Patent Description:
Modern food processing trends provide for greater access to macronutrients naturally present in foods. With the growth of consumer demand for high quality food, there is a related growth for improved food processing techniques to extract high-quality macronutrients consistent with consumer beliefs.

For example, it is common for users to require food sources to be organic and composed of ingredients that are non-genetically modified (non-GMO). Another example are consumers seeking to avoid particular food sources, such as consuming a plant-based diet.

In addition to demand for food types being driving by consumer choice, such choices are additionally fueled by consumer intelligence to allergic or inflammatory responses. It is not uncommon for a person to an some adverse reaction to a food source, with severity of reaction differing widely between consumers.

Amongst the macronutrients, protein remains the quintessential macronutrient for the promotion of growth and health maintenance. While protein is readily available and commonly found in many food sources, extraction as a supplement for manufactured food sources can be problematic in seeking specialized solutions.

A common protein supplements from non-plant based sources is whey protein, usable as an example of the concerns of modern protein source manufacturing. The quality of the protein product is directly related to the quality of the original source of protein, thus problems can arise from the quality of the original source. Another problem is whey protein is unavailable to vegan and other non-plant-based consumers.

Another problem is that protein quality and other attendant factors are directly affected by the manufacturing / extraction process. One attendant factor can be the absorption factor of the protein by the user, whether the protein is a quickly-digestible / absorbing protein.

The most common form of plant-based protein is soy protein. While serving several market needs, there exists a need for a wider variety of protein-types and a greater degree of stability in the protein itself. For example, consumers can have allergies or other inflammatory responses from the protein source.

The chickpea is a readily-available plant-based protein source lacking known consumer allergies. Chickpea protein has a long history a large degree of stability in food processing. Based on the dynamics of the chickpea itself, limited technology exists in chickpea protein extraction. Existing techniques require heavily structured processes, including operations within very narrow ranges and complicated processing steps.

<CIT> and <CIT> disclose the preparation of soy protein isolates including steps for preparing protein rich curds, enzymatic treatment, homogenizing- and heat-treatments thereof.

<CIT> discloses a process for concentrating oilseed protein comprising the steps of fine grinding and air-classifying the initial protein source followed by washing the ground protein source with water or an aqueous alcoholic solution.

As such, there exists a need for a method to efficiently extract high quality protein from chickpeas.

A dry fractionation method of the invention provides for generating a protein concentrate product therefrom. The method of the invention includes milling a plant-based flour to generate milled flour and generating a first protein concentrate from the milled flour using an air classifier. In the methods of the invention the plant-based flour can be a de-oiled or low oil content plant-based flour. The method includes processing the first protein concentrate to generate a protein rich curd.

The flour may be a chickpea flour, but it is recognized that other suitable types of flour may be utilized, where various types of flour utilize varying processing operations for protein extraction, as noted herein. Where a flour includes an oil content, the flour may be processed through a de-oiling process for oil removal, as well as reducing attendant moisture, such that a low-oil or de-oiled protein source improves operational efficiency. As used herein, various methods operate having an oil content in the <NUM>% to <NUM>% range, or lower. Whereby it is recognized that some protein sources begin with an oil content below this range such that de-oiling processes may be omitted. It is noted that the above range of <NUM>% to <NUM>% is an exemplary range and not limiting in nature, such that the herein described protein extraction may be performed using flour having an oil content above this range, and the noted range is one example for system operating efficiency.

As disclosed herein, the protein curd may be transferred to a wash station. Within the wash station, water may be added to acid curd to rehydrate the mixture. The wash station further includes a wash separator that may be fed by low-shear pump to the decanter centrifuge to separate the serum from the acid curd. The wash separator therein generates a second protein concentrate in the form of a curd.

Once the process completes one or more washing operations, a mixer receives the protein curd output, as well as a base, water and an enzymatic cocktail (protease).

The mixer output is a neutral hydrolyzed protein slurry. A high pressure homogenizer receives the slurry such that high pressure homogenization provides for texture, particle size control, and homogenization of the slurry.

The high pressure homogenizer generates an output of a homogenized protein slurry. This homogenized protein slurry is then pasteurized using a pasteurizer.

The pasteurization generates a pasteurized protein slurry. This slurry may be fed into a vacuum evaporator. As disclosed herein, the vacuum evaporator's pressure, temperature and flow rate may be dependent on pasteurization setup of the pasteurizer.

Water may be removed using the vacuum evaporator, producing an output of a cooled protein slurry. The cooled protein slurry may be fed into a dryer. The dryer performs drying operations to generate the dried protein concentrate product.

A better understanding of the disclosed technology will be obtained from the following detailed description taken in conjunction with the drawings.

<FIG> illustrates a system <NUM> including a first mixer <NUM>, a first separator <NUM>, a second separator <NUM> and a second mixer <NUM>. The system further includes a third separator <NUM>, a wash station <NUM>, a third mixer <NUM>, a homogenizer <NUM>, a pasteurizer <NUM>, a vacuum evaporator <NUM> and a dryer <NUM>.

<FIG> illustrates one example of a process flow operation for generating the chickpea concentrate as described herein. In this example, the process described herein makes the product of a chickpea concentrate.

