Patent ID: 12185739

It will be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention describes a novel system and process for improving the efficiency of recovering products from animal tissue. Also described is a novel system and process for improving throughput, especially yield of solid protein, based upon the initial feed of animal tissue. Further described in the present invention is a system and process for reducing the emission of VOC gases into the atmosphere during the processing of animal tissue.

Generally, condensing plural pieces of manufacturing equipment into a single unitary structure has been shown by the inventors to reduce downtime caused by material flow obstructions occurring at multiple locations in the system. Namely, material flow obstructions occur most frequently at inputs and outputs of manufacturing equipment. Material flow obstructions also occur within conduits connecting different pieces of manufacturing equipment. According to the inventors, processing animal tissue feedstock in a single filter-dryer-reaction tank to recover a wet cake including solid protein significantly improves downtime attributed to maintenance and repair. In addition, the current unitary invention is a highly automated process; more energy efficient; and requires less manpower than a system comprising multiple unit operations. Another advantage directly attributed to employing the above-mentioned system is a reduction in capital and operational costs associated with procuring and maintaining fewer pieces of equipment. Yet another advantage realized by the inventors is an improvement in yield of solid protein and shelf-life, derived from the wet cake by employing the system and method described herein.

The novel system and process will be discussed in greater detail below in view of the exemplary, non-limiting embodiments of the present invention. Each of the embodiments discussed hereinafter, unless expressly noted otherwise, are combinable and envisaged within the scope of the present invention. It is also understood that the embodiments, while preferred, are exemplary, and those of ordinary skilled in the art will understand certain modifications to the embodiments are possible without departing from the spirit of the invention.

System

FIG.1is a block diagram illustrating an exemplary embodiment of a recovery system100according to a first aspect of the present invention. According toFIG.1, the recovery system100includes an animal tissue feedstock101for introducing animal tissue. The animal tissue feedstock may be contained within a storage tank. The storage tank may be temperature controlled. Alternatively, the animal tissue may be housed in a cold room and conveyed downstream for processing either manually by technicians, or by any combination of automatic machinery including but not limited to screw conveyers, conduits/tubes, pumps, blowers, etc. In an exemplary embodiment, 304SS piping may be employed throughout the system. In another exemplary embodiment, a pump constructed of stainless steel may be employed to assist with transferring animal tissue downstream.

The recovery system100also includes an organic solvent feed102for introducing organic solvent. The organic solvent feed102may be contained within a storage tank. The storage tank may have a flat bottom and/or a closed top. The storage tank may also include a level transmitter. The level transmitter preferably is constructed from stainless steel. The tanks may include ports which directly or indirectly communicate with an inlet of nitrogen gas. The storage tank may also include a conservation valve, butterfly valve, and/or diaphragm valve. The organic solvent may be delivered downstream by any combination of equipment including but not limited to piping, pumps, blowers, or the like, as described above. The pump may be stainless steel and centrifugal. Piping may be employed as necessary for interconnecting the process unit operation and downstream equipment.

The present invention involves a highly scalable process and is capable of yielding protein powder and omega 3 oils ranging from lower to higher quantities. The inventive process is also reconfigurable in that parallel trains of systems can be implemented for concurrent production requirements.

Of particular importance, the recovery system100also includes a single, unitary, integrated filter-dryer-reactor tank110(referred to as “the FDR tank” hereinafter) which receives animal tissue and organic solvent for processing. The FDR tank110includes vacuum and heating modules. The FDR tank also includes a filter for separating solids from heavy liquids. The FDR tank110also comprises one or more agitation devices that agitate or stir the animal tissue feedstock and solvent mixture, as well as a drying module for yielding dry solid protein product once separated from the liquid component (i.e., the water, oil, solvent). Preferably, the FDR tank110is constructed of stainless steel and is of a sanitary design. The FDR tank110will be described in greater detail below with reference toFIG.2.

The recovery system also includes a solid product recovery system160and a solvent/liquid recycle (SLR) system170, as illustrated inFIG.1. The SLR system170may include one or more filtrate recovery tanks. Preferably, the filtrate recovery tanks are made of stainless steel. The filtrate tanks may include one or more ports which directly or indirectly communicate with an inlet for feeding nitrogen gas thereto. The nitrogen blanket maintains the organic solvent in a nonvolatile state. The SLR system170will be described in greater detail below with reference toFIG.3.

