RU2667161C1 - Method of manufacturing feeds by extrusion of biological and agricultural waste, production line for method implementation and feed obtained by provided method - Google Patents

Abstract

FIELD: agriculture.SUBSTANCE: group of inventions refers to agriculture, in particular to feed production. In process of obtaining feed, which includes separate grinding of vegetable and moisture-containing protein raw materials, mixing, extrusion and granulation, cooling is additionally included. During process of obtaining feed operations are carried out in the following order: grinding, mixing, extruding, cooling and granulation. After extrusion, raw material is subjected to enzymatic hydrolysis. Resulting food retains its safe properties for long time, including storage, has balance and better digestion of animals, preventing gastrointestinal diseases, and easy therapeutic effect.EFFECT: use of group of inventions will make it possible to obtain high-quality finished product in form of animal feed.10 cl, 1 dwg

Description

Application area

The claimed technical solution relates to the field of feed production.

State of the art

There are various methods of obtaining feed for productive and unproductive animals by grinding biological waste and grain mixtures. Some of these technologies include not only grinding, but also heat treatment, extrusion and fermentation.

Known described in patent RU2581223 "METHOD AND DEVICE FOR PREPARATION OF EXTRUDED FOOD AND FODDER PRODUCTS". The invention relates to the food and feed industry, and in particular to equipment for the extrusion processing of food and feed products. In the process, raw materials and water are fed into the extrusion chamber. Moistened raw materials are sent by conveyor screw elements sequentially to the zone with kneading screw elements, then by transporting screw elements to the zone of reversible screw elements, to the steam removal zone with transporting screw elements and then to the pre-extrusion zone of the extrusion chamber. Then the raw material is extruded through the forming die matrix. In the area with kneading screw elements carry out preliminary welding of raw materials with regenerative steam. Steam is diverted from the steam extraction zone through a steam line with an expansion chamber, a control valve and a nozzle. Through the nozzle, steam is fed into the zone with kneading screw elements. In the area of the reversible screw elements, the temperature is maintained at 160-200 ° C, the pressure is 3-10 MPa and the moisture content of the raw material is 12-20%. The device includes an extrusion chamber with successively located zones: conveying screw elements, kneading screw elements, conveying screw elements, reversible screw elements, conveying screw elements, pre-mold zone and forming die dies. Immediately after the zone of reversible screw elements, the transporting screw elements are made with a step 1.5-2 times greater than the step of the remaining screw elements, with the formation of a steam extraction zone communicated with the expansion chamber of the steam line. The steam line is equipped with a control valve and is connected by means of a nozzle to the area of the kneading screw elements. The length of the steam extraction zone is 1.0-1.5 turns of the conveying screw element in this zone.

The method directly describes the extrusion and installation for its implementation. There are no stages of preliminary preparation of raw materials for processing. Biomass is not safe for a long period of time during the preparation of a product. In addition, in the described method there is no fermentation step, which does not allow us to talk about the high quality of the resulting product.

A known method for producing an extruded product described in patent RU2585470 "METHOD FOR PRODUCING AN EXTRUDED PRODUCT OF HIGH FOOD VALUE ENRICHED BY A SCORPONOR". The invention relates to the food industry. A method of obtaining an extruded product of high nutritional value, enriched in scorzoner, includes the preparation of raw materials, which are used as potato starch, or corn, or wheat, or rice, or tapioca, or mixtures thereof, or wheat flour, or rye, or potato, or corn or mixtures thereof, or dry mashed potatoes in the form of flakes, or granules, or granules, or grains, or mixtures of various starch-containing raw materials, mixing the raw materials with an additive that increases the nutritional value of the product, and serving the resulting mixtures simultaneously with carbon dioxide in the solid phase into a twin screw extruder. As an additive, they are used in dry powdered or raw powdered form to the scorzoner separately or in a mixture with other plant materials in a different ratio. Carbon dioxide in the solid phase is fed in an amount of 0.5 wt. %, the extrusion is carried out at 100-200 ° C, the rotational speed of the metering screw and working screws 90-95 min-1. Unfinished extrudate is coated in sugar syrup, or in salt brine, or in sugar-juice syrup, or in sugar-fruit syrup, followed by drying.