The first mixer <NUM> receives flour, water and a base. The flour may be chickpea flour, but it is recognized that other suitable types of flour may be utilized. In this step, via the mixer, the flour is hydrated and there is a pH shift to solubilize the protein a solid-liquid extraction.

It is within the scope of the present invention that varying types of chickpea flour or the protein-based input ingredient(s) may be utilized, where the process described herein may be modified to account for such variations in the mixer <NUM> input. For example, the chick-pea flour may be a de-oiled flour, such that further processing operations described below for performing de-oiling operations may be omitted. For example, the flour may be pre-treated with a hexane extraction process, or other process to modify or adjust the physical composition of the flour, for example, as described in further detail in <FIG> below.

In the mixer <NUM>, hydration of the flour includes water ratio may range between <NUM>-<NUM>:<NUM> depending on equipment and desired purity of end product. While varying ranges may be utilized, this method includes a low-end ratio that is found to be <NUM>:<NUM>, with a high-end ratio dependent upon capacity of drying operations noted below. Operational temperature may range between <NUM> - <NUM> depending on the final product attribute, including generating a pH between <NUM>-<NUM>. The mixer <NUM> may operate using low shear conditions. Similarly, this example uses a reaction time between <NUM> - <NUM> depending on holding conditions.

It is noted that the above ranges and conditions, as well as ranges, conditions and values noted within the present specification, are exemplary in nature. The ranges and conditions are not limiting on the disclosed invention and the disclosures herein, wherein operations aspects outside the noted ranges may be utilized in the protein extraction process, as recognized by one skilled in the art.

Based on the mixing operations, the mixer outputs an initial alkalized slurry. The initial alkalized slurry is then transported to the first separator <NUM>. As described in further detail below, the initial alkalized slurry may be transported using a low sheer pump, but it is recognized that any suitable pump may be utilized.

The first separator <NUM> separates the initial alkalized slurry into a starch precipitate and a solubilized protein rich steam. The separator 104may be a decanter centrifuge. The starch precipitate is extracted and can be discarded. The solubilized protein rich stream is further processed to a second separator <NUM>.

A solubilized protein rich stream may be transferred to the separator <NUM> using a low-sheer pump, but any other suitable pump may be utilized.

The solubilized protein rich stream may be separated using the separator <NUM> being a disk-stack centrifuge to remove a cream fraction. The centrifuge output includes a concentrated oil cream and a de-oiled solubilized protein rich stream. The concentrated oil cream may be discarded or otherwise processed.

In some methods, separator <NUM>, wash station <NUM> and mixer <NUM> may be omitted from the process flow, whereby the de-oiled protein rich stream can be passed through filters to extract functional proteins. It is recognized that other processing or extraction steps may be utilized aside from the examples noted herein. The extracted proteins may then be subject to further processing steps described herein.

The present processing system transfers the de-oiled solubilized protein rich stream to a second mixer <NUM>. An acid is additionally added into the second mixer <NUM>.

The second mixer <NUM>, the combination of de-oiled solubilized protein rich stream and the acid generates a protein precipitate. In this second mixer tank <NUM>, acid is added to iso-electrically precipitate the protein. The temperature may range between <NUM>-<NUM> depending on the yield of protein extracted in the separation step using the first separator. The lower the temperature, the more native the protein will stay and the higher acid soluble loss. At high temps, higher yields and loss of some functionality will occur. The pH level may be between <NUM> - <NUM> depending on the temperature profile. Within the second mixer <NUM>, the agitation level may be low to promote flocculation. The acid type can be dependent on equipment and desired end functionality of protein.

The combination in the second mixer <NUM> generates the protein precipitate composed of a serum and an acid curd. The protein precipitate is provided to a third separator <NUM>. The protein precipitate may be fed by a low-shear pump to the third separator <NUM>, being a decanter centrifuge, to separate the serum from the acid curd. The serum protein is extracted, leaving a first protein curd transferred to the wash station <NUM>.

Within the wash station <NUM>, water is added to acid curd to rehydrate the mixture. The water is added via a water mixer to generate acid curd slurry. The wash station further includes a wash separator that may be fed by low-shear pump to the decanter centrifuge to separate the serum from the acid curd. The wash separator therein generates a second protein curd. Further examples of the wash station are described relative to <FIG> below.

Once the process completes one or more washing operations, a third mixer <NUM> receives the protein curd output, as well as a base, water and an enzymatic cocktail (protease). Within the mixer <NUM>, the protein curd may be hydrated between <NUM> and <NUM>% moisture. The protein curd is step-wise neutralized to a final pH of <NUM>- <NUM>. Varying step-wise pH adjustments, temperature, and hold times for the mixer are specific to optimal enzymatic reactivity.

The third mixer <NUM> output is a neutral hydrolyzed protein slurry. A high pressure homogenizer <NUM> receives the slurry such that high pressure homogenization provides for texture, particle size control, and homogenization of the slurry.

The high pressure homogenizer <NUM> generates an output of a homogenized protein slurry. This homogenized protein slurry is then pasteurized using the pasteurizer <NUM>. The pasteurizer may perform pasteurization at a minimum temperature of <NUM>, having a hold time that is dependent on pasteurizing temperature.