FIG.2is a cross-sectional view of the FDR tank110(also indicated by reference numeral200and used interchangeably throughout). The FDR tank200is an externally heated metal vessel, with agitation systems, capable of withstanding elevated pressures and vacuum compression vessel made of metal. Preferably the metal is selected from alloys suitable for sanitary processing requirements. More preferably, the metal is stainless steel. In another, exemplary embodiment, the FDR tank200generally is a monolithic or unitary structure capable of being pressurized and withstanding high levels of vacuum. That is, the FDR tank200is machined as a single piece rather than a collection of devices connected via conduits.

The FDR tank200may include a port215communicating directly or indirectly with a feed line for introducing animal tissue from the animal tissue feedstock201and/or a port216communicating directly or indirectly with a feed line for introducing organic solvent from the organic solvent feed202. Ozone, preferably, is fed from an ozone generator225which may be located upstream or downstream of the animal tissue feed201. The FDR tank200may also include a port218communicating directly or indirectly with a VOC recycling system that will be discussed later in detail. The FDR tank200also includes a port219communicating directly or indirectly with a solid product recovery tank260, which is generally illustrated as “solid product recovery160” inFIG.1. The FDR tank200further includes a discharge port217communicating directly or directly with the Solvent/Liquid Recycle system (SLR system)270(which is identified inFIG.1as Solvent/Liquid Recycle System170). Specifically, the SLR system recovers products from animal tissue including animal oils and water derived from the animal itself. The SLR system270also recovers organic solvent which may be recycled through the system according to user preferences. The FDR tank200may include a pump, a check valve (CV-01), and an isolation valve between the discharge port217and the SLR system270. The check valve (CV-01) can prevent a reverse flow of liquid back from the SLR system270into the FDR tank200.

Surrounding the FDR tank200is a heater system220. In an exemplary embodiment, the outer walls and bottom of the FDR tank200are surrounded by a conventional heating jacket containing a heating medium. Generally, the heating medium is steam or alternative heating transfer fluid. Preferably, a steam boiler capable of operating at6MMBTU is employed.

The FDR tank200may include a primary agitator assembly230. The primary agitator assembly230is located partially inside and partially outside the FDR tank200. The agitator assembly230may include a drive means231, which is, at least in part, preferably located outside of the FDR tank200. In an exemplary embodiment, the drive means231is located on or above the FDR tank200. The drive means231rotates a vertical, or near vertical shaft232which is located in or substantially within the FDR tank200. The shaft232may be rotated, clockwise or counterclockwise, at variable speeds as determined by the operator. The rotation speeds have a variable range. The shaft232includes one or more arms233with corresponding blades234extending there from, which facilitate movement of the feedstock and solvent mixture within the FDR tank200. The movement helps to ensure uniform heating and drying. The one or more arms233may be located at equal or non-equal distances from each another in the vertical and/or horizontal plane extending radially in the direction of the inner wall of the FDR tank200. Each of the one or more blades234located on the one or more arms233also radially extends in the direction of the inner wall of the FDR tank200and is configured to rotate around the shaft axis. The one or more blades234may be located at equal or non-equal distances from each other. The blades234may take on a number of shapes; however, the blades are preferably rectangular or substantially rectangular. Further, the blades234may include a radially inner portion that is substantially flat and lies substantially in a vertical plane. Alternatively, the blades234may lie with a positive or a negative pitch. In yet another exemplary embodiment, one or more of the blades may include a heating mechanism to provide an enhanced method of drying the solid protein product. The heating mechanism may be a part of the heating system220.

In a separate embodiment, microwave radiation may be employed as an alternate method for drying the solid product. Microwave radiation has been shown to provide more uniform drying while reducing damage to the product otherwise due to conventional heating mechanisms.

The FDR tank200may include a secondary agitator assembly250. Like the primary agitator assembly230, the secondary agitator assembly250is preferably located partially inside and partially outside of the FDR tank200. The secondary agitator assembly250may be a high shear agitator for facilitating mass transfer during the reaction phase of a mixture in the FDR tank200. The secondary agitator assembly250includes a driver251that is, at least in part, preferably located outside of the FDR tank200. It communicates with a rotatable shaft252, which is preferably located inside or substantially inside the vessel210. The shaft252may include one or more arms253and one or more corresponding blades254. Although the secondary agitator assembly250appears to be arranged inFIG.2in a vertical orientation, it may, in the alternative, be arranged at any angle relative to the FDR tank200.

Preferably, the FDR tank200also includes a vacuum system240capable of drawing a vacuum within the FDR tank200. The vacuum system240includes a vacuum pump241to reduce the air pressure in the FDR tank200.

Discharge of the final bulk solids from the FDR is preferably accomplished by using a pneumatic conveying system. This system avoids the need for manual removal of the product from the FDR. The pneumatic conveying system facilitates discharge of the solid protein product from the FDR to a final bulk container, such as a tote bind or a high strength woven sack.

