Spent Grain Dough Processing for Waste Valorization
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Solution Overview
Problem
Smaller breweries and distilleries face challenges in economically and practically processing spent grain, a high protein and fiber byproduct of alcohol production, which is typically considered a waste product and requires disposal.
Innovation Solution
Developing systems and methods to process spent grain into frozen dough products, including rapid cooling, storage, and combination with other ingredients to create high-fiber and protein-rich dough products like pizza dough, extending shelf life and enabling distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If spent grain is disposed of through traditional methods (giving away or paying for disposal), then disposal costs are minimized, but economic value is lost and environmental waste increases
Solution Approach 1:
The patent transforms spent grain from a waste product into a valuable ingredient by changing its physical and chemical parameters through controlled drying to achieve optimal moisture content (10-20%), freezing to preserve quality, and precise temperature control during processing. These parameter changes enable the spent grain to meet food safety standards while maintaining its nutritional value for use in dough products
Solution Approach 2:
The invention treats spent grain as a temporary byproduct that can be quickly transformed into a lasting valuable product. By using simple, cost-effective processing steps (drying, freezing, mixing) rather than complex manufacturing, the patent converts a disposable waste material into a reusable ingredient, minimizing processing complexity while maximizing economic value recovery
2Duration of action of stationary object
If spent grain is rapidly cooled and frozen for extended shelf life, then distribution capability is improved, but energy consumption increases
Solution Approach 1:
The patent applies preliminary rapid cooling and freezing to spent grain immediately after drying, before distribution. This preliminary action extends shelf life and enables long-term storage and distribution without requiring continuous energy-intensive cold storage throughout the supply chain. The spent grain is prepared in advance with optimal moisture content and frozen state, reducing the need for ongoing energy consumption during transport and storage
Solution Approach 2:
The invention utilizes phase transitions of water in spent grain through controlled freezing and thawing cycles. By rapidly freezing the spent grain to extend shelf life and then controlled thawing during processing, the patent achieves extended storage capability while minimizing energy consumption. The phase change from liquid to solid state preserves the spent grain quality without requiring continuous energy input
3Loss of substance
If spent grain is used as animal feed after drying, then waste utilization is improved, but nutritional quality for human consumption is reduced
Solution Approach 1:
The patent applies precise parameter control during processing to maintain nutritional quality for human consumption. By controlling drying temperature and time to achieve optimal moisture content (10-20%), and using gentle freezing methods, the patent preserves the high protein and fiber content of spent grain. These controlled parameter changes differentiate the processing from animal feed applications, maintaining the nutritional integrity required for human-safe food products
Solution Approach 2:
The invention creates a differentiated product pathway where spent grain is quickly transformed into a human-consumable product rather than being downcycled to animal feed. By using simple processing steps that preserve nutritional quality, the patent enables spent grain to serve as a valuable ingredient in dough products, maximizing its economic and nutritional value rather than accepting lower-quality animal feed applications
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
Utilizes spent grain as a human consumable product, reducing waste and providing a cost-effective solution for smaller operations by creating a high-fiber and protein-rich dough product with extended shelf life for distribution.
Implementation Method 1
rapidly cooling the spent grain prior to drying is not a concern
Implementation Method 2
The cooled and drained spent grain is then put in a new container where it is frozen, giving the grain an extended shelf life
Data Source
AI summary
The invention provides methods for the production of dough and bread products made at least in part of spent brewer's grain. The spent grain is removed from a brewing or distilling process, dried, frozen, and then further processed into a spent grain dough product. More specifically, the invention relates to the systems and methods for making frozen pizza dough balls composed at least in part of grain products that have been used in the process of brewing beer or distilling sprits such as whiskey.