The pasteurization, via the pasteurizer <NUM>, generates a pasteurized protein slurry. This slurry is fed into the vacuum evaporator <NUM>. The vacuum evaporator's pressure, temperature and flow rate may be dependent on the pasteurization setup of the pasteurizer. For example, having a high temperature (e.g., <NUM> (<NUM> °F) the vacuum evaporator may include a <NUM> second hold time with direct steam injection at a -<NUM> bar pressure, with a <NUM> second hold time w/ deltaT to <NUM> degrees at half bar.

Water is removed using the vacuum evaporator <NUM>, producing an output of a cooled protein slurry. The vacuum evaporator <NUM> can operate in various methods based on the desired properties of the cooled protein slurry. For example, one method may include higher order processing operations to remove aromatics attendant in the pasteurized protein slurry. In this example, if the final protein concentrate is usable for food supplements having taste parameters, the removal of the aromatics, also referred to as the volatiles, helps eliminate any subsequent aftertaste from the protein consumption. In other methods where the protein supplement may undergo further processing or combined in a manner where aromatics are not problematic, a less efficient operation of the vacuum evaporator <NUM>.

The cooled protein slurry may include volatile elements based on the vacuum evaporation process not removing native aromatics. Alternatively, the cooled protein may not include these volatile elements, as the elements are removed in the vacuum evaporation process.

The cooled protein slurry is fed into the dryer <NUM>. The dryer <NUM> performs drying operations to generate a dried protein concentrate. Different examples of dryer types and feed temperatures are dependent on one or more factors, including: pasteurization operations; evaporator conditions; hydration level of neutralized protein slurry; and characteristics necessary to consumer application, i.e. bulk density, moisture level, particle size, and agglomeration.

Therein, the dryer <NUM> generates the dried protein concentrate originated from the flour, water and base originated in the first mixer <NUM>.

As described in further detail below, <FIG> and <FIG> illustrate one specific example of chickpea protein generation using noted operational values.

<FIG> illustrates one example of wash station <NUM> of <FIG>. In this example, the wash station <NUM> includes a wash mixer <NUM> and a wash separator <NUM>. Within the wash station, water is added to acid curd to rehydrate the mixture. The water is added via the water mixer <NUM> to generate the acid curd slurry. In one example, slurry moisture can range from <NUM>-<NUM>% depending on equipment and purity of final product and pH can range between <NUM> and <NUM> depending on temperature profile. In one example, the temperature can range between <NUM>-<NUM> depending on previous precipitation condition, desired degree of denaturation, yield, and desired purity of the protein concentrate. In the water mixer <NUM>, agitation is low to further promote flocculation.

The wash station <NUM> further includes the wash separator <NUM> that may be fed by low-shear pump to the decanter centrifuge to separate the serum from the acid curd. The wash separator therein generates the second protein curd.

In different examples, the operations of the wash station may be iterated for further purity of the protein curd. For example, one technique may include a second wash station with the protein curd rehydrated and then fed by low-shear pump to another decanter centrifuge to further separate serum.

<FIG> illustrates one example of a wash station having multiple wash mixers <NUM>, <NUM> and multiple wash separators <NUM>, <NUM>. As illustrated, the output of the first wash separator <NUM> is fed directly into a second wash mixer <NUM>. The second wash mixer combines the separator <NUM> output with water, generating the washed protein slurry. This slurry is fed into the second wash separator <NUM> to generate the second protein curd.

<FIG> illustrates the wash station <NUM> having a single mixing/separating stage, whereas <FIG> illustrates multiple mixing/separating stages. It is recognized that the wash station <NUM> may include any number of mixing and separating stages, providing higher degree of second protein slurry clarity consistent with operational guidelines, operational efficiency and desired quality of the protein concentrate extracted from the dryer <NUM> of <FIG>.

<FIG> illustrates one example of a flowchart of steps of a method for generating a chickpea concentrate. The method described therein may be performed using the system <NUM> of <FIG>, whereas it is recognized that the steps may be performed using any other suitable machine or apparatus for performing the described operation.

A first step, step <NUM>, is generating an initial alkalized slurry by combining flour, water and base. As described above, the flour is a chickpea based flour.

An air classified protein concentrate is used. It is recognized that various other methods exist such that based on preceding processing conditions, a chickpea flour-type input in some manner or another, is fed into the system.

A next step, step <NUM>, is generating a solubilized rich protein stream by separating the initial alkalized slurry. This step may be performed using a separator, wherein in one embodiment the step includes the removal of a starch precipitate from the slurry.

A next step, <NUM>, is generating a de-oiled solubilized rich protein stream by separating the solubilized rich protein stream. This step may be performing using a separator, including generating a concentrated oil cream as well as the de-oiled solubilized rich protein stream.

A next step, step <NUM>, generating a protein precipitate including an acid curd by mixing the de-oiled solubilized rich protein stream with an acid and separating the acid curd from the protein precipitate. This step may be performed using the second mixer <NUM> as described above.

A next step, step <NUM>, is washing the first protein curd using a wash station to generate a second protein curd. As described in further detail below, this step may include iterative washing operations, generating the second protein curd.

A next step, step <NUM>, is generating a neutral hydrolyzed protein slurry by mixing the second protein curd with a base and water. This step may be performed using the third mixer of <FIG> above.

A next step, step <NUM>, is generating a homogenized protein slurry from the protein slurry. The homogenization may be performed using a high pressure homogenizer as described above.

