WO2019068154A1 - Process for producing roasted mate extract - Google Patents

Abstract

The present invention deals with a process for obtaining soluble extracts of herbs, such as yerba mate, where a fluidized bed roasting step is associated with a reactor extraction step that operates under high vacuum and with application of ultrasound, composing, along with traditional stages of selection of crushed weed, grinding, screening and grading, an innovative process compared to current practice.

Description

 DESCRIPTIVE REPORT

 PROCESS OF OBTAINING THE EXTRACT OF TOASTED MATE

 Field of the Invention

 The present invention relates to a process for obtaining a food product, more specifically from a process for extracting soluble extracts from vegetables, more specifically from a process of extracting mate solids using a roasting step in a fluidized bed and a step of extraction of solubles carried out under vacuum and applying ultrasound to the medium.

 History of the invention

 The great demand for natural food free of chemical additives has increased the need for the development of new processing technologies that bring, in essence, fundamental items such as efficiency, economy, quality and food safety.

 In order for the food industry to guarantee such requirements, which are increasingly present in the so-called "conscious consumption", it is necessary to develop industrial processes that preserve the original characteristics of the food in order to deliver to the consumer products with aroma, flavor and nutritional value close to or even superior to the raw materials of origin.

 [004] In the specific case of this technology, we sought to solve the main problems that characterize the production of roasted mate extract that serves as the basis for "ready-to-drink" beverages produced from the matelexlex paraguariensis herb, such as maté tea , toasted mate tea or flavored maté tea.

Currently, extracts or concentrated preparations from the herb mate have as main commercial appeal the fact of maintaining the organoleptic and nutritional properties of the raw material of origin. [006] It occurs that the herb mat to be processed and retain such characteristics must comply with several criteria of processing not to lose the compounds beneficial to health, as well as those that guarantee their peculiar flavor.

[007] In this context, the greatest technological challenge to obtain these extracts is to process the raw material in such a way as to preserve most of the properties of the plant "in natura".

 [008] The current processes commonly used to "toast" mate and obtain toasted mate, use methods from other branches of the food industry. The best known and used is the process in the "roasting" of the coffee, adapted to the needs and conditions of the herb mate.

 [009] This system uses furnaces equipped with a rotating chamber or cylinder, with or without stirrers, in which maté (leaves and branches) are kept at temperatures between 180 ° C and 220 ° C for times not exceeding 15 minutes.

[010] In these conditions, leaves of yerba mate that have granulometry and density different from each other and in relation to the branches, end up generating an irregular toast of the particles. That is, while the larger particles go through insufficient heating, the smaller particles undergo what is described as burning or charring.

 [011] Thus, many of the characteristics of yerba mate, such as aroma, sugars, caffeine and other substances, are lost with increasing process temperature.

In this respect, the proposed innovation took into account such undesirable particularity of the conventional process, in order to propose the "toast" stage in a flowable bed, where, necessarily, the mate must be previously classified, separated into two phases (leaves and twigs), and homogenized by granulometrically, in order to standardize the process and thereby considerably decrease the temperature and residence time in the thereby avoiding the degradation of the above-mentioned compounds.

Therefore, the homogenization and standardization of the roasted mate are of fundamental importance for the following stages of extraction, concentration and stabilization of the roasted mate liquid extract, keeping most of the characteristics of the mate.

 [014] Concomitant with the innovative process of canning of maté herb in flowable bed, it was necessary to develop a technique of extraction and production of extracts that reproduce the same conditions of processing and maintenance of the integrity of the properties of the raw materials , in this specific case of the mate herb, and that they avoid problems of alteration or deterioration of the quality obtained in the stage of toast.

 [015] To this end, an innovative process has been developed that uses the ultrasonic technology added to the vacuum percolation system in a stirred reactor.

[016] This technique allows the processing of the herb mate at temperatures lower than the conventional process of aqueous extraction, generating gains of sensorial quality and physicochemical properties of the obtained extract.

[017] Already known in the state of the art, ultrasound is still little used in large-scale processes and little known for this purpose. However, given its peculiarities, it brings unique advantages to the process of extracting herbal and / or herbal solubles, facilitating over time processing, extracts quality and energy consumption.

The improvement of the extraction of the soluble ones, using more improved techniques, aims to optimize the process, minimizing costs of production and, of course, to increase the efficiency of the use of the raw material.

[019] In this context, the main advantages are the quantitative and qualitative improvement of the extracts produced, optimization of equipment due to high productivity in a reduced time, a significant reduction in the consumption of thermal and electrical energy, greater use of the raw material and gain of efficiency in the process.

 Thus, it is understood that the novel character of the art is characterized as containing such benefits not yet known in the state of the art.