The FDR system is a highly automated system that utilizes a state of the PLC (Programmable Logic Controller) or similar logic processor. High speed input and output signals are integrated as part of the automation to permit the control system to rapidly respond to process deviations and automatically return the process to within specification. The complex mechanical nature of the FDR requires critical safety interlocks, and the automated system's logic processor scans these conditions on a continual basis to ensure that the FDR equipment and auxiliaries are protected. Customized programming of the logic processor permits the implementation of various software library modules that can be deployed depending on the requirements of the process. For example, different animal tissue feed stocks may require slightly different processing conditions in order to yield high quality protein product. The nature of the automation process will permit the implementation of a recipe driven system that can be tailored to various feed stocks and related processing conditions.

In another embodiment, the automated system used for the production of protein shall conform to a hierarchical model that combines process automation with Business Intelligence (BI) involving Manufacturing Execution Systems (MES) encompassed by an overarching Enterprise Resource Planning (ERP) system. The Instrumentation, Systems and Automation (ISA) S95 standard establishes a four tier hierarchical model for a manufacturing enterprise network. It characterizes generic application software and network architectures for manufacturing control systems as described under Table 1. The primary protein production process occurs at Level 0 with Level 1 instrumentation that monitors the process operating parameters within specification. Level 2 comprises the logic controllers, which may include a combination of PLC, DCS or SCADA systems. These Level 2 logic processors contain the proprietary source code and application recipes that define the protein production process. Since the Enterprise Control System is by definition a networked structure, information and data derived from the process and Levels 1 and 2 are transferred to Level 3 material planning and quality systems. Level 3 is the repository for raw material and finished goods analytical data as well as inventory levels. Level 4 is the final repository for all information related to the protein manufacturing operations. Level 4 analyzes internal manufacturing data and couples it against external marketing an forecasting information in order to optimize the schedule, raw material usages, and finished goods inventories.

TABLE 1SA95 Enterprise Control System Integration HierarchySA95 LayerFunctionDescriptionLevel 4ERPEnterprise Resource PlanningCRMCustomer Relationship ManagementAPOAdvance Planning OptimizationLevel 3MESManufacturing Execution SystemsLIMSLaboratory Information ManagementSystemsCMMSCalibration Maintenance ManagementSystemsWMSWarehouse Management SystemsLevel 2PLCProgrammable Logic ControllersDCS, BASDistributed Control Systems, BuildingAutomation SystemsSCADASupervisory Control and Data AcquisitionLevel 1DevicesProcess measurements and terminal controlequipmentLevel 0ProcessThe physical manufacturing process

FIG.3illustrates a recovery system300(also indicated by reference numeral100and used interchangeably throughout) in greater detail in accordance with exemplary embodiments of the present invention. More particularly,FIG.3illustrates the SLR system370in detail (also indicated by reference numeral370inFIG.2and used interchangeably throughout). In addition to the detailed features illustrated inFIG.3, the recovery system300may further include such features as air compressors and nitrogen systems, for example, to maintain an inert environment inside the aforementioned filtration and storage tanks, depending on the type of organic solvent(s) used. The recovery system300may also employ sensors for detecting explosive conditions and corresponding alarms to indicate, for example, that the concentration of organic solvent vapors exceed permissible threshold limits.

Turning attention back toFIG.3, the SLR system370, as mentioned, comprises a filtrate tank371, although more than one tank is conceivable (see filtrate tank372). The filtrate tank371may be located upstream of one or more filters373. The filters373help remove residual solids from the filtrate (i.e., the solvent, liquid and oil mixture). The filters373may be located anywhere in the SLR system370as required for the removal of the residual solids.

The SLR system370may also include a distillation unit375, such as a fractional distillation tower or WEE, (wiped film evaporator). Distillation unit375operates to recover fats/oils from the organic solvent/water. Distillation unit375may be located downstream of the filtrate tank371. Pumps and blowers may be employed as necessary for transferring the various liquids downstream for further processing. The SLR system370may include more than one distillation unit, if needed.

The SLR system370preferably includes an ozone generator374. As shown inFIG.3, the ozone generator374is located downstream of the filtrate tank371, and it reacts with and neutralizes amines in the filtrate, thereby eliminating the odor (e.g., fishy odor) associated with the amines. Odors associated with fish are due to the natural process of decay. Bacterial enzymes attack the flesh of fish, and this triggers an oxidation reduction reaction. The muscle of the fish which contains trimethylamine oxide (TMAO) breaks down by decomposition, thus producing trimethylamine and dimethylamine. These two amines give rise to the characteristic fishy odor. Thus, the ozone removes this odor by destroying the molecules, bacteria, and spores that cause unpleasant smells. Triatomic oxygen is ozone. In a reverse reaction using Ozone, the third oxygen atom attaches itself to the amine molecules and ultimately renders them odorless. The ozone generator374can be also located at other part of the SLR system370where deodorization is needed.

