protein-rich liquid fraction is separated and removed during the grinding process, preventing protein contamination of the chitin pulp without requiring additional hydrolysis steps.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent segments the processing into distinct functional zones within the grinding apparatus: a grinding zone that mechanically processes the insects, and a separation zone with a screen that divides the mixture into chitin pulp and protein-rich liquid fraction. This segmentation allows simultaneous killing and separation without protein denaturation.

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If scalding and additional enzymatic hydrolysis are used to separate proteins from chitin pulp, then protein separation is achieved, but operational costs and investment in machinery increase substantially

Engineering Contradiction:

Improveprotein separationVSAvoidoperational cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces the chemical/enzymatic system (scalding and enzymatic hydrolysis) with a mechanical separation system. The grinding apparatus with its integrated screen performs both mechanical comminution and separation in one unit, eliminating the need for expensive enzymatic hydrolysis equipment and reducing operational costs while achieving effective protein-chitin separation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If scalding and enzymatic hydrolysis steps are implemented, then protein fraction can be separated, but additional raw materials and energy consumption are required

Engineering Contradiction:

Improvebiomass separationVSAvoidenergy consumption

Core Design Contradiction:

Manufacturing precisionVSUse of energy by moving object

Solution Approach 1:

The patent implements continuous processing where living insects are fed continuously into the grinding apparatus, ground, and separated in a single uninterrupted flow. The protein-rich liquid fraction is separated and removed continuously during grinding, eliminating the need for separate batch processing steps like scalding and enzymatic hydrolysis, thereby reducing energy consumption and raw material usage.

Inventive Principle:

Principle #20Continuity of useful action

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 method enables economically feasible separation of insect larvae biomass into valuable fractions, reducing operational costs and energy consumption, while maintaining the quality of chitin and recovering proteins and fats effectively, suitable for large-scale processing.

Implementation Method 1

grinding the larvae by means of the grinding apparatus comprising at least two counter-rotating screws to generate ground biomass

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Implementation Method 2

separating the ground biomass into a pulp and a liquid fraction by means of a transport screw placed in a gradually narrowing cylinder, whereby the cylinder at least over the length of the transport screw is equipped with a mesh-shaped material

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Data Source

PatentUS11591414B2Method for separating larvae in a pulp and a liquid fraction

Publication Date: 2023.02.28 VLAAMSE INSTELLING VOOR TECHNOLOGISCH ONDERZOEK NV (VITO)

AI summary

The present invention relates to a method for separating larvae into a pulp fraction and a liquid fraction, including the steps of introducing living larvae into a grinding apparatus whist adding water, grinding the larvae by means of counter-rotating screws and separating the ground biomass of larvae into a pulp and liquid fraction. In particular, the invention is applicable to the larvae of the black soldier fly and produces a chitin-rich pulp and a fat-and-protein-rich liquid fraction.