Sunflower Meal Fractionation for High Protein Animal Feed
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Solution Overview
Problem
Current methods for preparing sunflower meal fractions do not achieve high enough protein content and low enough fiber content to make them a viable alternative to soybean meal for animal feed, particularly for young birds, mammals, and fish, with most processes resulting in fractions containing less than 50% protein and more than 10% crude fibers.
Innovation Solution
A process involving deagglomeration, successive sieving, and air sieving of sunflower meal to separate fractions based on particle size and shape, resulting in a sunflower meal fraction with at least 50% protein and less than 10% crude fibers, utilizing deagglomeration devices like roller mills and air sieving equipment to achieve the desired separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional sunflower meal is used after oil extraction, then the process is simple and low cost, but the protein content is low (25-28%) and fiber content is high (>20%)
Solution Approach 1:
The patent applies segmentation by dividing sunflower meal into multiple fractions through sequential sieving operations. The meal is separated into different size fractions (e.g., <600μm, 600-1250μm, >1250μm) and further processed to isolate high-protein components from fiber-rich components, achieving protein content >50% in specific fractions.
Solution Approach 2:
The patent applies local quality by treating different size fractions differently through selective processing steps. Each fraction receives specific deagglomeration, sieving, or air classification treatments tailored to its particle size characteristics, optimizing protein concentration in the final product while removing fibers from specific size ranges.
2Quantity of substance
If dehulling is performed prior to extraction to increase protein level, then protein content increases to 34-38% and fiber content reduces to about 15%, but the fraction meal can only be used in limited amounts for feeding animals
Solution Approach 1:
The patent segments the dehulled meal into multiple particle size fractions and selectively processes them to achieve different product specifications. By controlling particle size distribution through sequential sieving, the process produces fractions with optimized protein content and fiber content suitable for various animal feed applications, expanding feed applicability.
Solution Approach 2:
The patent changes physical parameters (particle size distribution, moisture content) through controlled deagglomeration and sieving processes. By adjusting these parameters, the process produces fractions with protein content >50% and fiber content <10%, meeting the specifications required for broader animal feed applicability including young birds, mammals, and fish.
3Quantity of substance
If fine crushing and sizing is used to separate protein and fiber fractions, then particle size separation is achieved, but the protein content of obtained fractions does not exceed 40%
Solution Approach 1:
The patent applies multi-stage segmentation with sequential sieving operations. Instead of a single sizing step, the process divides meal into multiple fractions at different stages, with each fraction undergoing further processing. This multi-level segmentation achieves both high separation precision and high protein content (>50%) in the final fraction by progressively isolating protein-rich particles from fiber-rich particles.
Solution Approach 2:
The patent introduces air classification as an additional separation dimension beyond mechanical sizing. Air classification separates particles based on density and aerodynamic properties, providing an orthogonal separation mechanism that complements size-based sieving. This multi-dimensional approach achieves superior separation precision and higher protein concentration in the final fraction.
4Quantity of substance
If multiple protein separation steps with fluted rollers or impact mills are used, then protein content could exceed 40%, but no experimental result supports this assertion and the process complexity increases
Solution Approach 1:
The patent extracts fiber components from the meal matrix through selective size-based separation rather than relying on multiple intensive protein separation steps. By removing fiber-rich fractions early in the process and concentrating protein-rich fractions through sequential sieving, the process achieves high protein content with fewer processing steps, improving productivity and providing experimentally verified results.
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 effectively produces sunflower meal fractions with enhanced protein content and reduced fiber content, making them suitable for use as an alternative to soybean meal in animal feed, with a yield that is acceptable at an industrial scale.
Implementation Method 1
subsequent single air separation into a first fraction with high raw protein and low raw fibre content and a second fraction with low raw protein and high raw fibre content
Data Source
AI summary
A process for preparing a sunflower meal fraction containing at least 50% of proteins and 10% or less of crude fibers. Sunflower meal fraction obtained by the process thereof and its use for preparing animal feed compositions.