Analysis of the state of the art

 The document BR 10 2015 017419 5 shows a washing system and saphire for hot water in natura herb mate and dryer equipment of maté herb with water that promotes the sapeco and the washing of the maté herb by means of a specific equipment, which uses heat exchange for water, avoiding the use of flames for the leaf sapling, while using water to perform leaf washing.

 The filed application 0701881-9, already filed, discloses a process for preparing a liquid extract and concentrated with mate herb, tea or other plants used for infusions using an aqueous solution of propylene glycol for extraction in towers of washing step associated with a heating step of the solution.

Patent 0901134-0 relates to a process for the production of yerba mate concentrate comprising five steps: (i) grinding of fresh yerba mate, (ii) filtering, (iii) adding the ingredients, (iv) ) heating to 100 ° C for 5 minutes, (v) bottling.

 [024] Document MU 9001057-4 brings an equipment for sowing and drying mat leaves by steam of hot water, which uses heat exchange by hot water.

The document PI 1002236-8 discloses a method of trapping and sapping for leaves of maté herb with hot water vapor for elimination of toxicity with temperature controlled and previously calculated, for the purpose of the preparation of the leaf, for the human consumption. The application CN104605059 shows a beverage production system from leaves and stalks of maté, being subjected to a counter-extraction, cooling, separation, filtration and milling, in order to obtain a powder of maté herb which is administered in an essential oil extraction reactor by refluxing with heating.

 [027] US20160338375 discloses a method of extracting tea comprising multi-stage pressure extraction.

 The patent PI0404296-4 provides a process for extracting the matte which provides for toasting in a rotary cylinder toaster heated by indirect heat, the percolation with hot water.

Description of the figures

 Figure 1 illustrates the state of the art with regard to herbal teas, such as yerba mate, for the preparation of infusions, where a toaster is provided with a rotating chamber or cylinder (3) where the raw material is supplied, which is supplied by a generally larger inlet 2 and a generally lower outlet 4 where the gases are expelled by chimneys 1.

 Figure 2 illustrates the fluidized bed toaster model of the present invention, where the air inlet (5) and outlet (6), and the agitator (7) are observed.

[031] Figure 3 represents the reactor for the extraction of the solubles, provided with a stirrer (8) and a sonotrode (9). Additionally, the reactor may be provided with an inner coil (10) and an outer jacket (11) to provide for maintaining the temperature of the equipment.

Figure 4 schematically shows the toasting process, identifying the supply silo 12, the heat generator 13, the heat exchanger 14, the toaster 15, the chiller (16) and the discharge hopper (17). Figure 5 schematically shows the solvent extraction process, identifying the high vacuum reactor (18) provided with a circulating bed mechanical agitation system, the storage tank (19), the storage tank the storage silo 21, the separation screen 22, the plate cooler 23, the extract storage tank 24, the pasteurizer tank 25, and the storage unit 21, package (26).

Detailed description of the innovation

 The present invention deals with a process for the extraction of plant extracts, mainly mate grass [llex paraguarienses], in order to preserve the organoleptic characteristics offered by this plant species, generating a product of color, flavor and properties compatible with the requirements of the current consumer market.

 [035] In opposition to the usual process practiced by the industry, this innovation proposes the use of an innovative roasting stage, associated to an innovative stage of extraction of the solubles, composing an innovative process to obtain toasted mate extract.

 The innovative toast uses a fluidized bed apparatus, shown in Figure 2, where the bed, formed by the solid feedstock fed by the supply silo (12), is percolated by a gaseous flow of heated air originating in a A preferred embodiment is an indirect heating system, preferably composed of a biomass heat generator (13) and a heat exchanger (14).

 The upward flow of heated air maintains the solids in an intermediate state between a static bed and the suspension in the upflow, similarly to that occurring in pneumatic transport, so as to avoid thinning and generation of fines (powder and particles below standard granulometry).

[038] To this end, the proposed solution uses a mixed fluidized bed, where fluidization is carried out by the gas flow inflated in the bed and partly by means of a mechanical movement of blades or propellers of the agitator (7), which aid in the phenomenon of entrainment and circulation of the materials to be fluidized.

[039] By this process, flow velocities above certain levels are avoided, which would cause significant losses of product by the pneumatic drag.

 Furthermore, this technology allows the uniform heating of the raw material particles, since heated air transfers heat to the material in a regular and constant manner, providing a gradual increase in temperature without the "heat peaks" which, in the system, cause the product to burn.

 [041] In order for the toast to be homogeneous, a prior classification of the raw material is necessary, so that the particle size is kept within adequate limits.

 [042] Thus, before the toast itself, the processed yerba mate (canned herb), previously prepared through the sapeco and drying processes, is selected, discarding the inadequate amount of raw material. Then, grinding, sieving and sorting are carried out to remove sticks and possible sheets of irregular shapes and granulometry.

