Deboned Poultry Protein Isolation via Alkaline Solubilization
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Solution Overview
Problem
Current methods for isolating protein from animal muscle tissue, particularly from deboned poultry, face challenges such as high calcium and sodium content, oxidation, and loss of functional properties, especially when starting materials contain high bone concentrations, leading to undesirable product characteristics like brown color and microbial contamination.
Innovation Solution
A process involving the comminution of poultry with bone, followed by solubilization using acid or base to adjust pH between 3.6 and 4.4 or 8.3 and 10.5, separating protein from fat, and precipitating the protein to reduce sodium and calcium content, while stabilizing the fat against oxidation, resulting in a high-yield, functional protein product with retained raw meat color and low microorganism levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional acid solubilization is used to recover protein from deboned poultry, then protein extraction efficiency is improved, but calcium content and oxidation increase while functional properties are lost
Solution Approach 1:
The patent changes the pH parameter to an alkaline range (pH 8.3-10.5) instead of conventional acidic conditions, which fundamentally alters the solubilization mechanism. This parameter change enables protein extraction while avoiding calcium contamination and oxidation, as the alkaline environment prevents heme-catalyzed oxidation and keeps calcium insoluble.
Solution Approach 2:
The patent replicates the natural solubilization process that occurs during animal digestion in the rumen, where alkaline conditions naturally break down muscle tissue. By copying this biological process, the invention achieves effective protein extraction without the harmful side effects of conventional acid treatment.
2Quantity of substance
If acid solubilization is used to extract protein, then protein is recovered, but raw meat color is lost and brown color develops
Solution Approach 1:
The patent maintains pH in the alkaline range (8.3-10.5) throughout the solubilization and separation process, which prevents the formation of brown-colored compounds. This parameter control preserves the raw meat color (a* value ≥ 10) while achieving effective protein extraction, eliminating the need for subsequent acidification that would cause color degradation.
3Quantity of substance
If conventional processing is used, then protein is isolated, but fat oxidation occurs and functional properties are compromised
Solution Approach 1:
The patent uses alkaline pH conditions (8.3-10.5) that create an environment unfavorable for oxidative reactions. This parameter change stabilizes fat by preventing heme-catalyzed oxidation, maintaining fat functionality and preventing the formation of oxidation products that would compromise product quality.
4Quantity of substance
If high bone concentration material is processed, then more protein is available for extraction, but calcium content in final product increases
Solution Approach 1:
The patent exploits the differential solubility of calcium at alkaline pH by maintaining conditions where calcium remains insoluble while protein is solubilized. This parameter control enables the processing of high-bone-concentration materials to maximize protein availability while automatically filtering out calcium through the alkaline solubilization process.
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 protein product with high protein content, low fat, and improved texture, meeting the criteria for 'finely textured meat' or 'lean finely textured meat' with reduced sodium and calcium, stable against oxidation, and maintaining the original raw meat color, suitable for use in food products.
Implementation Method 1
solubilizing the animal muscle tissue to a pH between equal to or between about 3.6 and about 4.4 or to a pH between about 8.3 and about 10.5 to thereby obtain a solubilized liquid protein composition
Implementation Method 2
separating the solid fat from the solubilized liquid protein composition
Implementation Method 3
stabilizing the fat against oxidation
Implementation Method 4
precipitating the protein in the reduced fat solubilized liquid protein solution
Data Source
AI summary
A protein fraction and an oxidation stable fat fraction are recovered from poultry containing fat, bone and protein. The poultry is comminuted, solubilized with a food grade acid or base to form a liquid protein fraction and a solid fat fraction. The protein in liquid fraction is precipitated and the protein product retains the color of raw meat.