Deodorization of the solvent and liquid products are further achieved through the use of in-line activated carbon filters. Activated carbon is a well established material for removal of organic contaminants from a process stream. The benefit of using activated carbon in the SLR process is that trace amines are further eliminated along with the associated odor attributed to the fishy amine smell.

The SLR system370may include condensers downstream of the distillation unit375to recover water and organic solvent. Further processing equipment may be required as necessary to obtain purified water. The purified water may then be transferred to a recovery tank396.

The SLR system370may further include one or more distillation units380to recover purified animal oil (e.g., omega-3 oil). Preferably, the distillation unit380may contain a phase separation apparatus. The distillation unit380is located downstream of the distillation unit375. The distillation unit380generally separates the animal oil from waste solid fat. The distillation unit380may, for example, be a Thin Film Evaporator (TFE), Wiped Film Evaporator (WFE) or a molecular distillation unit. Specifically, a molecular distillation unit, may be employed to recover a purified omega-3 oil from waste solid fat. Various grades of purity may be achieved and techniques readily known in the art may be employed to achieve a final grade of omega-3 oil. Oil may be transferred to a recovery tank397while residues are captured in a tank398.

Referring back toFIG.3, recovery system300may include a controller391. The controller391may include an electrical motor control center. The controller generally provides the operator with an interface through which the operator can achieve real-time, automated control over the various components and subsystems that make up recovery system300. The controller391may, for example, communicate with and/or provide control over tank volumes, temperatures, device states, sensors and alarms.

The system300may further include one or more grinders305. The grinders305are preferably made of stainless steel construction and configured to grind raw animal tissue feedstock, such as fish, into ¼″ to ½″ cube sizes. The grinders305are located upstream of the FDR tank310, such that the grinders305grind animal tissue feedstock received from the animal tissue feedstock storage tank/room301into smaller particles, as specified above, for further processing.

After the animal tissue feedstock is ground, the feedstock may be combined with an organic solvent for preparing a homogenized slurry or mixture. As shown inFIG.3, system300includes preparation tanks330for combining the animal tissue feedstock and the organic solvent. The preparation tank330preferably processes up to 50 gpm. The preparation tank330may be a heated agitated tank. The preparation tank330is also located upstream of the FDR tank310. Level sensors and flowmeters may be employed in or associated with the preparation tank330, in order to provide feedback information to the operator through controller391, to help ensure adequate flow in accordance with operator preferences.

System300may also comprise a milling apparatus350and a solid product recovery system360. The milling apparatus350mills the solid product to obtain a granular or powder form of the recovered solid protein. The milled product may further be cured in an oven. After curing, the finished product is stored in a final product storage facility. Upon completion of these processes, the product with all of its protein properties, can be managed in such a way so as to give it physical characteristics sufficient to allow it to be consumed and ingested by children and adults easily and without unpleasant flavors or odors which have a disagreeable impact or which give rise to rejection. For example, without limitation, the powder may be pressed into a solid pill form, placed in a capsule to be swallowed, or added to a liquid and consumed as a beverage. The recovered solid protein may then be collected by the solid product recovery system360.

Recovery system300also comprises an organic solvent recycle system390. Preferably, the solvent is isopropyl alcohol (IPA); however, it will be readily apparent to those skilled in the art that solvents other than IPA may be used. As mentioned above, the organic solvent may be distilled from the water by use of a heated still and condensers. However, once the solvent is removed from the water, the solvent may be transported back to a solvent storage tank302. This recycled organic solvent may or may not be combined with new or fresh solvent prior to being transferred to the FDR tank310, where it will be combined with re-filtered wet cake, or transferred to preparation tank330, where it will be combined with the animal tissue. Refiltered wet cake is the residual solid protein product that remains behind in the FDR following each reactor recycle process. Recall that once the raw fish/IPA mixture is sent to the FDR tank310. IPA is then filtered off and the filtrate is transferred to the solvent recovery system. Solid protein product remains behind in the FDR tank310. Another charge of IPA is then sent to the FDR tank310where the solid protein product undergoes a second reactor/heating/filtration cycle. IPA is once again filtered off leaving behind the solid protein “wet cake”. This recycle process is conducted one more time for a total of 3 times. In general, the total number or recycles will range from 1 to 4, and is determined by the final product desired quality. The FDR tank310and preparation tank330may receive one of the following with respect to organic solvent: entirely new (fresh) organic solvent, entirely recycled organic solvent, or a combination thereof. As is apparent, the solvent recycle system390includes piping, as described above, for transporting the organic solvent between the solvent recovery tank395of the SLR system370, the organic solvent storage tank302and the FDR tank310.