Therefrom, step <NUM>, is generating a cooled protein slurry by pasteurizing the homogenized slurry. The protein slurry may be cooled using a vacuum evaporator, similar to the evaporator <NUM> of <FIG> with operations conditions as described above.

The cooling of the protein slurry can be performed to varying degrees generating varying quality levels of cooled protein slurry. Using a higher order of evaporating, undesired aromatics may be extracted from the protein slurry.

Step <NUM> is extracting the protein concentrate from the cooled protein slurry. This step may be performed using a dryer performing drying operations, extracting water as the byproduct of the drying process. Therein, in this embodiment, the method provides the extracting of protein concentrate from chickpea flour.

<FIG> illustrates one example of a portion of the system of <FIG>. The illustrated system of <FIG> includes the first mixer <NUM>, the first separator <NUM> and the second separator <NUM>. Whereas, in this example, the outputs from the first mixer <NUM> is transferred to the first separator using a low sheer pump <NUM>. Similarly, the output of the first separator <NUM> is transferred to the second separator <NUM> using a low sheer pump <NUM>. A positive displacement pump can be used to achieve low shear conditions. An example of this pump is the Waukesha Universal II Pump, Model <NUM>-U2 available from Waukesha Cherry-Burrell in Delavan Wisconsin.

<FIG> illustrates a flowchart of one example of further operations of the wash step <NUM> of <FIG>. The steps of <FIG> may be performed using the elements of <FIG> described above.

A first step, step <NUM>, is hydrating the protein curd in a wash mixer to generate a washed protein slurry. A next step, step <NUM>, is separating the moisture from the washed protein slurry. In the methodology of <FIG>, a determination is made if there are further washing iterations, step <NUM>.

In the event further washings are requested or required, step <NUM> is transferring the output of the wash mixer from the wash separator into another wash mixer. Thereupon, the method re-iterates to step <NUM>. In the event the determination of step <NUM> is that no further washing is requested or required, the method reverts to step <NUM>, outputting the second protein curd. Therefore, the methodology allows for the iterative washing of the protein curd, if desired.

<FIG> and <FIG> illustrate a processing flowchart of one example of a chickpea protein extraction process. While noted with exemplary values, the process of <FIG> and <FIG>, including the exemplary values, are not limiting in nature as varying processing values may be readily utilized, as recognized by one skilled in the art.

The process begins in <FIG>, wherein <NUM> Chickpea flour <NUM> is liquefied with <NUM> water <NUM> using a liquefier <NUM>. The combined slurry enters a first reaction tank <NUM> in which the pH is adjusted to <NUM> using aqueous sodium hydroxide <NUM>, temperature at <NUM> and held under low shear conditions for approximately <NUM> minutes. Using the first decanter <NUM>, approximately <NUM> of wet starch <NUM> is then extracted and the protein rich liquid is passed through a <NUM>-phase cream separator <NUM>. This cream separator extracts approximately <NUM> of concentrated oil <NUM>.

The de-oiled protein stream from the <NUM>-phase cream separator <NUM> then passes into a second reaction tank <NUM>, in which the pH is adjusted to <NUM> using aqueous phosphoric acid <NUM>, temperature at <NUM> and held approximately <NUM> minutes. From the second decanter <NUM>, <NUM> aqueous sugars and acid soluble proteins <NUM> are removed to the light phase. From the second decanter <NUM>, the protein curd is then provided to a third reaction tank <NUM>, rehydrated to <NUM>% dry solids with <NUM> water <NUM> at <NUM> If necessary, the pH is adjusted back to <NUM> using aqueous phosphoric acid <NUM> and held for approximately <NUM> minutes.

The rehydrated protein rich slurry is then passed through a third decanter <NUM>, removing approximately <NUM> of serum <NUM> consisting of primarily aqueous sugars <NUM>. A fourth reaction tank <NUM> receives the second acid curd from the third decanter <NUM>, combines with <NUM> of water at <NUM> <NUM>, to achieve a <NUM>% dry solid mixture. The pH is adjusted to approximately <NUM> using calcium hydroxide <NUM> and then a protease cocktail <NUM> is added to cleave the proteins for end application.

In this process, the enzymatic reaction is allowed to take place for approximately <NUM> under low shear conditions and fed to a High Temperature/Short Time pasteurizer <NUM> to kill any microbial and terminate the enzymatic reaction.

The slurry is then fed to a vacuum evaporator <NUM> to increase the solids level. The output of the evaporator <NUM> is then spray dried using spray dryer <NUM>. In this example, the process obtains <NUM> of a hydrolyzed protein concentrate <NUM> at minimum <NUM>% protein.

<FIG> illustrates one example of another technique for generating plant-based protein extraction by de-oiling the material prior to the protein extraction process. The elements of <FIG> provide for pre-processing of the flour, as illustrated in <FIG>, but include the removal of oil, sugars and other organics within the flour.

The process of <FIG> includes a de-oiling processor <NUM>, as described in further detail in <FIG>. The de-oiling processor receives the food element from which the protein is extracted. In the processes of <FIG>, the food source is chickpeas, but as noted herein, any other suitable type of food source may be utilized. Via the de-oiling process, the processor <NUM> generates de-oiled flour <NUM>.