In the described method, a method for preparing a product of predominantly plant content is presented, which imposes certain restrictions on the scope of the invention. In the described method there are no stages of grinding and fermentation.

The known method described in patent RU2179398 "METHOD FOR PRODUCING FOOD FOR PETS BASED ON A LIQUID HYDROLYZATE FROM MEAT RAW MATERIALS". The invention is intended for use in the feed industry, in the production of pet food (cats and dogs). A method for the production of pet food includes the sequential enzymatic and acid hydrolysis of raw materials, which are pre-minced chicken offal (offal), the raw materials being processed with a proteolytic enzyme preparation in the ratio of endo- and exopeptidases of 1: 1; 1: 1.5; 1.5: 1 in an amount of 0.1% by weight of the raw material at 50-60 ° C for 0.5-1.0 hours, and acid hydrolysis is carried out at 95-100 ° C for 20-30 minutes until the pH reaches 5.0- 5.5, the resulting hydrolyzate is divided into parts and one part is fed with the feed to the extruder to introduce the granules formed in it in an amount of 1-2% and the other to a cutter for spraying onto the surface of the granules in an amount of 5% of the weight of the granules. The consumption of pet food based on a liquid hydrolyzate has a positive effect on the restoration of the skin and improve the structure of animal hair. Amino acids and peptides that are part of the hydrolyzate, increase the immunity of animals.

In the described method, enzymatic and acid hydrolysis is carried out before extrusion, which does not allow to obtain a safe product for a long time. In the described method, the emphasis is on the processing of raw meat, therefore, fermentation is carried out only by a proteolytic enzyme preparation, and the preparation stage of the compound feed is not described, which does not allow to draw any conclusions about the carbohydrate component of the resulting product.

The known method described in patent RU2315485 "METHOD FOR PREPARING FOOD FOR ANIMALS". The invention is intended for feed production. A method of preparing animal feed involves grinding green plants and treating them with a filler and feed additives under pressure and temperature, the treatment being carried out in a press extruder at a pressure of 20-30 kg / cm2 and a temperature of 60-80 ° C for 30-60 seconds s zeolite in an amount of 0.5% by weight of feed and carbon ammonium salt in an amount of 0.5% by weight of feed. The nutritional value of the feed increases and its shelf life increases.

In the described method, the emphasis is on the preparation of feed from raw materials mainly plant content. The method includes grinding, enrichment, pressure treatment, heating, and also adding zeolite.

The known method disclosed in patent RU2223673 "METHOD FOR PRODUCING COMBINED EXTRUSION PRODUCTS FROM MEAT AND VEGETABLE RAW MATERIALS". The invention relates to the food industry, mainly to the meat industry and the production of extruded food. The method involves the preparation of meat and vegetable raw materials. Lentils and semolina are used as plant materials. In this case, the lentils are pre-crushed to a particle size of 0.5-1.0 mm, collagen mass obtained by processing secondary collagen-containing raw materials of the meat industry with proteolytic enzymes, for example megaterin or protosubtiline, and poultry meat are used as meat raw materials. Raw meat is dehydrated by freeze drying to a moisture content of 14-18% and crushed to a particle size of 0.5-1.0 mm Additionally, combined food additives are used in the form of powdered dairy and vegetable semi-finished products. All components are dosed, mixed and extruded meat-vegetable mixture at a certain ratio of components in wt. % After extrusion, flavoring agents (powdered sugar, table salt, spices) are applied to the surface of the products. The method allows to increase the biological value of the combined extrusion products from meat and vegetable raw materials, to enrich them with physiologically active biopolymers, as well as to expand the functionality of low-grade collagen-containing raw materials of the meat industry, which is not very popular for food purposes.