The recovery system300may include a recovery tank396for collecting water, a recovery tank397for collecting oils, including omega-3 fatty acids, and a residue discarding tank398for collecting residue. Still further, recovery system300comprises a VOC recycling system392for capturing emissions of fumes/vapors formed in the FDR tank310. As shown inFIG.3, for example, emissions exit the vessel FDR tank310via a port, and the vapors may be transferred to a fume condenser and chiller for condensing the vapors into usable organic solvent. The condensed organic solvent may be transferred via a solvent recycle line to the organic storage tank302for reuse.

Process

According to an aspect of the present invention, a process is described for recovering products originally derived from animal tissue. In one embodiment, solid protein product is recovered. In another embodiment, solid protein product in addition to water derived from animal tissue are recovered. In a further embodiment, solid protein product, water and animal oil derived from the animal tissue are recovered.

Animal tissue, for the purposes of this application, is defined as having eukaryotic cells of various shapes and sizes. Animal cells are further characterized as excluding cell walls which are present in all plant cells. The animal tissue may include but is not limited to land and marine animals such as insects, fish, poultry and red meat. In an exemplary embodiment, the animal tissue feedstock contains fish. In yet another exemplary embodiment, animal tissue feedstock is maintained at temperatures less than 50° F., preferably less than 45° F., and more preferably less than or equal to 40° F., prior to being processed by the purification system of this invention.

As stated, the animal tissue may be fish, and in particular, raw fish. The raw fish should be fresh and handled in a sanitary manner. The quality of the raw material should also be verified. The fish is also ground, as explained above (see e.g., mill350), into pieces so as to form a fishmeal prior to mixing with organic solvent and further processing.

An organic solvent is generally employed in the process. The solvent may include an alcohol, wherein the hydroxyl functional group is bonded to a carbon atom. In an alternative embodiment, the solvent may be selected from those organic solvents with a volatile organic content (VOC) ranging between about 200-500 g/L. In still another alternative embodiment, the solvent is selected such that it meets VOC regulations promulgated by local governing authority. In a preferred embodiment, the solvent, as stated, is IPA (isopropyl alcohol).

A mixture of fishmeal and solvent is initially heated; however, a low heat is preferably used so there is no risk of decomposition of the protein product due to thermal degradation. The mixture of fishmeal and solvent should sufficiently be balanced so that the fishmeal dissolves into a viscous liquid during processing in the FDR tank, and in particular, the heating process, which is done at a controlled temperature by means of a variable control system that prevents the destabilization of the which, in turn, would reduce or eliminate the potency of the protein. The ratio of animal tissue to solvent will, of course, depend on various factors including but not limited to the specific animal tissue and solvent used. Where the animal feedstock is raw fish and IPA is employed as the organic solvent, the ratio of fish in kilograms to IPA in liters ranges between about 1:1 to 1:2.2; 1:2.1; 1:2.0; 1:1.9; 1:1.8; 1:1.7; 1:1.6; 1:1.5; 1:1.4; 1:1.3; 1:1.2; and 1:1.1. More preferably the ratio is about 1:2. In a preferred, commercial embodiment of the present invention, upon scale-up, about 5,000 Kg of raw fish and about 10,000 L of organic solvent are combined to form the mixture of fishmeal and solvent.

As illustrated inFIGS.1-3, the mixture of animal tissue and organic solvent is fed, e.g., via a screw conveyer from the preparation tank (e.g., see preparation tank330) to the FDR tank (see e.g., FDR tank310), where it is heated, with agitation at a temperature ranging between 45-75° C. for approximately 2 hours in the FDR tank. The primary agitator assembly, as discussed above, ensures uniform heating and prevents decomposition of the animal tissue and organic solvent mixture, particularly that portion of the mixture in proximity of the walls or bottom of the compression vessel. In doing so, protein with a high concentration is recovered, specifically with 85% or higher pure protein, as characterized through a complete aminogram. An aminogram is a collection of amino acids present in a product depending on the type of animal tissue. The recovered protein may be a complete aminogram, non-hygroscopic, and substantially free, of fish odor or smell contributed by amines. The recovered protein may also be non-hygroscopic and sterile, and visually, the protein, may exhibit a cream color.