Similar to the process of <FIG>, the de-oiled flour is therein provided to the mixer <NUM>, along with water and a base to generate the initial alkalized slurry. Where the de-oiling processor <NUM> includes a flour mill, the de-oiled flour <NUM> may be the same flour input as noted in <FIG>. If the processor <NUM> uses a roller mill / flaker, additional milling may be required to convert the flakes to a powder format usable as a direct input to the mixer <NUM>.

With respect to the processing operation described above in <FIG>, the inclusion of the de-oiling processor thereby modifies the <FIG> processes flow. Whereas in <FIG>, the solubilized protein rich stream is fed to the separator <NUM> to remove a cream fractionation, this step is therefore extraneous. Rather, where the separator <NUM> de-oiled the solubilized protein rich stream, this stream is in this embodiment without oil. Thus, the solubilized protein rich stream is fed directly to the mixer <NUM> as illustrated in <FIG>.

With respect to the above-noted operational aspects of the system of <FIG>, these operational ratios and flow rates are based on a function of water solubility. The de-oiling process of the processor <NUM> therefore does not materially change the operational ratios noted above and therefore in one process the same operational ratios for the process of <FIG> may be utilized in <FIG>.

<FIG> illustrates one example of the de-oiling processor <NUM> of <FIG>. In this example, the de-oiling is performed using a decortication device <NUM>, a milling or roller-flaker <NUM>, a mixer <NUM>, decanter centrifuge <NUM> and a dryer <NUM>.

The decortication device <NUM>, mixer <NUM>, decanter centrifuge <NUM> and dryer <NUM> may be any suitable device operative to perform the processing operations described herein, as recognized by one skilled in the art. The milling / roller-flaker <NUM> represents one of several varying examples operative within the present system. The device <NUM> may be a roller mill / flaker that is operative to process the decorticated chickpeas and generate flakes. The device <NUM> may, in another example, be a flour mill operative to mill flour instead of flakes.

The decortication device <NUM> receives the chickpeas, which can be provided raw. The device <NUM> operates to remove the cortexes from the chickpea, removing the outer hull and exposing the protein-rich insides. The device <NUM> generates cortex waste <NUM>, which can be discarded. The device <NUM> further outputs the chickpeas having the shells or cortexes removed to the milling / roller-flaker device <NUM>.

The milling / roller-flaker device <NUM> operates to mill the chickpeas into a milled or flour feedstock. In one example, instead of being milled to a particular powder, the device <NUM> may flake the chickpeas to a designated flake size, such as in one example having flakes in the range of <NUM> to <NUM>, but such range is not limiting in nature. Whether the device <NUM> is a flaker or a miller, the output <NUM> still includes its oil. As noted herein, the flake ranges of <NUM> to <NUM> are exemplary ranges, but not express limiting ranges. It is recognized that smaller flake size may be utilized up until the flakes have a powder consistency. It is further recognized that larger flakes may be utilized where larger flakes may require further processing for efficient de-oiling.

As part of the de-oiling process, the mixer <NUM> therein mixes the flour <NUM> with ethyl alcohol <NUM>, more commonly referred to as ethanol. The mixture of the ethanol with the flour provides for removal of the oil from the flour in accordance with known oil-extraction techniques. The mixer <NUM> may be an immersion or ethanol-wetting tank, which may include a mixing element to saturate the flour with ethanol. It is recognized that one example uses pure ethanol herein, but other variations of ethanol may be utilized including ethanol mixed with other liquids, including have a water concentration or other mixture recognized by one skilled in the art, including for example ethanol recovered from a recycling loop as described below in <FIG>.

The mixer <NUM> output is a mixture <NUM> of the flour and ethanol. The decanter centrifuge <NUM> receives the mixture <NUM> and therein extracts ethyl alcohol recycling stream <NUM>, consistent of ethyl alcohol with oils, sugar and other organics absorbed therein. The extractor <NUM> additionally generates the de-oiled flour <NUM> with remaining ethanol. In this example, the flour mixture <NUM> is a wet mixture, which is then provided to the dryer <NUM>.

The desolventizing dryer <NUM> therein dries the flour mixture to remove final amounts of ethanol. A dryer output includes ethanol vapor <NUM>, which can be collected and condensed for recirculation back to the mixer <NUM>. The dryer also outputs the de-oiled flour <NUM>, which is then made available to the mixer <NUM>, as noted in <FIG> and <FIG>.

<FIG> illustrates another example of the de-oiling processor <NUM>. This example includes the decortication device <NUM>, milling / roller-flaker <NUM> and dryer <NUM>, but instead uses a counter-current extraction unit <NUM>. By way of example, the unit <NUM> may be a Crown Countercurrent solvent extraction unit, manufactured by Crown Ironworks, Roseville, MN.

Similar to the operations of <FIG>, the decortication device <NUM> generates waste <NUM>, as well as the input to the milling / roller-flaker <NUM>. Depending on whether the device <NUM> is a roller miller / flaker or a flour mill, the output is either flakes or flour, having oil contained therein.

In this example, the counter-current extraction unit <NUM> receives the flake/flour plus oil mixture <NUM>. Performing operations consistent with countercurrent extraction, the device <NUM> therein generates two outputs. Ethanol recycling stream <NUM> is the first output stream and de-oiled flour with ethanol <NUM> is the second stream. Therein the dryer <NUM> generates the ethanol vapor and de-oiled flour <NUM>.

