Continuous Polyphenol Extraction via Twin-Screw Extrusion

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Solution Overview

Problem

Current polyphenol extraction processes are inefficient, requiring significant solvent use, being discontinuous, expensive, and energy-intensive, with low yields, and are not suitable for solid fibrous materials like vine shoots and bark.

Innovation Solution

A continuous process involving drying, grinding, defibration in an extruder with a solvent, separation of the soluble phase, and recovery of the crude extract containing polyphenols, using a co-rotating twin-screw extruder and minimal solvent, followed by concentration and potential purification.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If maceration in solvent is used for polyphenol extraction, then polyphenols can be obtained, but significant amount of solvent is required and extraction yield is low

Engineering Contradiction:

Improvepolyphenol extraction yieldVSAvoidsolvent consumption

Core Design Contradiction:

Quantity of substanceVSLoss of substance

Solution Approach 1:

The patent replaces the chemical maceration process with a mechanical extrusion system. The extruder uses mechanical force, heat, and pressure to extract polyphenols from plant material, eliminating the need for large volumes of solvent while achieving higher extraction yields through direct mechanical cell disruption and pressure-driven extraction.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the extraction parameters by applying controlled temperature (through heating zones in the extruder), pressure (through the screw compression), and mechanical shear force. These parameter changes enable efficient polyphenol extraction without requiring significant solvent volumes, as the mechanical energy directly facilitates the extraction process.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If batchwise maceration process is used, then polyphenols can be extracted, but the process is lengthy and requires significant energy

Engineering Contradiction:

Improveextraction speedVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The patent implements a continuous extrusion process where plant material is continuously fed into the extruder, processed through heating and mechanical zones, and extracted polyphenols are continuously collected. This continuous operation eliminates the downtime between batches inherent in maceration processes, significantly increasing productivity while using energy only during the active extraction period.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The patent incorporates preliminary drying of the plant material before extrusion to reduce moisture content. This preliminary action prepares the material for more efficient mechanical processing in the extruder, reducing the energy required during the actual extraction process and preventing energy loss from heating excess water during extraction.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If flash decompression process is used, then extraction can be performed, but it is not suitable for solid fibrous materials such as vine shoots, bark, seeds

Engineering Contradiction:

Improvematerial compatibilityVSAvoidprocess effectiveness

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent uses a dynamic extrusion system with adjustable screw speed, compression ratio, and temperature zones that can be optimized for different material types. The mechanical system adapts to various fibrous materials (vine shoots, bark, seeds, oilseed cakes) by adjusting operational parameters, maintaining both versatility across material types and reliability of extraction effectiveness for each specific material.

Inventive Principle:

Principle #15Dynamics

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 process achieves high polyphenol recovery with reduced solvent use, higher yields, and lower costs, particularly for viniferine from vine co-products, making it more efficient and economical compared to previous methods.

Implementation Method 1

defibration of the ground raw material in an extruder in the presence of a solvent

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Implementation Method 2

defibration of the ground raw material in an extruder in the presence of a solvent

Methodology Applied

Scientific EffectSolvation: Solvation

Implementation Method 3

separation of the soluble phase and the fibers, carried out using a press sleeve mounted at the level of a compression zone of the extruder or carried out at the outlet of the extruder by filtration under nitrogen or pressing

Methodology Applied

Scientific EffectFiltration: Filter (physical)

Data Source

PatentEP2920160B1Method for obtaining polyphenols from a vegetable raw material containing same

Publication Date: 2022.07.27 EXINNOV

AI summary

The subject matter of the invention is a method for obtaining polyphenols from a vegetable raw material containing same, characterised in that it comprises at least the following steps: - optionally drying the raw material containing the polyphenols, - crushing the raw material, - defibrating the crushed raw material in an extruder in the presence of a solvent, - separating the soluble phase from the fibres, - recovering the soluble phase, crude extract, containing the polyphenols.