Spent Grain Drying and Milling System for Flour Production
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Solution Overview
Problem
The brewing industry faces challenges in utilizing spent grain byproducts due to their high moisture content, which leads to spoilage and makes them unsuitable for food applications, and the resulting dry spent grain has an unpleasant texture that requires further processing into flour for human consumption.
Innovation Solution
A system and method involving gravity drainage, mechanical pressing, and fluid bed drying to reduce moisture content, followed by milling to convert wet spent grain into dry spent grain flour, utilizing a combination of gravity drainage containers, mechanical presses, fluid bed processors, and milling devices like disc mills or impact mills to achieve the desired consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wet spent grain is used directly, then nutritional content is preserved, but high moisture content causes spoilage and makes it unsuitable for food applications
Solution Approach 1:
The patent applies parameter changes by systematically reducing the moisture content of spent grain from >70% to below 9% through multiple drying stages (gravity drainage, mechanical pressing, fluid bed drying). This parameter transformation enables the grain to transition from a perishable state to a shelf-stable state suitable for food applications while preserving nutritional content.
2Reliability
If wet spent grain is dried quickly, then shelf stability is achieved, but the resulting dry spent grain has sharp and gritty texture that is disagreeable for consumption
Solution Approach 1:
The patent segments the drying process into multiple distinct stages: gravity drainage for initial moisture removal, mechanical pressing for further dehydration, and fluid bed drying for final moisture reduction to below 9%. This segmentation allows controlled, progressive drying that preserves nutritional content while achieving the desired texture and shelf stability.
Solution Approach 2:
The patent replaces traditional mechanical drying methods with a fluid bed drying system that uses fluidized air to remove moisture. This substitution enables more uniform and controlled drying that prevents the formation of sharp, gritty textures while maintaining shelf stability and palatability.
3Reliability
If multiple drying stages are implemented, then moisture content is reduced to below 9%, but process complexity increases
Solution Approach 1:
The patent divides the drying process into three sequential stages: gravity drainage containers for initial moisture removal, mechanical presses for further dehydration, and fluid bed dryers for final moisture reduction to below 9%. Each stage builds upon the previous one to achieve progressive moisture reduction while maintaining manageable process complexity.
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 process efficiently converts wet spent grain into shelf-stable dry spent grain flour, preserving nutritional content and improving palatability, enabling its use in various food applications while reducing waste and increasing brewery profitability.
Implementation Method 1
a device for removing moisture from the spent grain by action of gravity
Implementation Method 2
a mechanical press for removing additional moisture
Implementation Method 3
a fluid bed processor or dryer for removing still additional moisture
Implementation Method 4
a fluid bed processor or dryer for removing still additional moisture
Data Source
AI summary
A process for converting spent grain into flour by drying and milling is disclosed. The process includes the steps of introducing a quantity of wet spent grain into a container for removing moisture by the action of gravity. After the gravity drying, the wet spent grain is transferred to a press to mechanically remove additional moisture. The wet spent grain is placed in a fluid bed processor where the grain additional moisture is removed through heating and fluidization. Some embodiments may include a dust collection system in connection with the fluid bed processor, wherein the dust collection system incorporates a separator for separating the grains. Once dried, the dry spent grain is introduced into a mill to be ground into the proper flour consistency. The resulting flour product can then be used for a variety of foodstuff applications.