The animal tissue may be fed by a screw conveyer to a preparation tank (see e.g., preparation tank330). The organic solvent is then added to ensure an adequate mixture is formed prior to being fed to the FDR tank (see e.g., FDR tank3). The preparation tank may also include an agitator, as well as a jacketing and insulation system to permit external heating and cooling. Preferably, the mixture is heated to a temperature not exceeding 75° C., for example, about 45-50° C. The resulting homogeneous mixture is then fed to the FDR tank.

In the FDR tank, the homogeneous mixture is again heated and agitated, then filtered. The residual protein wet-cake is then dried, preferably using heat and vacuum or microwave. By so doing, several unit operations are condensed into a single piece of equipment. Namely, slurry vessels, product centrifuges/filtering mechanisms, stand-alone drying apparatuses, along with accompanying valves, conduits, blowers, pumps, sensors, controllers, and the like, that assist with the transfer of the mixture between each operation are not required. As a result, production cycle time for recovering product, such as for example solid protein, significantly is reduced. Within the FDR tank, the process generally is automated and operates in closed circuit, e.g., closed system.

After the mixture is heated and agitated for a period of approximately 2 hours, as mentioned above, the FDR tank operates in a filtration mode. The filtrate including the organic solvent is discharged from the FDR tank to the SLR system. A wet cake is retained in the FDR tank. The FDR tank then operates in heating/drying mode under full vacuum at a temperature not exceeding 80° C., for example, from about 50-80° C. for 1 hour to 10 hours to recover solid.

After filtration, one or more heating, agitation and filtration cycles may be employed. For each additional heating, agitation and filtration cycle, organic solvent is fed into the FDR tank. As explained above, the solvent may be new (fresh) solvent, recycled solvent recovered from the SLR system, or a combination of both. The recycled solvent may be transferred from the SLR system through the use of a solvent recycle system (see e.g., solvent recycle system390) to the solvent storage tank (see e.g., solvent storage tank302), thus promoting green manufacturing initiatives. After the above-mentioned one or more heating, agitation and filtration cycles, the FDR tank operates in heating/drying mode under full vacuum at a temperature ranging from about 50-80° C. for 1 hour to 10 hours to dry and recover solid protein from the solid portion of the mixture retained in the FDR tank.

The recovered solid protein is ultimately discharged from through an outlet port in the FDR tank to a storage tank. The solid protein may be reviewed and analyzed by quality control to ensure adequate yield of protein. In an exemplary embodiment, the solid protein is present in a yield of about 15-25 wt. % based upon the animal tissue entering the FDR tank110. Preferably, the yield is greater than about 18 wt. % solid protein recovered from animal tissue entering the FDR tank110.

A laboratory analysis of the recovered solid protein from the system exhibited protein concentrations in the range of about 85-95%. The quality of the final product is generally excellent at least because the product is not degraded as the process is low temperature, e.g., not generally exceeding 80° C., in order to prevent thermal degradation of the protein. Hence, the organoleptic structure is maintained resulting in a relatively complete amino gram on the high quality concentration of protein on the final product. The product exceeds all FDA requirements for a supplement and is an excellent product for world food needs. The 35 gram serving provides sufficient protein to meet a person's amino acid requirement like a full meal. The most frequently used methods for making these determinations at the protein level, are electrophoresis and thin layer chromatography; and it has been possible to demonstrate that there exists at least one specific protein for each species.

The recovered protein also has a long shelf life defined as maintaining a fairly constant profile over a long period of time. In one embodiment, the recovered solid protein product was tested in a laboratory simulating environmental conditions over 10 years. The constant profile may be attributed to the product's non-hygroscopic, or substantially non-hygroscopic nature. That is, the recovered, solid protein does not absorb humidity or grow any bacteriological processes in view of the low moisture content. Preferably the moisture content is less than about 8 wt. % of the recovered, solid protein.

The recovered protein has amino acid compositions that are balanced to afford a nutritionally advantageous characteristic. The recovered protein may also be sufficiently stable and sterile, i.e., substantially or entirely 100%.

Further, in accordance with the process of the present invention, the filtrate (i.e., the heavy liquids) that are extracted as a result of the filtering in the FDR tank is transferred to the SLR. The filtrate may include but is not limited to oils, fats, solvent and water. When the animal tissue is fish, the oil may include omega-3 fatty acids. In the SLR system, the filtrate may first be transferred to a filtrate tank (see e.g., filtrate tank371), and subsequently filtered once again (see e.g., filter373) to remove residual solids. Alternatively, the filtrate may directly be transferred to a solvent recovery or distillation tower (see e.g., distillation unit375), in order to separate the organic solvent/water from oils/fats. As previously stated, the solvent may be transferred to a recovery tank395, and thereafter, employed as recycled organic solvent. The water may be transferred to a recovery tank396and purified further as necessary.