In the presented method, only lentils and semolina are presented as plant materials. There is a processing of raw meat proteolytic enzymes. Mixing heterogeneous raw materials occurs after processing with enzymes. Extrusion is carried out after fermentation and mixing of the components.

The known method disclosed in patent RU2215427 "METHOD FOR PROCESSING WASTE ANIMAL AND VEGETABLE ORIGIN", which is the prototype of the claimed invention. The invention described in RU221527, is intended for use in feed production and is aimed at the disposal of animal and vegetable waste to obtain protein additives to the feed ration of animals, birds and fish. A method of processing animal and vegetable waste includes dosing of components, their grinding, mixing, extrusion and cooling. After extrusion, rapid forced pneumatic removal of steam and air from the extrudate is carried out. When the humidity of the initial mixture above 30%, repeated extrusion is carried out with rapid forced pneumatic removal of steam and air from the extrudate. The content of animal waste in the initial mixture is 10-80%. The product during processing is exposed to temperature and pressure for a short period of time, therefore, the digestibility of the protein and the digestibility of lysine are ensured.

The said patent discloses a method for processing animal and vegetable raw materials, which includes dosing, grinding of components, mixing, extrusion and cooling, as well as quick forced air removal. In the described method there is no fermentation step. The main disadvantages of this technology is that the resulting product is conditionally safe only at the exit of the extruder. In addition, according to this technology, only a limited number of types of raw materials can be processed, which imposes certain restrictions on the breadth of processing of biological waste.

Thus, we can conclude that the currently existing technical solutions do not use the full potential of the extrusion and fermentation bundle to the full and therefore do not provide a product with high consumer properties.

The objective of the proposed method for the manufacture of feed by extrusion of biological and agricultural raw materials is to obtain a safe product over a long period of time, including storage, balance and better assimilation of animals by the body, additionally having prophylactic properties that prevent gastrointestinal diseases and an easy therapeutic effect, the use of vegetable and moisture-containing protein raw materials. In addition, another feature of the claimed invention is the ability to use in the process of processing all types of biological raw materials, including crop waste and slaughter.

The manufacture of feed by extrusion of biological and agricultural raw materials is as follows.

Grinding of vegetable and moisture-containing protein raw materials is carried out separately. In cases where this is required, grinding is carried out in several stages with a gradual decrease in the size of the fraction. At this stage, if necessary, add mycelium of fungi, yeast cells or other components according to the recipe.

Then the raw materials of plant and animal origin are fed into the mixing system, where they are mixed until a homogeneous mass. Moreover, if necessary, carry out additional disinfection by quartzization, ozonation or any other known method.

After that, the resulting homogeneous mass is fed into the extruder unit and extruded. This implies finding the raw material at a temperature of from 20 ° C to 180 ° C and a pressure of 3 to 50 atmospheres for 5 to 30 seconds. The release of pressure in the medium upon exiting the extruder barrel leads to a decrease in the solubility of gases in the cytoplasm of the cell and the release of gases (such as oxygen, nitrogen, carbon dioxide) with rupture of the cell membrane. At the same time, cells and cellular organisms die, the functioning of which requires the presence of a living cell membrane (for example, helminths, cell bacteria and pathogenic fungi).

Further, in the extruded product, autolysis begins. During cell metabolism, there is a constant synthesis / destruction of RNA (m-RNA, t-RNA), which requires the presence of ribonucleases in the cytoplasm. At this time, the contents of the substrate are subject to the action of endogenous enzymes, primarily ribonuclease. Upon destruction of the cell wall, ribonuclease enter the substrate, but continue to be active until inactivation. During this process, the potential pathogenic viral load decreases and the long fragments of the nucleic acid chains break into shorter ones, which increases the energy and nutritional value of the substrate.

