Today’s supermarket shelves are bursting with protein enriched and high protein extensions of branded product ranges. Cereals, breakfast and snack bars, drinks, sports compounds and even chocolate commonly announce their high protein status alongside the benefits of eating protein. Proteins are a key building block of living organisms along with carbohydrates and fats and are indispensable for human and animal nutrition and high protein variants are merchandised with the benefits of muscle building, weight loss and keeping you feeling fuller for longer.
Today’s protein concentrate technology is focused on vegetable proteins as a more healthy, sustainable and responsible sourcing option than animal protein.
Hosokawa Micron has been helping companies boost vegetable protein concentration for many years and continues to develop the technology to deliver concentration values to between 40 and 70% protein. The basis of the protein shifting process is to take a natural vegetable product such as a legume, with a defined protein value and split this into two fractions; one with a higher protein level and one with a protein level lower than the feed material.
There are two different processes available for the user with the lower energy standard process the favoured method of manufacturing the protein concentrate for all the starchy seeds named here. The quality of the end products is thereby aimed at meeting current minimum market requirements. However for meeting the maximum requirements in both qualitative and quantitative terms, Hosokawa’s high-precision process, which uses a higher efficiency classifier (more energy input) is available.
The range of protein yielding plant based seeds is extensive with peas, soya, fava beans, rapeseed and sunflower seeds identified as having dry matter protein levels of between 22 – 26% and being suited to dry, mechanical processing methods of protein shifting.
Give Peas a Chance
The humble peas. One of the oldest known vegetables offers plant-based protein levels of 20-25% and good processing attributes. Grown across the world, the peas is increasingly identified as a super plant in terms of its ability to help meet the escalating demand for protein to feed the world’s population. Here we look at how Hosokawa Micron’s established protein shifting process is applied to the processing of peas.
The basis of the mechanical manufacture of protein concentrates is the disintegration of the core conglomerate into its individual components. The composition of peas includes two main components for the disintegration process.
Assuming that the shell and thus the fibres have been removed, what remains is protein (approx. 23%) and starch (approx. 55%). These are fed to a Zirkoplex classifier mill, capable of accurate particle size reduction. An optimum disintegration degree of the pea’s protein, starch, etc. is thus ensured.
After the grinding process, the components thus liberated are separated in a downstream air classifier. The various constituents are dispersed as a function of their density in the airflow and
routed to the classifying wheel. The classifying wheel parameters make an effective separation of the ground dispersed material possible.
The classifier yields two end products, i.e. the fines fraction with a high proportion of protein or protein concentrate, and a coarse fraction with a high proportion of starch and a strongly depleted residual protein content. Dependent on the degree of material disintegration, up to 70% of the protein portion can be routed to the fines fraction.
Besides protein enrichment, the concentrated starchy raw materials in the coarse fraction can be employed for industrial applications in new and attractive markets.
Soya Grits and Rapeseed
In the case of these oleriferous plant seeds, the protein concentrate is generated as the end product from the oil extraction process.
The grits, comprising mainly fibres and proteins, remaining after the extraction process are fed to a grinding step that is usually combined with drying. The two raw materials are again separated in the downstream air classification process as a function of the different densities into the two fractions, i.e. coarse material and fine material. Protein enrichment of up to 70% can be achieved with this process in the case of soya grits. If one considers the market values of soya grits and soya grits concentrate, it is possible to almost double the margin in this way.
Furthermore, optimum composition of different amino acids can be achieved by processing different raw materials. The diversity of systems which permit the processing of different raw materials on one and the same installation is a significant production advantages. With over 40 years’ experience and expertise in protein shifting Hosokawa offers both the standard process and a high-precision process, which uses a higher efficiency classifier (more energy input) to meet customer requirements in this respect.
|Comparison of standard and high-precision process|
|Standard process||High-precision process|
|Fines portion||Protein content||Fines portion||Protein content|
|Peas (yellow)||30 %||> 50 %||35 %||> 55 %|
|Beans (fava beans)||25 – 30 %||> 60 %||> 35 %||> 60 %|
|Lupins (white)||not possible||> 40 %||> 60 %|
|SPC (soya protein concentrate)*||> 60 %||> 65 %||65 %||> 65 %|
*Soya grits with approx. 50-55% protein was used as a basis
A Hosokawa article, published in the highly respected journal, Control Engineering Europe, details how Hosokawa Micron’s development of a digital twin processing plant was a significant milestone on a digital journey that has produced a new revenue stream and new data driven manufacturing services for customers.
‘We set out on a path to building the process industry’s first digital twin plant, combining VR, AR, AI and big data to create a tool where the actions in a virtual world control real world activity – bridging the gap between the physical and digital world,’ explains Iain Crosley, MD, Hosokawa Micron Ltd.
‘We sought specialist help and took advice from the best in virtual reality and artificial intelligence modelling to develop a digital twin that could help us achieve our business growth objectives. Of course there were obstacles along the way and barriers to overcome and we hope that in sharing our experience with others, companies might identify the benefits of connecting the real and virtual worlds of manufacturing and feel able to move forward in a digital future for their own business.’
To read the full article click on Control Engineering Europe.
Hosokawa Micron is pleased to announce their sponsorship of the hugely popular, drinks reception at the Chemicals Northwest Awards 2019.
The event will be held at Imperial War Museum North, Manchester on 28th March 2019 and is a celebration of the important role of the chemical sector in the Northwest and the innovation, excellence and success of local companies.
This is the second year of sponsorship by Hosokawa and the 2019 Chemicals Northwest Awards will span business activities ranging from Innovation to Sustainability and Young Talent to Supplier to the Chemical Industry.
‘We have had a close working relationship with Chemicals Northwest for many, many years and have welcomed their enterprise in supporting the chemicals sector in this area and are keen to welcome attendees of this well attended and respected event’, says Stewart Bryan, Commercial Manager, Hosokawa Micron Ltd.
James Moore, Business Manager, Hosokawa Micron will be speaking at the Manufacturing Leaders’ Summit, part of Digital Manufacturing Week, held 13th – 16th November, 2018 at Exhibition Centre Liverpool.
Under a Future-Proof Your Business event banner, James’s presentation is entitled ‘Digital Transformation in the Real World’ and explains how knowledge and experience gained on Hosokawa’s own digital journey is now being used to benefit other manufacturers.
‘It is appropriate for Hosokawa Micron to be part of this event, the largest community of industry pioneers discussing the new age of digital manufacturing. With a toolkit of support activities, we can offer proven, practical help to other businesses achieve real commercial advantages through a journey of digital transformation.
The event provides the opportunity for innovative business leaders to meet their peers, share their stories and grow their understanding of what tools, techniques and technologies are best placed to drive their next period of growth, MLS sets the scene for the future in digital manufacturing.’