The recovered oils, for example, omega-3 fatty acids, may be filtered to remove residue (see e.g., filter373) and to increase the purity thereof. It may also be treated with ozone to remove the odor by neutralizing any amines present in the oil. The residue may be transferred to a discarding tank (see e.g., residue discard tank398). The oils, including omega-3 fatty acids, may be transferred to a first recovery tank (see e.g., recovery tank397). There, the oil may undergo further purification, as required, according to a further embodiment and transferred to another recovery tank397b. The recovered oils including omega-3 fatty acids are polyunsaturated fatty acids with a double bond on the end of the carbon chain. They are considered essential fatty acids. Humans cannot readily make omega-3 fatty acids in their bodies, and therefore it must be obtained from other sources since they play an important role for normal metabolism.

In an exemplary embodiment, omega-3 fatty acids are recovered in amounts greater than or equal to about 5% of the original animal tissue feedstock (whereby 1 L=0.96 Kg). Preferably omega-3 fatty acids are recovered in amounts of greater than or equal to 6% of the original animal tissue feedstock, More preferably, omega-3 fatty acids are recovered in amounts greater than or equal to 7% of original animal tissue feedstock. [811 L/2*0.96=389 kg].

In yet another embodiment, the organic solvent/water may independently be recovered by employing extractive distillation. Namely, a third component is introduced into the process. For example, when isopropyl alcohol (IPA) is the organic solvent, diisopropyl ether (IPE) may be employed whereby IPA and IPE combine to completely separate water therefrom. The water is recovered at outlet396and may be further subjected to another ozone treatment. In still another exemplary embodiment, distilled water is recovered in amounts less than or equal to about 35% of the initial liquids portion entering the SLR system37. Preferably, water is recovered in amounts less than or equal to about 30% of the liquids portion entering the SLR system370. More preferably, water is recovered in amounts less than or equal to about 25% of the liquids portion.

On the other hand, the IPA/IPE mixture is then further distilled in a secondary distillation column to recover IPA. The IPA may be transferred to a recovery tank395for further processing as discussed above.

RESULTS AND EXAMPLES

The following examples illustrate specific aspects of the present invention. The examples are not intended to limit the scope of the present invention. Test results may vary for different types of fish species, but the method and system are applicable to all fish species. Table 2, as shown below, describes the composition an amino gram of solid, protein powder recovered from fish according to an embodiment of the present invention. Specifically, the yield of protein is 85.4%, moisture is 7.68%, crude fat is 1.42%.

TABLE 2CERTIFICATE OF ANALYSISSample IdentificationSample #: 05-5432 Advance Protein Powder, Serving = 35 gMethod:B0202: Amino Acid Profile (Total) by AOAC 98170PB100 NLEA Abbreviated Nutrient Package (Proximate)Results: OF AMINO GRAM Sample #05-5432TheoreticalTest/100 gServingUnitsLevelProtein - Food85.429.9grams85-90%Protein = Nitrogen × 6.38Ash9.203.22gramsMoisture By Vacuum Oven7.682.69gramsCrude Fat By Acid Hydrolysis1.420.497grams0.5%Calories, Calculated340119caloriesTotal Amino Acid ProfileTryptophan1.060.371gramsCysteine0.830.291gramsMethionine2.510.879gramsAspartic Acid4.581.6gramsThreonine2.150.753gramsSerine1.640.574gramsGlutamic Acid6.642.32gramsProline1.890.662gramsGlycine2.540.889gramsAlanine2.91.015gramsValine2.310.809gramsIsoleucine2.030.711gramsLeucine3.511.23gramsTyrosine1.540.539gramsPhenylalanine1.860.651gramsLysine, Total3.921.37gramsHistidine1.220.427gramsArginine2.971.04grams

As shown in Table 2, specific tests conducted on the recovered solid, protein powder derived from fish. As shown, the protein has over 98% digestible protein according to the well-known Pepsin test (0.2% Pepsin). Pepsin is a material that is used to digest protein structures. The Pepsin test is used to determine how much protein is within a mixture. The test involves analyzing the amount of protein that was digested, then back calculating that amount to the original quantity of protein material in the sample undergoing analysis. The trans fatty acid isomers are less than 0.1 wt. %, and preferably less than 0.05 wt. %. The amount of cholesterol is less than 0.1 wt. %, preferably less than 0.05 wt. %, and more preferably less than 0.02 wt. % of a 100 g serving.