[043] In this way, a mass of solids of a fairly similar size and shape is obtained, favoring the optimization of the toasting process in the fluidised bed, which occurs preferably in temperatures between 140 ° C and 170 ° C in an average time between 30min to 40min.

[044] After the toasting process, in a preferred process configuration of the present invention, the matte is withdrawn from the bottom of the bed of the roaster (15), being discharged through a conveyor thread into the chiller (16) to be subsequently packed into big bags from a mold (17), then sent to the process of extracting the solubles.

The novel solvent extraction step is utilized from a high vacuum reactor (18) for maceration or percolation of the feedstock, provided with a circulating bed mechanical stirring system, as shown in Figure 3, and with the aid of ultrasound applied to the pulp in reaction by means of a sonotrode (9), where the already roasted and previously stabilized mate is inserted into the reactor together with the solvent, usually treated and sterilized water from the storage tank ( 19) previously added to the holding tank (20), supplied directly from the storage bin (21).

Under these conditions, the extraction at lower temperatures, preferably between 50 ° C and 75 ° C, can be operated, thus maintaining several organoleptic characteristics of the roasted mate, providing reduction of costs with electric and thermal energy, in addition to optimize the use of equipment.

[047] After the extraction period, typically carried out between 50 ° C and 75 ° C, the pulp is transferred, in a preferred embodiment, by means of a pneumatic pump to the separating screen (22), where the solids are separated of the extract obtained, the liquid being pumped through a plate cooler (23) to the extract storage tank (24) for stabilization.

[048] Typically, after a period of 24 hours, the extract stored in the storage tank (24) is transferred by centrifugal pump to the pasteurizing tank (25) and is heated, preferably between 60 ° C and 75 ° C.

From the pasteurizer tank 25, the extract is stabilized and heated and pumped into the packaging unit 26, where, in a preferred embodiment, it is filled into plastic packages provided with an automatic nozzle, arranged in a carton, followed of palletisation.

[050] Around these stages of toasting and extraction of solubles are added the ancillary stages, carried out in traditional technologies, covering:

a) Pre-toast:

 i) selection of processed yerba mate (weeded herb), previously prepared through the sapeco and drying processes;

 ii) grinding, sifting and classification for removal of sticks and possible sheets of irregular shapes and granulometry;

 iii) storage;

b) Post-toast:

 i) cooling;

 ii) storage for stabilization of roasted mate (custody or parking)

c) Post-extraction:

 i) fixed sieve discharge for phase separation (solid / liquid);

 ii) storage of the extract under refrigeration for removal of fine solids;

 iii) pasteurization;

 iv) addition of preservatives (eg potassium sorbate and sodium benzoate); v) storage;

 (vi) shipment.

 [051] Thus, the innovative nature of the process is summarized by the use of mixed fluidized bed technology associated with vacuum maceration with the aid of ultrasound, applied to reduce operating costs, maintain the main characteristics of roasted mate ( color, aroma, flavor), in addition to optimizing the production system of vegetable extracts.

[052] This innovation is not limited to the representations here commented or illustrated, and should be understood in its wide scope. Many modifications and other representations of the invention will come to the mind of one skilled in the art at which innovation belongs, having the benefit of the teaching presented in the foregoing descriptions and accompanying drawings. Furthermore, it is to be understood that the invention is not limited to the specific form disclosed, and that modifications and other forms are to be understood as falling within the scope of the appended claims. Although specific terms are employed here, they are used only in a generic and descriptive manner and not as a limiting purpose.

Claims

 A method of obtaining roasted mate extract comprising:  (a) a toasting step in a mixed fluid bed toaster (15), wherein the bed formed by the solid feedstock is moved by a stirrer (7) and percolated by an ascending gaseous or liquid flow, which maintains the solids in an intermediate state between a static bed and the upflow suspension, so as to avoid shearing and fines generation; associated with  b) a step of extracting solids carried out in a reactor (18) operating under high vacuum for the maceration or percolation of the raw material, provided with a mechanical stirring system (8) with circulating bed and with the aid of applied ultrasound to the pulp in reaction by means of a sonotrode (9). Process for obtaining toasted mate extract according to claim 1, characterized in that it additionally comprises the steps of "pre-toast" comprising the steps of:  a) selection of processed yerba mate (weeded herb), previously prepared through the processes of sapeco and drying;  b) grinding, sieving and sorting for sticks removal and possible irregular elements;  c) storage.  Process for obtaining roasted mate extract according to claim 1, characterized in that it additionally comprises the steps of "toasting", comprising the steps of:  a) cooling;  b) storage for stabilization of roasted mate; Process for obtaining toasted mate extract according to claim 1, characterized in that it additionally comprises the steps of "Post-extraction", comprising the steps of: (a) fixed sieve discharge for phase separation (solid / liquid); b) storage of the extract under refrigeration to remove fine solid particulates; c) pasteurization; d) addition of preservatives; e) storage; f) shipment.