Protein Ingredient Compaction for Better Flow and Low Dust
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Solution Overview
Problem
Existing protein ingredients, particularly protein concentrates and isolates, suffer from poor handling properties such as low bulk density, poor flowability, high dustiness, and inadequate wettability and dispersibility, which are not adequately optimized by current production methods, and often involve costly and denaturing thermal treatments or the use of additives.
Innovation Solution
A method involving compaction of the starting material to increase particle size, followed by milling, without heat treatment or additives, to enhance handling properties like bulk density, flowability, and wettability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If thermal post treatment is applied to improve flowability, then flowability is improved, but protein denaturation occurs and production cost increases
Solution Approach 1:
The invention changes the particle size parameter from fine (micron range) to coarse (visible particles), which fundamentally alters the flow characteristics. This physical parameter change improves flowability without requiring thermal treatment, thus avoiding protein denaturation while maintaining production cost efficiency.
Solution Approach 2:
The invention replaces the thermal treatment mechanism with a mechanical size selection mechanism. Instead of using heat to improve flowability, the system uses mechanical means (sieving, air classification, or centrifugal separation) to select particles of appropriate size, achieving the same flowability improvement without thermal denaturation.
2Productivity
If spray drying is optimized for drying efficiency, then drying efficiency is improved, but powder rheology and flowability are not optimized
Solution Approach 1:
The invention segments the protein particles into different size classes using sieves or air classification. By separating particles based on size, the system can select the optimal particle size range for both drying efficiency and desired powder rheology, rather than producing a uniform fine particle population that compromises flowability.
Solution Approach 2:
The invention introduces dynamic size selection mechanisms (air classification, centrifugal separation) that can adapt particle size distribution based on process conditions. This allows the system to optimize both drying efficiency and powder rheology by dynamically adjusting separation parameters rather than relying on fixed spray drying settings.
3Manufacturing precision
If fine particle size is used to achieve high separation purity, then separation purity is improved, but handling properties deteriorate
Solution Approach 1:
The invention applies local quality selection by identifying and retaining only the particles within the optimal size range (coarse fraction) while discarding both too-fine and too-coarse particles. This selective retention creates a product with superior handling properties while maintaining high separation purity through targeted size-based separation.
Solution Approach 2:
Instead of starting with fine particles and attempting to improve handling properties through thermal treatment or additives, the invention inverts the approach by directly producing coarse particles through size-based separation. This inversion of the traditional fine-particle approach fundamentally improves handling properties while maintaining separation purity.
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 improves handling properties by increasing particle size, reducing dustiness, and enhancing dispersibility and wettability, while avoiding thermal denaturation and additive use, thus reducing costs and improving applicative value.
Implementation Method 1
a) providing a protein concentrate or a protein isolate in the form of a wet powder, preferably having a moisture content comprised from 6% to 16%, more preferably from 8% to 14%, b) compressing the wet powder of step a), to obtain pellets
Implementation Method 2
c) milling the pellets obtained in step b), to obtain a powder
Implementation Method 3
d) classifying (for example sieving or air classifying) the powder obtained in step c), to obtain at least one target coarse fraction
Data Source
AI summary
The present invention relates to protein ingredients, such as protein concentrates and protein isolates, having improved handling properties, in particular exhibiting higher bulk density and flowability, while having a low dustiness compared with their reference on the market. The present invention also relates to compositions comprising said protein ingredients. The present invention further relates to a method for obtaining protein ingredients having improved handling properties, wherein said method comprises a compaction step followed by a milling step and, optionally, a classifying step. The claimed method advantageously does not require any thermal treatment, thereby keeping the native properties of the protein ingredients, while being of a low cost.