Soluble Material Processing With Shear, Hydrolysis, and Adiabatic Expansion
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Solution Overview
Problem
Conventional methods for processing soybeans using extruders face issues such as the necessity of steaming treatments and insufficient sterilization, and the use of supercritical water methods is limited to batch processes with zein as the sole protein source and excessive water usage.
Innovation Solution
A production method involving a solid raw material with hydrolyzable components and fibrous materials, treated at high temperatures and pressures with shearing forces, followed by adiabatic expansion, to produce a soluble material without requiring large batch apparatuses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a batch type heating and pressurization container is used for heating treatment, then uniform heating can be achieved, but the container size increases, processing time increases, and energy consumption increases
Solution Approach 1:
The patent replaces the mechanical batch heating system with a continuous extrusion system that combines mechanical shearing, thermal heating, and pressurization in one continuous process, eliminating the need for separate batch heating containers and operations
Solution Approach 2:
The patent implements continuous processing through the extruder that continuously feeds, heats, pressurizes, and extrudes the material in a single uninterrupted operation, replacing the intermittent batch process with continuous action to reduce processing time and energy consumption
2Productivity
If continuous heating treatment is performed using an extruder, then processing time is reduced, but contamination of general viable bacteria increases
Solution Approach 1:
The patent changes the thermal and mechanical parameters by applying high temperature (170-190°C), high pressure, and intense shearing forces simultaneously during extrusion, creating conditions that sterilize the material while maintaining continuous processing benefits
Solution Approach 2:
The patent replaces conventional thermal sterilization methods with a combination of mechanical shearing, high pressure, and controlled thermal heating in the extrusion system, achieving sterilization through the integrated process rather than separate thermal treatment
3Object-affected harmful factors
If water is added to cracked whole soybeans before extrusion, then sterilization is improved, but a steaming treatment becomes necessary
Solution Approach 1:
The patent merges the water addition, heating, pressurization, and extrusion steps into a single integrated extrusion process, eliminating the need for separate steaming treatment by combining multiple functions in one operation
Solution Approach 2:
The extrusion system performs multiple functions simultaneously including water addition, heating, pressurization, shearing, and sterilization in one continuous operation, making the process self-sufficient and eliminating the need for separate steaming equipment and steps
4Manufacturing precision
If supercritical water or subcritical water is used for hydrolyzation, then protein hydrolysis can be achieved, but the method is limited to batch processes with excessive water usage
Solution Approach 1:
The patent changes the water quantity parameter by using a controlled amount of water (0.04 to 2.4 parts by weight per part dry raw material) instead of excessive water, while maintaining the necessary hydrolysis conditions through controlled temperature and pressure during extrusion
Solution Approach 2:
The patent replaces the water-intensive batch hydrolysis method with a mechanical extrusion system that achieves hydrolysis through combined mechanical shearing, thermal heating, and pressurization with minimal water, eliminating the need for excessive water addition
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 method achieves sufficient sterilization and high solubilization ratios, producing a soluble material suitable for food products without the need for steaming and using excessive water, while avoiding the use of complex apparatuses.
Implementation Method 1
hydrolyze at least a part of the hydrolyzable material
Implementation Method 2
halting the pressurization to cause adiabatic expansion
Data Source
AI summary
Provided is a production method for a soluble material, including: causing a solid raw material containing at least one component of a hydrolyzable material selected from the group consisting of a protein, a carbohydrate and a lipid, and a fibrous material, and water in an amount corresponding to 0.04 to 2.4 parts by weight with respect to 1 part by weight of a dry amount of the raw material to coexist; applying a shearing force in a state where heating and pressurization are performed at 200 to 374° C. and in a pressure range equal to or higher than a vapor-liquid coexistence curve of water to hydrolyze at least a part of the hydrolyzable material and/or to amorphize at least a part of the fibrous material; and halting the pressurization to cause adiabatic expansion.