Methods of manufacturing products from material comprising oilcake, compositions produced from materials comprising processed oilcake, and systems for processing oilcake

• US 10,645,950 B2
• Filed: 11/01/2019
• Issued: 05/12/2020
• Est. Priority Date: 05/01/2017
• Status: Active Grant

• Current Assignee: Usarium Inc.
• Original Assignee: Usarium Inc.
• Inventors: Manchuliantsau, Aleh, Tkacheva, Anastasia
• Primary Examiner(s): Becker, Drew E
• Application Number:
  US16/671,342
• Publication Number:
  US 20200060308A1
• Time in Patent Office: 193 Days
• Field of Search: 426 31, 426 49, 426 52- 54, 426465, 426472-473, 426481-485, 426516, 426518-520, 426802
• CPC Class Codes: A23J 1/005 from vegetable waste materials
• CPC Class Codes: A23J 1/006 from vegetable materials A23J1/005, A23J1/12 and A23J1/14 take precedence
• CPC Class Codes: A23J 1/008 from microorganisms A23J1/18 takes precedence
• CPC Class Codes: A23J 1/144 Desolventization
• CPC Class Codes: A23J 1/148 by treatment involving enzymes or microorganisms enzymatic hydrolysis of proteins A23J3/34
• CPC Class Codes: A23J 3/14 Vegetable proteins
• CPC Class Codes: A23J 3/16 from soybean
• CPC Class Codes: A23J 3/227 Meat-like textured foods meat extenders A23L13/00
• CPC Class Codes: A23J 3/26 using extrusion or expansion
• CPC Class Codes: A23J 3/32 using chemical agents
• CPC Class Codes: A23J 3/346 of vegetable proteins
• CPC Class Codes: A23J 3/347 of proteins from microorganisms or unicellular algae
• CPC Class Codes: A23J 3/348 of proteins obtained from waste materials A23J3/341, A23J3/346 take precedence
• CPC Class Codes: A23K 10/37 from waste material from hydrolysates of wood or straw A23K10/32; from molasses A23K10/33
• CPC Class Codes: A23K 10/38 from distillers' or brewers' waste
• CPC Class Codes: A23K 40/25 by extrusion
• CPC Class Codes: A23L 11/05 Mashed or comminuted pulses or legumes; Products made therefrom A23L11/30 takes precedence; tofu or soya cheese A23L11/45; soy drinks A23L11/65
• CPC Class Codes: A23L 11/07 Soya beans, e.g. oil-extracted soya bean flakes A23L11/30 takes precedence
• CPC Class Codes: A23L 11/31 by heating without chemical treatment, e.g. steam treatment, cooking
• CPC Class Codes: A23L 11/32 by extraction with solvents
• CPC Class Codes: A23L 11/33 : using enzymes; Enzymatic transformation of pulses or legumes
• CPC Class Codes: A23L 25/30 : Mashed or comminuted products, e.g. pulp, pastes, meal, powders; Products made therefrom, e.g. blocks, flakes, snacks; Liquid or semi-liquid products A23L25/10 and A23L25/40 take precedence
• CPC Class Codes: A23L 33/185 : Vegetable proteins
• CPC Class Codes: A23L 5/21 : by heating without chemical treatment, e.g. steam treatment, cooking
• CPC Class Codes: A23L 5/23 : by extraction with solvents
• CPC Class Codes: A23L 5/25 : using enzymes
• CPC Class Codes: A23P 30/20 : Extruding
• CPC Class Codes: A23P 30/34 : by extrusion-expansion
• CPC Class Codes: A23V 2200/262 : All vegetarian ingredients, i.e. meat-free
• CPC Class Codes: A23V 2200/264 : All vegan ingredients, i.e. all animal product free
• CPC Class Codes: A23V 2250/548 : Vegetable protein
• CPC Class Codes: A23V 2250/5488 : Soybean protein
• CPC Class Codes: A23V 2300/16 : Extrusion
• CPC Class Codes: A23V 2300/18 : Fractionation
• CPC Class Codes: A23V 2300/24 : Heat, thermal treatment
• CPC Class Codes: A23V 2300/28 : Hydrolysis, degree of hydrolysis

Abstract

Methods of manufacturing products from material comprising oilcake, compositions produced from materials comprising processed oilcake, and systems for processing oilcake are provided herein. The method comprises de-solubilizing protein in a material comprising oilcake to produce a processed material comprising an insoluble protein fraction. The processed material is hydrolyzed to produce a mixture comprising the insoluble protein fraction and a hydrolyzed fraction. The insoluble protein fraction is separated from the hydrolyzed fraction. The insoluble protein fraction is processed into a product.

Claims

1. A method comprising:

de-solubilizing protein in a first material comprising oilcake to produce a processed material comprising an insoluble protein fraction by extruding the first material in a pressure range of 10 bar to 80 bar;

hydrolyzing the processed material to produce a mixture comprising the insoluble protein fraction and a hydrolyzed fraction;

separating the insoluble protein fraction from the hydrolyzed fraction; and

processing the insoluble protein fraction into a product by extruding the insoluble protein fraction in a pressure range of 10 bar to 80 bar.

2. The method of claim 1, wherein the first material further comprises at least one of a distiller grain, pulp, a pomace, a legume, a mushroom, or microbial protein, or any combination thereof.

3. The method of claim 1, wherein the oilcake comprises at least one of a sunflower oilcake, a soybean oilcake, a cottonseed oilcake, a rapeseed oilcake, a canola oilcake, a copra oilcake, a palm kernel oilcake, a peanut oilcake, an olive oilcake, or a locust bean cake, or any combination thereof.

4. The method of claim 1, wherein the oilcake comprises sunflower oilcake.

5. The method of claim 1, wherein the product is a meat-analog.

6. The method of claim 1, further comprising at least one of toasting the first material, drying the first material, adding salt to the first material, or adjusting the pH of the first material, or any combination thereof.

7. The method of claim 1, further comprising extruding the first material or the insoluble protein fraction in a temperature range of 70 degrees Celsius to 200 degrees Celsius.

8. The method of claim 7, wherein extruding the insoluble protein fraction comprises adjusting a moisture content of the insoluble protein fraction to be in a range of 40 percent to 80 percent of moisture based on the total weight of the insoluble protein fraction.

9. The method of claim 1, wherein de-solubilizing protein in the first material and processing the insoluble protein fraction are performed in the same extruder.

10. The method of claim 1, wherein de-solubilizing protein in the first material and processing the insoluble protein fraction are performed in different extruders.

11. The method of claim 1, further comprising contacting the protein fraction with a cooled section of a barrel of an extruder during processing.

12. The method of claim 1, wherein hydrolyzing comprises at least one of adding enzyme and adding an acid.

13. The method of claim 1, wherein hydrolyzing comprises adding enzyme.

14. The method of claim 13, wherein the enzyme comprises at least one of cellulase, alpha-galactosidase, xylanase, glucanase, amylase, liginase, transglutaminase, endoglucanase, or hemicellulase, or any combination thereof.

15. The method of claim 1, wherein separating comprises at least one of centrifuging the mixture, decanting the mixture, or precipitating the protein fraction from the mixture, or any combination thereof.

16. The method of claim 1, wherein processing the insoluble protein fraction comprising fractionating.

17. The method of claim 1, further comprising mixing the product with at least one of a starch, a flour, a mineral, a vitamin, water, oil, protein, or a food agent, or any combination thereof.

18. The method of claim 1, further comprising adding water to the mixture at a ratio in a range of 1 part of mixture:

6 parts of water to 1 part of mixture;

2 parts of water.