Sieve-Press Mash Extract Production with Counter-Current Segmentation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing mash extracts for yeast-fermented beverages, such as beer, face challenges in achieving high gravity extracts with efficient extraction yields while minimizing electricity consumption and extract losses.
Innovation Solution
The method employs sieve-press combinations for continuous separation of mash extracts, involving mashing starch-containing materials, enzymatic hydrolysis, and multiple stages of sieving and pressing to achieve high solids content and recirculation of wash water, resulting in high gravity mash extracts with minimal extract losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple wash vessels and screen separators are used for continuous counter-current extraction, then extraction yield is improved, but device complexity and electricity consumption increase
Solution Approach 1:
The extraction process is divided into multiple stages with separate wash vessels and screen separators operating in counter-current fashion. Each stage performs a specific separation function, allowing the system to achieve high extraction yields through progressive enrichment of the extract while managing complexity through functional segmentation.
Solution Approach 2:
The patent introduces a temporal dimension to the extraction process by implementing continuous counter-current flow across multiple stages. This transforms a simple single-stage separation into a multi-dimensional process where material flows through space and time in coordinated patterns, achieving higher extraction efficiency without proportionally increasing device complexity.
2Productivity
If multiple wash vessels and screen separators are used for continuous counter-current extraction, then extraction yield is improved, but electricity consumption increases
Solution Approach 1:
The system segments the extraction process into distinct stages, each handling a portion of the separation task. This allows energy consumption to be distributed across multiple smaller units rather than requiring one large high-energy device, achieving high extraction yield through cumulative effect while managing overall energy usage.
Solution Approach 2:
The counter-current continuous extraction system maintains constant flow and separation action across all stages simultaneously. This continuous operation ensures that energy is used efficiently at every moment with no idle periods, maximizing extraction yield per unit of energy consumed through uninterrupted multi-stage processing.
3Device complexity
If simple screen separation is used, then device complexity is reduced, but extraction yield and gravity of mash extract decrease
Solution Approach 1:
Rather than using one complex high-capacity separator, the patent employs multiple simple screen separators arranged in counter-current stages. Each separator performs a basic screening function, but the cumulative effect across stages achieves high extraction yield and gravity without requiring any single device to be overly complex.
Solution Approach 2:
The patent combines multiple simple separation stages into an integrated counter-current system. By merging the output of one stage with the input of the next in a coordinated flow pattern, the system achieves extraction performance comparable to complex single-stage systems while using simpler, more maintainable individual components.
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 approach enables the production of high gravity mash extracts with low electricity consumption and high extraction yields, maintaining high efficiency and robustness, suitable for continuous operation with minimal extract losses.
Implementation Method 1
passing the heat-treated mash across a first vibrating sieve for separation into a fermentable mash extract and wet spent grain
Implementation Method 2
transferring the wet spent grain to a first press and pressing said wet spent grain to obtain dewatered spent grain
Implementation Method 3
passing the slurry across a second vibrating sieve for separation into washed spent grain and wash water
Implementation Method 4
transferring the washed spent grain to a second press and pressing said washed spent grain to obtain spent grain residue and rest water
Implementation Method 5
heating the mash and enzymatically hydrolysing the starch
Data Source
Figure 1
Figure 2
Figure 3
AI summary
One aspect of the invention concerns a method comprising: a. mashing particulate, starch-containing and optionally malted raw materials with water; b. heat ing the mash and enzymatically hydrolysing the starch; c. passing the heat-treated mash across a first sieve for separation into a fermentable mash extract and wet spent grain; d. transferring the wet spent grain, optionally after said wet spent grain has been subjected to a washing and sieving operation, to a first press and pressing said wet spent grain to obtain dewatered spent grain and additional fermentable mash extract. The present method offers the advantages of (i) being very robust, (ii) enabling the production of high gravity mash extracts (iii) consuming very little electricit y and (iv) achieving high extraction yields. The invention also provides an apparatus for carrying out the aforementioned method.