It is recognized that for the examples of <FIG> and <FIG>, where the device <NUM> is a roller mill / flaker, the described flour includes flakes. These flakes are then further processed by a flour mill prior to insertion into the mixer <NUM> of <FIG> and <FIG>. Moreover, for ease of terminology, where described in <FIG> and <FIG>, describing flour after device <NUM>, such description includes flakes relating to examples employing the flaker instead of the flour mill.

The dryer <NUM> of <FIG> and <FIG> may additionally include varying examples not expressly illustrated. For example, one dryer <NUM> type may be an air/nitrogen air-flow dryer that generates the de-oiled flour. Another example of the dryer <NUM> may be a vacuum dryer. Another example may utilize a desolventizing toaster in operation with the vacuum dryer.

The variances of elements noted in <FIG> and <FIG> provide for a large number of varying examples. It is within the scope of this process for utilizing any variation of the devices <NUM>, <NUM>, <NUM>, <NUM> and <NUM>. For example, one example may include a roller miller / flaker <NUM> with a mixer <NUM>, decanter centrifuge <NUM> and a vacuum dryer <NUM>. For example, another example may include a flour mill <NUM>, a countercurrent extraction unit <NUM> and an air-nitrogen air-flow dryer <NUM>. Such examples are illustrative in nature only and not limiting.

Therein, the process of decortication with milling and/or roller-flaking of the feedstock and ethanol-based extraction results in efficient processing of the protein source while preserving the food grade nature of all fractions. The above process is described with chickpeas, but is also operable on other members of legume family, as well as any suitable feedstock having an oil content.

<FIG> illustrates one example of an ethanol recycling loop usable with the processor <NUM> of <FIG>. The recycling loop receives the ethanol recycling stream <NUM>, consisting of oil extracted from the material, ethanol and sugar. A distillation column <NUM> separates the input <NUM> into azeotropic ethanol <NUM> and concentrated oil, sugar and other organics <NUM>. In one example, molecular sieves may be used to extract water from the ethanol <NUM>. Such ethanol can then be recycled back to the mixer <NUM> of <FIG> and/or the countercurrent extraction unit <NUM> of <FIG>.

In <FIG>, a mixer <NUM> receives both the concentrated oil and sugar <NUM> as well as water <NUM>. A disc stack centrifuge <NUM> receives the mixture and output purified oil <NUM> and sugar and water mixture <NUM>. A dryer <NUM> dries the input <NUM> to produce water vapor <NUM> and molasses <NUM>. In one example, an optional enzymatic process may be performed prior to the dryer <NUM>. Regardless, in the system of <FIG>, the ethanol <NUM> can be recycled and re-used in the de-oiling process. It is recognized by one skilled in the art that further variations of the recycling operations may be utilized.

Further processing of the protein source provides for the improvement of yield and purity of the protein concentrates. As described herein, the exemplary protein source is chickpea, but any other plant-based protein source may be utilized. The present processing is not expressly limited to chickpeas, but using chickpeas as one example. <FIG> illustrates one embodiment of a system and method for improving protein concentrate yields and purity, complementary to the systems and methods described above. The system <NUM> of <FIG> may operate prior to the mixer <NUM> as noted above in <FIG>. The system <NUM> of <FIG> may additionally receive de-oiled protein flour, such as flour <NUM> generated from the de-oiled processor <NUM> described above.

The system <NUM> includes a mill <NUM> and an air classifier system <NUM>. The mill <NUM> may be any suitable milling device, such as by way of example of a jet mill, hammer, pin or any other suitable device recognized by one skilled in the art. The air classifier <NUM>, as described in further detail below, may be one or more air classification systems operative to process and classify the concentrate output within a defined classification range.

In the operation of the system <NUM>, the mill <NUM> receives the de-oiled flour <NUM> and generates milled de-oiled flour <NUM>. In an exemplary embodiment, the particle size can range between <NUM> and <NUM> micron, but it is recognized that any other suitable particle size range is within the scope herein. It is further noted that while the system <NUM> illustrates the mill <NUM> receiving the de-oiled flour <NUM>, the mill may additionally process flour not having been subjected to the de-oiling process of <FIG>, such that generated milling output <NUM> would then be milled flour instead of milled de-oiled flour <NUM>.

The air classifier <NUM> therein performs air classification operations, such as described in <FIG> below. The classification process therein generates a protein concentrate <NUM>, which with respect to the above-described protein extraction process, may then be received by the mixer <NUM>, along with water and base to produce the initial alkalized slurry. It is recognized that in the embodiment where the protein concentrate <NUM> is from the milled de-oiled flour, the subsequent processing of <FIG> therein excludes creamer <NUM> similar to the de-oiled example described above. It is further noted that in some protein sources having a high oil content, the oil content can disrupt the efficiency of the milling process by causing the mill to operate at a slower pace to avoid getting gummed up, such that by de-oiling the flour to lower its oil content, and remove attendant moisture, the milling operations can operate more efficiently, as well as eliminate oil removal processing operation(s) at later protein extraction stage(s).