TABLE 2CERTIFICATE OF ANALYSISSample identification:Sample #: 05-5432 Advance Protein Powder, Serving = 35 gMethod:B0003: Customized Analyses (Pepsin (0.2%) Digestible Protein)B7033: Cholesterol by Gas Chromatography (GC), AOAC 994.10Q0201: Total Trans Fatty Acid by Gas Chromatography (GC),AOAC 996.06Results: Sample #05-5432Test/100 g/ServingUnitsPepsin (0.2%) Digestible Protein98.134.3gramsTotal Trans Fatty Acid Isomers0.020.007gramsCholesterol0.01730.00605grams

As shown in Table 3 below, an elemental scan of the solid protein power indicates the following elements present in mg per serving. Also shown below in Table 3 is the amount of each element in parts per million.

TABLE 3CERTIFICATE OF ANALYSIS AMINOGRAMSample Identification:Sample #: 05-5432 Advance Protein Powder. Serving = 35 gMethod:AL194: Elemenlal Scan (65) by ICP MSResults: Sample #05-5432TestResultResultElemental(mcg/serving)(ppm)Lithium<35<1Boron<35<1Magnesium56,0001,600Phosphorus220,0006,400Calcium770,00022,000Titanium772.2Chromium912.6Iron4,600130Nickel<35<1Zinc2,07059Germanium<35<1Selenium912.6Strontium3,900110Zirconium<35<1Molybdenum<35<1Rhodium<35<1Silver<35<1IndiumNANAAntimony<35<1Cesium<35<1Lanthanum<35<1Praseodymium<35<1Beryllium<35<1Sodium70,0002,000Aluminum2,00056Potassium190,0005,500Scandium<35<1Vanadium<35<1Manganese1203.3Cobalt<35<1Copper1604.7AdvanceInternationalResultCorporationTest(mcg/serving)Result (ppm)Gallium<35<1Arsenic<35<1Rubidium491.4Yttrium<35<1Niobium<35<1Ruthenium<35<1Palladium<35<1Cadmium<35<1Tin<180<5Tellurium<35<1Barium631.8Cerium<35<1Neodymium<35<1Samarium<35<1Gadolinium<35<1Dysprosium<35<1Erbium<35<1

Table 4 shown below compares the nutritional content for 25 mg protein of one example of the recovered solid protein of the inventive process and system which subsequently has been milled into a powder “APP” versus 25 mg protein of commercial products on the market. APP is derived from fish. Specifically, APP has fewer calories than each of the commercial products except for NB soy. APP has fewer carbohydrates and fat than NB soy. Compared with JF soy, APP has fewer calories and less fat. Compared with each DFH whey, JF whey, GNC whey, Whey isolate and Whey concentrate, APP has fewer calories, carbohydrates, fat, saturated fat and cholesterol.

TABLE 4Standardized to 25 grams of protein per servingDFHJFGNCWheyWheyJFNBAPPwheywheywheyIsolateconcentratesoysoyCalories10013513113511312511091Protein25 g25 g25 g25 g25 g25 g25 g25 gCarbohydrate0 g3 g3 g4.2 g2.8 g3.1 g0 g0.7 gFat0 g2.1 g1.4 g2.1 g0.7 g1.6 g0.9 g0.2 gSaturated Fat:0 g2.1 g2.3 g1.0 g0.5 g1.0 g0 g0 gCholesterol0 g31.3 mg69.4 mg72.9 mg2.8 mg64.6 mg0 g0 g

Table 5 shown below compares chemical elements existing in 25 mg of one example of the recovered solid protein of the inventive process and system which subsequently has been milled into powder “APP” versus 25 mg protein of commercial products on the market. APP is derived from fish. Notably, the calcium, iron and zinc contents of 25 mg APP is significantly greater than for each of DFH whey, JF whey, GNC whey, Whey Isolate, Whey concentrate, JF soy and NB soy. The amount of iron present in APP is significantly greater than in each of DFH whey, JF whey, GNC whey, Whey isolate, and Whey concentrate.

TABLE 5Comparing mineral content per 25 gramsof protein as a percentage of the RDADFHJFGNCWheyWheyJFNBAPPwheywheywheyIsolateconcentratesoysoyCalcium55%12.5%9.0%8.3%18.8%2.9%5.0%Iron18.1%4.2%1.8%22.2%22.2%Magnesium10%3.5%2.8%Zinc9.8%6.7%Sodium2.1%2.0%1.7%2.6%2%2.3%0.6%Potassium4.6%4.6%3.7%5.7%8.7%3.7%10.6%12.9%Phosphorus18.4%21.3%8.9%29.3%,