Wasted Egg Coagulation Process Using Acidification and Scraped Surface Heat Exchanger
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The poultry industry faces challenges in processing wasted eggs due to their high viscosity and tendency to coagulate, which causes equipment clogging and results in expensive and inefficient handling and conversion into valuable materials.
Innovation Solution
A process involving the separation of egg liquid from shells, acidification to a pH range of 3 to 6, and heating in a scraped surface heat exchanger to produce a coagulated egg product with controlled characteristics, suitable for animal food, including optional drying and grinding steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heated in a conventional heat exchanger, then pasteurization is achieved, but coagulation occurs causing equipment fouling and breakdown
Solution Approach 1:
The patent applies preliminary action by adjusting the pH of the liquid egg product to below its isoelectric point (pH 4.6) before heating. This pre-acidification prevents coagulation during subsequent thermal processing in conventional heat exchangers, eliminating the fouling and equipment breakdown problems that would otherwise occur. The pH adjustment is performed upstream of the heat exchanger to prepare the egg product for stable thermal processing.
2Ease of manufacture
If spray dried to produce egg powder, then valuable product is obtained, but processing cost becomes prohibitively expensive for waste material
Solution Approach 1:
The patent applies parameter changes by modifying the pH parameter of the liquid egg product to below its isoelectric point before heating and drying. This parameter adjustment fundamentally changes the protein behavior during processing, enabling the production of a coagulated egg product suitable for animal feed without requiring expensive spray drying equipment and energy input. The process transformation from spray drying to acidified thermal processing significantly reduces manufacturing costs while maintaining product value for waste egg utilization.
3Manufacturing precision
If heated to coagulate the egg, then protein denaturation is achieved, but equipment clogging occurs due to high viscosity
Solution Approach 1:
The patent applies preliminary action by adjusting the pH to below the isoelectric point before heating. This pre-treatment prevents protein coagulation during the heating process, maintaining low viscosity and preventing equipment clogging. The pH adjustment is performed upstream to prepare the egg product for smooth flow through heating and drying equipment, ensuring continuous operation without interruptions from clogging.
Solution Approach 2:
The patent applies parameter changes by modifying the pH parameter to control protein charge and solubility. By maintaining pH below the isoelectric point throughout processing, the proteins remain soluble and do not coagulate, preserving fluidity and preventing equipment clogging while still achieving the desired protein denaturation and product stability in the final coagulated egg product.
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 converts wasted eggs into a shelf-stable, high-protein, high-fat coagulated egg product with low moisture content, suitable for animal food, avoiding equipment clogging and ensuring efficient handling and storage.
Implementation Method 1
heating in a scraped surface heat exchanger to produce a coagulated egg product
Implementation Method 2
heating and coagulating the acidified liquid egg
Implementation Method 3
acidification to a pH range of 3 to 6
Data Source
Figure 1
AI summary
A process to coagulate wasted eggs which comprises an acidification step of the liquid egg, followed by a coagulation step using a heat exchanger, preferably a scraped surface heat exchanger, and optionally a drying step. The obtained coagulated egg product has useful properties and can be used as animal food. The process allows the disposal of wasted eggs generated in the poultry and related industries and the production of a valuable by-product with high protein and fat content.