After that, at a temperature of from 20 ° C to 60 ° C, a complex of exogenous protease and cellulase class enzymes occurs together or separately in the feed. Cellulases complete the destruction of long carbohydrates (plant cellulose, cell wall fragments), begun at the extrusion stage, to short carbohydrates, reducing the allergenicity of the product and increasing its nutritional value. Proteases increase the digestibility of the protein component of the substrate, destroying proteins, including native, pathogenic proteins (protein toxins, prions) and structural proteins of viruses, if present, which helps to increase the safety of the substrate. Also, proteases destroy endogenous enzymes, terminating the process of autolysis, which helps to stabilize the composition of the substrate, and inactivate ribonuclease.

However, the use of a complete set of enzymes is optional. For example, if it is necessary to stimulate the immune system, cellulase is not used. This leads to a decrease in the nutritional value of the product, but increases its immunostimulating effect.

After this, the raw materials are cooled, dehydrated and mixed again. At this stage, there is the possibility of additional disinfection of raw materials, for example, by quartzization or ozonation. In addition, at this stage there is the possibility of additional enrichment of the product with additives. At this stage, proteases are inactivated during heating and drying.

Then granulation is carried out with a granule size depending on the specific consumption. After this, the product is packaged and packaged in consumer packaging with a volume sufficient to contain the finished product.

The technical result of the claimed invention is to obtain feed that retains its safe properties for a long time, including storage, which has a balance and the best assimilation of animals by the body, preventing gastrointestinal diseases and a light therapeutic effect, with conditionally infected raw materials, use biological waste and crop waste to obtain feed.

The technical result is achieved due to the fact that in the feed manufacturing method, which includes separate grinding of vegetable and moisture-containing protein raw materials, mixing, extruding and granulating, cooling is additionally included, and the operations are carried out in the following order: grinding, mixing, extruding, cooling and granulating while during and after extrusion of the raw materials is subjected to enzymatic hydrolysis.

The inventive method is industrially applicable.

The second object of the claimed invention is a production line for implementing the above method of manufacturing feed by extrusion of biological and agricultural waste.

The known line described in patent RU33485 "Line processing of biological waste." This is a biological waste processing line, including extruders, devices for feeding waste and filler to a mixer, a device for feeding the resulting mixture to an extruder and a system for removing and cooling the finished product, characterized in that parallel extruders are combined in blocks of two or more and share a common system loading and the general system of pneumatic conveying and cooling of the finished product.

The presented technological line is very limited in its capabilities, it does not allow to process any biological waste, it does not allow maximum avoidance of human contact with conditionally infected raw materials.

The known line described in patent RU99283 "PRODUCTION LINE FOR EXTRUDED PRODUCTS". The utility model relates to the processing of food raw materials and can be used in the production lines of extruded products for humans, animals, birds and fish. The extruded products production line, containing hoppers, mixers, extruder, cooler, conveyors, granulator, is divided into a preparation section, including a hopper, at least two crushers, a mixer, a precipitating cyclone and a storage hopper, an extrusion section, comprising at least two hoppers - drives, extruder press and hood, grinder preparation section including crusher, cyclone precipitator and storage bin, auxiliary materials section, including mixer, crusher and precipitator cyclone, granule section The company includes a storage hopper, a granulator, a cooler and a dust collector, a packaging and packing section, including a storage hopper and a bag-loading complex. Thus, the use of the invention allows to expand the types of raw materials used to create extruded products, for example, milk thistle, expired food products, wheat and so on.

The presented production line does not allow avoiding the organization of cutting sites and does not allow minimizing human contact with conditionally infected raw materials.