For clarity of terminology, as described herein, the air classification technique generates varying outputs of protein concentrates. By comparison, the protein extraction process, such as described herein including <FIG> for example, generate protein concentrate product. The protein concentrates from the air classification systems undergo further processing to generate the protein concentrate product. Therefore, in reference to air classifications, the protein concentrates are the air classification output, separate from the protein concentrate product. Whereby, it is noted that the protein concentrate product, as generated herein, may be sold or otherwise distributed for consumption or processed for manufacturing of food products. Similarly, the protein concentrates from the air classifier(s) may additionally be sold or otherwise distributed for consumption or processed for manufacturing of food products.

<FIG> illustrates multiple embodiments of the air classifier <NUM>, as well as the exemplary jet mill <NUM>, as one embodiment of the mill <NUM> of <FIG>. The mill <NUM> receives the flour <NUM>, generating milled flour <NUM>. A first air classifier <NUM> receives the milled flour <NUM> to generate a first protein concentrate <NUM>. By way of example, the classifier <NUM> may be a Netzch Model CFS30 manufactured by Netzch Inc. of Exton, PA. The classifier <NUM> may have a designated percentage target split of to fines based on desired protein concentrate. In this example, the light fraction in the first air classifier <NUM> may be between <NUM>% and <NUM>% split. The air classification generates the protein concentrate <NUM> and a starch concentrate <NUM>, using known air classification techniques.

In one embodiment, the starch concentrate <NUM> is then re-fed back to the air classifier <NUM> for further refinement and processing.

Further refining the protein concentrate <NUM> produces a higher purity level of the protein concentrate used for the wet process. The feeding of the protein concentrate <NUM> to another air classifier, improves the purity level by extracting further starch concentrate, leaving a higher purity level in the protein concentrate.

In the method of the invention, the air classifier <NUM> includes a second air classifier <NUM>, which receives an input of the starch concentrate <NUM>. The second air classifier <NUM> therein performs further air classification operations to generate a second protein concentrate <NUM>, which extracts further protein from the starch concentrate <NUM>, improving the yield of protein concentrate from the flour <NUM>. The concentrate <NUM> is then added into the protein extraction process along with the first protein concentrate <NUM>.

The second air classifier <NUM> additionally generates a second starch concentrate <NUM>. This second starch concentrate <NUM> may be feed back to the first air classifier <NUM> for further refinement. In an additional embodiment, the starch concentrate from an air classifier may be fed back to the mill <NUM>. For example, starch concentrate <NUM> from the first air classifier <NUM> may include particles whereby the protein was not sufficiently removed from the starch granules in a first pass. Thereby, in this embodiment, reprocessing the starch concentrate <NUM> back through the mill <NUM> can improve protein capture yields.

In further embodiments, any suitable number of air classifiers may be used, illustrated here as air classifier N <NUM>, where N may be any suitable integer. For example, to maximize yield, a process may include four or five air classifiers operating to generate the protein concentrate, such as concentrate <NUM>. It is recognized that additional air classifiers operate on the starch concentrate produced by the previous air classifier, so there is a degree of diminishing returns for producible yield using multiple air classifiers on starch concentrates. Similarly, while not expressly illustrated in <FIG>, additional air classifiers may be used on the protein concentrate <NUM>, <NUM> and/or <NUM> to improve the purity of the protein concentrate.

By way of example, one embodiment may include the first air classifier <NUM> generating a concentration split of <NUM>-<NUM>% by feed mass to the starch concentrate <NUM> and the protein concentrate <NUM> can be greater than <NUM>%. The second air classifier <NUM> may additionally split <NUM>-<NUM>% by feed mass to the starch concentrate <NUM> and protein concentrate <NUM> can be greater than <NUM>% purity. A third air classifier <NUM> may generate the same split of <NUM>-<NUM>% to the starch concentrate and protein purity greater than <NUM>%. The further air classification of the starch concentrate improves yield by separating additional protein concentrate.

Similarly, in one embodiment, a range for the split by weight between the protein concentrate <NUM> and the starch concentrate <NUM> may be approximately <NUM>% by weight of the protein rich fraction, the protein concentrate <NUM> and approximately <NUM>% by weight of the starch concentrate <NUM>, plus or minus <NUM>% each. Therein, in this embodiment, the concentration of the protein concentrate <NUM> may be <NUM>% protein on a dry basis with a range of +/- <NUM>%. In this embodiment, the protein concentration of the starch concentrate may be <NUM>% +/- <NUM>%. Therefore, this air classification process may be repeated one or more times to further extract additional protein concentrate, to improve yield and/or purity. For example, the protein concentrate <NUM> can be further air classified to remove particles finer and lighter than the protein at a split of approximately <NUM>-<NUM>% to fine fraction. Upon further air classification, the starch concentrate may be ash, such as fibers, inorganic materials or other matters, or other insoluble materials, leaving the higher purity protein concentrate.

<FIG> illustrates several embodiments for processing the protein concentrate <NUM>. In the method of the invention, the concentrate <NUM> is the protein concentrate <NUM> in combination with concentrate <NUM>. The concentrate <NUM> may also comprise protein concentrate <NUM>. A mixer <NUM> receives the concentrate <NUM>, water, acid and enzymatic cocktail. The enzymatic cocktail includes enzymes and may be composed of a carbohydrate specific cocktail, such as by way of example pectinase, amylase, gluco-amaylase, cellulose, or any other suitable mixture recognized by one skilled in the art.

