Lysine Feed Additive Granulation via Membrane Filtration
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Solution Overview
Problem
Conventional methods for preparing lysine-containing animal feed additives result in variable component contents due to fermentation conditions, leading to inconsistent lysine levels and process complexities such as high costs and stickiness.
Innovation Solution
A method involving membrane filtration of a lysine-producing microorganism's fermentation broth to separate a filtrate and sludge, followed by drying and granulation at controlled temperatures, and coating with a sludge, diluent, or free lysine to standardize lysine content and reduce hygroscopicity, resulting in granules with consistent lysine content and improved storage properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fermentation broth is used directly to prepare animal feed additive, then the process is simple and cost is low, but the lysine content varies significantly according to fermentation conditions
Solution Approach 1:
The patent extracts and separates the lysine-containing filtrate from the fermentation broth through membrane filtration, isolating the useful component (lysine) from the variable fermentation matrix. This extraction allows standardization of lysine content while maintaining process simplicity, as the separation step concentrates and stabilizes the lysine content regardless of fermentation variations.
Solution Approach 2:
The patent changes the concentration parameter by drying the filtrate to obtain a concentrate with controlled total solid content (48-52 wt%), and then granulating it to achieve standardized lysine content (65% or more). This parameter transformation converts the variable fermentation broth into a standardized granular product with consistent composition.
2Quantity of substance
If the fermentation broth is concentrated by azeotropic distillation, then the lysine content increases, but the process cost and complexity increase
Solution Approach 1:
The patent replaces the complex azeotropic distillation system with a simpler membrane filtration followed by drying and granulation process. Instead of using energy-intensive distillation to concentrate lysine, the invention uses mechanical filtration to separate the filtrate, then employs controlled drying and granulation to achieve concentration and standardization, significantly reducing process complexity and cost.
3Manufacturing precision
If the granules are coated with sludge and coating agents, then the lysine content is standardized and hygroscopicity is reduced, but the process steps increase
Solution Approach 1:
The patent merges multiple functions into the coating step: the coating agent serves both to standardize the lysine content (by adjusting with free lysine) and to prevent hygroscopicity (by adding moisture prevention agents). This combination of functions in a single step achieves precise lysine standardization and improved storage properties without proportionally increasing process complexity.
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 granular animal feed additives with a standardized lysine content of 65% or more, maintaining high apparent density and low sugar content, allowing for precise lysine adjustment and long-term storage with reduced hygroscopicity.
Implementation Method 1
filtering, with a membrane filter, a fermentation broth obtained from a lysine producing microorganism cultured in a lysine producing condition to obtain a lysine-containing filtrate and a microorganism-containing sludge
Implementation Method 2
drying the filtrate to obtain a concentrate with a total solid content of 48 to 52 wt %
Implementation Method 3
granule-drying the concentrate at a temperature of 50° C. to 60° C. to obtain granules
Data Source
AI summary
Provided are a method for preparing a granular animal feed additive and the granular animal feed additive prepared by the method. The method includes: filtering, with a membrane filter, a fermentation broth obtained from a lysine producing microorganism cultured in a lysine producing condition to obtain a lysine-containing filtrate and a microorganism-containing sludge; drying the filtrate to obtain a concentrate with a total solid content of 48 to 52 wt %; granule-drying the concentrate at a temperature of 50° C. to 60° C. to obtain granules; and coating the granules with a coating agent containing one or more selected from the group consisting of the sludge, a diluent or a free lysine as a lysine content adjustor, and a moisture prevention agent, to obtain lysine granules having the following properties:Lysine content (lysine sulfate)65% or moreGrain size 300–1,200 μm, 90% or moreApparent density 620–720 kg/m3Protein content 10–15%Total sugar content >0–1%Inorganic material content >0–3%Water content >0–3%Carboxylic acid content >0–8%SO4− ion content 20–25%.