The known line described in patent RU2304417 "LINE FOR PRODUCTION OF EXTRUDED FOOD". The invention relates to the processing of food raw materials and can be used in the production lines of extruded animal feed. The line includes containers for bulk cereal components with dispensers, a mixer, an extruder and a cooler. The line is additionally equipped with bunkers for storing liquid components with volumetric dispensers, steam shirts and nozzles for spraying liquid components, a conveyor belt, a container for storing fat-and-vitamin components, which has a volumetric dispenser in the bottom and is equipped with a steam jacket, high pressure pump, belt dryer and granulator. The belt dryer has a sifter with a confuser for collecting fine fractions. A steam jacket is installed on the mixer body to stabilize the temperature regime of the mixing process. The extrusion zone of the extruder is made in the form of a die with a coextrusion head to obtain a filling product. The coextrusion head is in the form of a cylinder with a tube located inside it, communicated through a pump with a volumetric dispenser of a container for storing fat-vitamin components. The line has a recirculation pipe designed for the subsequent use of waste heat carrier from the dryer in steam jackets of bunkers for storing liquid components, a container for storing fat-vitamin components and a mixer. Using the invention will allow to obtain a finished product enriched in fats and vitamins.

In the presented production line there is no cooling column, a system for dehydrolysis and fermentation.

A known line described in patent RU2315535 "PRODUCTION LINE FOR EXTRUDED PRODUCTS". The invention relates to the processing of food raw materials and can be used in the production lines of extruded products. The line contains a loading hopper, a mixer, a device for preliminary hydrothermal processing of the feedstock, an extruder, a knife for cutting granules, a sifter, crusher, cyclone. The mixer and the device for preliminary hydrothermal processing of the feedstock are made in the form of one horizontal trough-like body with nozzles for supplying steam into the body, inside of which there is a rotating perforated screw for the passage of steam into the body. The boot device of the extruder is arranged to move along the surface of the extruder body. The sifting cooler is a cylindrical inclined housing with a funnel for supplying extruded products, nozzles for supplying cooling air and for exhausting exhaust air with dust fractions, in which an inclined cylindrical rotating two-section perforated drum is located, the first section having smaller openings and the second openings corresponding to the standard diameter of the extruded products. The lower part of the sifter-cooler housing is divided into two discharge hoppers, the first section of the perforated drum with small holes being located above the first discharge hopper, and the second section of the perforated drum with holes for standard extruded products is located above the second discharge hopper. On the filling machine, the finished product is packaged, then packaged in boxes on a packaging machine, and a large fraction of extruded products comes out of the inclined cylindrical drum, which is then crushed by a crusher and sent to the intermediate storage hopper, and the small fraction is sent to the intermediate hopper the accumulator, the exhaust air from the sifting cooler with pulverulent fractions is fed into the cyclone, where they are collected and sent to the intermediate storage hopper, from which they stepping a conditioner for steaming and then fed to the extruder for re-molding. The invention allows to eliminate marriage and reduce the loss of raw materials, select the most rational modes for processing non-standard products without compromising their quality.

In the presented production line there is no cooling column, a system for dehydrolysis and fermentation.

The objective of the claimed technological line is, in addition to the implementation of the method of manufacturing feed disclosed above, the maximum exclusion of human contact with biological waste as conditionally infected raw materials.

Description of the production line

The technological line is illustrated by the drawing, which shows a block diagram and is arranged as follows.

At least one grinding device is connected to a mixing device. It should be understood that when working with plant and protein raw materials at the same time it is better to have at least two grinding devices connected in parallel with the mixing device. This will speed up the processing of raw materials.

The mixing device is connected to an extruder, which, in turn, is connected to the cooling column with a dispersion table.

A cooling column with a dispersion table is connected to another mixing device. Further, a granulating device and another cooling column with a dispersion table are connected in series to the mixing device.

It should be understood that all of these devices can be interconnected by lifting and transport mechanisms. This will reduce human contact with raw materials and increase the manufacturability of production.

The technical result of the claimed technological line is the possibility of implementing the above method.

The technical result is achieved due to the fact that in the processing line for the manufacture of feed, including at least one device for grinding, at least one device for mixing, an extruder, at least one device for granulation, also installed at least one cooling column with a dispersion table.

