Protein Isolation from Mechanically Deboned Poultry via pH Control
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Solution Overview
Problem
Existing processes for isolating protein from animal muscle tissue, particularly from mechanically deboned poultry, face challenges such as high calcium and sodium content, oxidation, and microorganism presence, which affect the quality and stability of the final product, and result in undesirable textures and flavors.
Innovation Solution
A process involving the comminution of poultry with water, followed by acidification to pH 3.6-4.4 to solubilize muscle tissue, separation of solid fat, and subsequent neutralization to precipitate protein, which reduces microorganisms, stabilizes fat against oxidation, and adjusts pH to form a stable protein product with reduced sodium and calcium content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mechanically deboned poultry is used as starting material to maximize protein recovery, then protein yield is improved, but calcium content and oxidation levels increase
Solution Approach 1:
The patent applies parameter changes by carefully controlling pH levels during processing. The pH is adjusted to specific ranges (3.0-5.0 for protein solubilization, then 5.5-7.0 for protein precipitation) to optimize protein recovery while minimizing calcium extraction from bone and reducing oxidation. This parameter control allows high protein yield from mechanically deboned poultry without the harmful effects of high calcium and oxidation.
2Productivity
If acid solubilization is used to extract protein from muscle tissue, then protein recovery is improved, but sodium content and oxidation increase
Solution Approach 1:
The patent uses parameter changes by controlling pH within specific ranges (3.0-5.0) during acid solubilization to maximize protein extraction while minimizing sodium content in the final product. The process also controls oxidation by maintaining reduced pH conditions and limiting exposure to oxidizing environments, thereby achieving high protein recovery without excessive sodium or oxidation.
Solution Approach 2:
The patent employs feedback control by monitoring and adjusting pH levels at various stages of the process. pH is measured and adjusted to maintain optimal ranges for protein solubilization and precipitation, ensuring high recovery while controlling harmful factors like sodium content and oxidation through continuous process monitoring.
3Productivity
If conventional protein isolation processes are used, then protein is recovered, but microorganism contamination and undesirable textures occur
Solution Approach 1:
The patent applies parameter changes by maintaining specific pH ranges (3.0-5.0 during solubilization, 5.5-7.0 for precipitation) and temperature conditions that create an unfavorable environment for microorganism growth while preserving protein functionality. These controlled parameters enable high protein recovery with minimal contamination and desirable texture characteristics.
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 high yields of functional protein with improved color, texture, and stability, meeting the criteria for 'finely textured meat' or 'lean finely textured meat' standards, while reducing oxidation and microorganism levels, and producing a fat product with low water content.
Implementation Method 1
adding a food grade acid to effect a pH of 3.6 to 4.4 thereby to solubilize said protein
Implementation Method 2
adding a food grade alkali to said soluble protein to neutralize acid in said protein and to precipitate said protein
Implementation Method 3
separating the solid fat from the acidic solution of said animal muscle protein
Data Source
Figure 1
AI summary
A protein fraction and an oxidation stable fat fraction are recovered from poultry containing fat, bone and protein. The poultry is comminuted, mixed with a food grade acid at pH 3,6 to 4.4 to form a liquid protein fraction and a solid fat fraction. The liquid fraction is mixed with a food grade alkali to precipitate the protein.