The mixer <NUM> mixes the liquids and provides the mixture to a centrifuge <NUM>. The centrifuge <NUM> separates the mixture into a water and sugar output <NUM>, leaving protein rich curd <NUM>. The protein rich curd <NUM> is then be further processed for protein extraction, as described in further detail below.

The mixture of the protein concentrate <NUM>, water and acid is then fed to the centrifuge <NUM>. Where the centrifuge <NUM> extracts the sugar and water <NUM>, the protein rich curd output is then provided to a second processing stage <NUM>. In this embodiment, the second processing stage <NUM> includes a second mixer <NUM> and a second centrifuge <NUM>. The protein rich curd is mixed in the second mixer <NUM> with an acid, and feed to the centrifuge <NUM>. Sugar and water is extracted, to generate a second protein rich curd <NUM> output. Similar to the protein rich curd <NUM>, the curd <NUM> is then further processed for protein extraction.

With respect to <FIG>, the processing techniques of <FIG> are integrated therein. Varying embodiments of protein extraction using the air classification utilize the <FIG> processing system <NUM>, including additional or further refinements of the process. For example, with respect to <FIG>, mixer <NUM> may operate similar to the mixer <NUM>, therein additionally receiving the enzyme mixture. The centrifuge <NUM> operates similar to the separator <NUM>, generating the rich protein curd <NUM>, referred to as first protein curd with reference to <FIG> above. The wash station <NUM> of <FIG> operates consistent with the second processing stage <NUM> of <FIG>, as further described in <FIG> above. Thus, the protein rich curd <NUM> is consistent with the second protein curd of <FIG>.

The protein rich curd <NUM> and/or <NUM> is provided to the mixer <NUM>, which includes an enzyme cocktail as noted above.

<FIG> illustrates another embodiment for processing the protein concentrate as generated consistent with one or more embodiments above. A mixer <NUM> receives the protein concentrate <NUM> along with water and a base. The mixture is fed to a centrifuge <NUM>, whereby starch <NUM> is extracted. With starch extracted, a solubilized protein rich stream <NUM> is then fed to a second mixer <NUM>. Within the mixer <NUM>, the stream <NUM> is combined with acid. The output of the second mixture is fed to a second centrifuge <NUM>, whereby sugar and water is extracted to generate the protein rich curd <NUM>.

<FIG> illustrates a similar commonality with the system of <FIG>, where the mixer <NUM> operates consistent with the mixer <NUM> of <FIG>, having the input of water and base, instead of acid. By replacement of acid with a base, the centrifuge <NUM> operates similar to the separator <NUM>, to extract the protein curd <NUM>, which is similar to the first protein curd of <FIG>. The mixer <NUM> and centrifuge <NUM> operates similar to the wash station <NUM> of <FIG>, whereby the protein rich curd <NUM> is similar to the second protein curd of <FIG>.

Similar to the embodiments of <FIG>, the curd <NUM> is then further processed for protein extraction, consistent with the above-described techniques. For example, the curd <NUM> may be fed to the mixer <NUM> of <FIG> with the inclusion of an enzyme cocktail.

As noted herein, wherein the described example of an extraction unit is a centrifuge, it is recognized that any other suitable extraction or separator device may be utilized and the technique herein is not expressly limited to using a centrifuge.

Therefore, the above air classification technique provides for improving protein yield usable for protein extraction from plant-based source(s) such as chickpeas, other legumes and other like feedstocks. A maximum protein concentration is reached in which no further protein can be concentrated without sacrificing yield, or in various embodiments a maximum cannot be overcome due to particles or agglomerates having the same mass cannot be separated in a dry media. The present technique therein introduces materials into a solvent to separate materials by other physio-chemical properties.

It is recognized that varying the processing conditions noted above adjusts the output volume and concentrate levels. Whereas within the scope of the present invention, reducing processing time or reducing ingredient combinations may generate reduced concentration levels acceptable for varying industrial or commercial uses. Similarly, refinements may include increased quality or other attributes of the protein concentrate, such as digestibility, after taste / aromatics, consistency, mouthfeel, by way of example. As such, the varying operational variations are within the scope of the present invention and the noted example and ranges above are exemplary and not limiting in their disclosure.

In addition the method and system described herein, the present method and system additionally allows a chickpea concentrate made by the process described herein. The chickpea concentrate is made, in various embodiments, using the above described methods and systems.

Therefore, the present method, system and chickpea concentrate overcomes the limitations of the prior art by allow for the utilization of chickpea as a vital protein source. The method and system incorporate varying operational guidelines, such as acidity levels, processing times, flow rates, temperature ranges, to generate the herein described chickpea concentrate.

Claim 1:
A dry fractionation method for generating a protein concentrate product from a plant-based flour, the method comprising:
milling the plant-based flour to generate milled flour;
generating a first protein concentrate and a first starch concentrate from the milled flour using a first air classifier;
generating a second protein concentrate using the first starch concentrate with a second air classifier;
processing the first protein concentrate and the second protein concentrate to generate a protein rich curd;
generating a neutral hydrolyzed protein slurry by mixing the protein rich curd with a base, an enzymatic cocktail and water;
generating a homogenized protein slurry from the neutral hydrolyzed protein slurry;
generating a pasteurized protein slurry by pasteurizing the homogenized protein slurry;
generating a cooled protein slurry by cooling the pasteurized protein slurry; and
extracting the protein concentrate product from the cooled protein slurry.