The third object of the claimed invention is feed obtained by the described method

Known meat and vegetable feed described in patent RU2163453 "meat-and-vegetable feed for non-productive animals (options) and the way to obtain it." The invention is intended for use in feed production. Two feed options for non-productive animals are proposed. The first of them contains, wt.%: Meat raw materials 10 - 50; cereal flour 10 - 20; minced bone 5–50. An additional 5–30% vegetables and 10–20% protein stabilizer are added to the feed. The second version of the feed contains, wt.%: Minced meat 5 - 50; vegetables 10-30; cereal flour 10 - 20; protein stabilizer 10 - 20. An additional 10 - 50% of raw meat is added to the feed. Flavor and vitamin supplements, binders are additionally introduced into both feed variants, and cereal flour is pre-processed in an extruder. The inventive feed is obtained by a method that includes grinding the ingredients of the raw materials, mixing the crushed ingredients of the raw materials with ingredients that do not require grinding: conventional or extruded cereal flour, binders, flavoring and vitamin additives, a protein stabilizer, and adding pre-ground to ground meat food bones followed by heat treatment of the mixture. Before heat treatment, the mixture is formed in the form of bars of sausages, sausages or sausages. The feed has a high nutritional and biological value, is optimally balanced in composition, the use of edible bone reduces the cost of feed. The method of obtaining feed allows you to rationally use the waste of meat production and produce feed for non-productive animals in the conditions of meat processing enterprises with standard technological means.

This feed is obtained using a completely different technology and at each stage of its production it is impossible to obtain a safe product.

Feed description

The feed obtained by the claimed method may have an initial composition with an arbitrary ratio of plant and protein raw materials, ranging from 10% to 90% of each type of component.

It is necessary to understand that the peculiarity of its preparation, due to sequential extrusion and enzymatic lysis, allows prolonging autolysis and fermentation, thereby allowing to increase the “work” time of enzymes, reducing the need for further digestion of the product by the end user. In addition, proteases inactivated at the drying stage, which do not work in the dehydrated product, are activated again only after they enter the digestive tract, which ensures the stability and safety of the feed.

The technical result of the claimed feed is the preservation of its safety properties for a long time, including storage, increased digestibility by the body of animals, the prevention of gastrointestinal diseases and an easy therapeutic effect.

Claims (10)

1. A method of manufacturing feed by extrusion of biological and agricultural waste, characterized in that during the implementation of the method, the grinding of biological and agricultural waste is carried out separately, the crushed raw materials are fed into the mixing system for mixing to a homogeneous mass, the obtained homogeneous mass is fed to the extrusion, and the extrusion process carried out at a temperature of from 20 to 180 ° C, a pressure of from 3 to 50 atmospheres, after extrusion, the raw materials are subjected to enzymatic hydrolysis, and then hlazhdayut, dewatered and conduct granulation. 2. The method according to p. 1, in which during mixing the raw materials are sterilized using quartzization or ozonation. 3. The method according to p. 1, characterized in that the grinding is carried out in several stages with a sequential reduction in the size of the fraction. 4. The method according to p. 1, characterized in that during the grinding process in the raw material add additional components: mycelia, yeast cells or other additives. 5. The method according to p. 1, characterized in that after extrusion of the raw materials is cooled, dehydrated and re-mixing. 6. The method according to any one of the above paragraphs, characterized in that the enzymatic hydrolysis is carried out at a temperature of from 20 to 60 ° C. 7. A feed processing line according to claim 1, comprising at least one grinding device connected to at least one mixing device connected to an extruder, wherein the extruder is connected to a cooling column with a dispersion barrel, a cooling column connected to another mixing device, to which a granulating device and another cooling column with a dispersion barrel are connected in series. 8. The production line according to claim 7, characterized in that all the devices included in its composition are interconnected by lifting and transport mechanisms. 9. The production line according to claim 7 or 8, characterized in that at least two devices for grinding vegetable and protein raw materials are simultaneously included in it. 10. Food, characterized in that it is obtained by the method according to p. 1.

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