RU2802471C1 - Method for manufacturing biodegradable molds and application of the method for disposal of beer production waste - Google Patents

Abstract

FIELD: food industry.

SUBSTANCE: invention is related in particular to disposal of brewery waste. The method of production of a biodegradable moulded product with creation of water vapor pressure inside the composite mould includes the division of brewer's grains into two uneven parts, and the first smaller part is used without processing, with natural moisture content, the second larger part is subjected to a drying process until the moisture content is 0.1 to 20%, while the first part in an amount of from 1 to 10% of the measured volume is placed at the bottom of the mould heated to 140°C, then the second part of the material used is added there in the amount of the remaining volume, after which the upper part of the mould, heated to 140°C, is closed, and pressing is carried out for 3-7 seconds with a pressure of 1 to 100 t/cm² with a simultaneous increase in the temperature of the mould in the range from 140 to 250°C, after which the mould is opened and the finished product is taken out.

EFFECT: invention makes it possible to dispose of brewery production waste (brewer's grains).

3 cl, 2 ex

Description

The object of this invention is the production of biodegradable molded products, including disposable tableware, with the creation of water vapor pressure inside the composite form, from brewing waste - beer grains, which are recycled as a result of this process. In this case, the beer grains are divided into two uneven parts, the proportion of which is determined based on the degree of moisture of the grains in the initial state and after the drying process, after which a mixture of two parts of beer grains is pressed under high pressure and heat, resulting in a finished product. Due to the fact that the proposed method does not use synthetic additives, the resulting disposable tableware has good biodegradability without causing damage to the environment.

There are known methods for producing biodegradable tableware.

There are known methods according to patent RU 2309652 C2 (KR 10-2003-0051269) for producing biodegradable molded tableware from plant materials. The dishes are made by molding by compressing at high temperature a composition containing 1-30 wt. % crop residues, 1-30 wt. % corn flour, 1-10 wt. % paper mulberry bark, 1-10 wt. % moss and 30-96 wt. % mixture of cereal grain flour as the remainder.

The disadvantage of using this method is the low economic feasibility of using valuable food raw materials (wheat and corn flour) for the production of disposable tableware, which is quite expensive and in demand in the food industry, as well as the limited availability of some components, such as moss and mulberry bark.

There is a known method for producing biodegradable tableware from a mixture of components according to the invention patent RU 2760306. This method of producing biodegradable tableware is achieved by preparing the composition as follows: adding potato starch and gelatin dissolved in water to the crushed wheat bran, brought to a homogeneous state in a water bath mixing states in a certain sequence with the following ratio of components, in% of the total mass of the composition: water - 50, wheat bran - 25, potato starch - 15, gelatin - 10. The disadvantage of this method is the use of relatively expensive food raw materials: gelatin, starch, bran. Due to constant competition with the food industry for these raw materials, the economic feasibility of this method is severely limited.

There is a known method for producing biodegradable tableware from a mixture of components according to the invention patent RU 2725039 C1. This method of producing biodegradable tableware is achieved by molding a mixture of grain meal with a particle size from 0.2 to 3.00 mm in an amount of (95-98) wt. %, having a moisture content of no more than 9%, and crushed biodegradable film in an amount of (2-5) wt. %, consisting of the following components, wt. %: potato starch - (4.2-5.0), sodium alginate - (0.1-0.8), glycerin - (5.0-20.0), distilled water - the rest, in a mold at heat and pressure.

The disadvantage of this method is the labor-intensive process of creating a biodegradable film, as well as the use of food raw materials - bran, which is actively used in the food industry and the production of animal feed, which economically increases the cost of manufactured products.

The closest to the invention is a method for producing biodegradable molded products, in particular tableware and packaging (invention patent EP 027907 B1, IPC D21J 1/00, D21J 3/00, published 09.29.2017). This method of producing biodegradable molded products involves the use of water vapor pressure inside the composite mold to mix bulk components with granule sizes from 0.01 to 2.80 mm in an amount of 95-100 wt. % containing more than 14 wt. % water. Placing the prepared mixture in a special mold, closing the mold and then simultaneously exposing the mixture to a temperature of 120°C or higher and a pressure from 1 to 10 MPa.

A limitation of the use of this method is the high involvement of bran in the production of food products, as a result of competition with which for raw materials, the economic feasibility of using bran as a raw material for the production of disposable tableware is reduced.

The technical problem according to the invention is solved due to the fact that the production of molded products from beer production waste - beer grains - begins with dividing the feedstock into two uneven parts: the first, smaller part is left without any processing, the second, larger part is subjected to drying (mechanical , thermal, or combinations thereof). The proportion of filling into the mold of the first and second parts is determined based on the humidity of each part. The first part of a smaller amount, without any pre-treatment of natural moisture, is placed in an amount of no more than 30% (depending on the moisture content of the feedstock) of the measured volume in a preheated from 100 ° C in the lower part of the mold, consisting of two parts, after which up to 99% of the measured volume (depending on the moisture content of the raw materials) is placed the second part of the dried beer grains to a moisture content of 0 to 30%, after which the mold is closed, and by creating a pressure of up to 100 t/cm2 while simultaneously heating the mold to 250° Molding is carried out. The moisture contained in grains of natural humidity from the action of temperature and pressure instantly boils and steams the entire volume of grains in a composite form. As a result of the influence of two factors: steam and pressure, a product is formed that is suitable for use as disposable tableware. The pressing process itself lasts 3-7 seconds, after which you can open the mold and remove the finished product.

Also the object of this invention is a method for recycling beer production waste - beer grains by producing biodegradable molded products.

There are several known methods for recycling spent grains:

- A method for processing beer grains into dry food. The limitation for the use of this technology is the short shelf life of pellets, and the associated risks of the formation of mycotoxins that cause liver damage in animals.

- Method of using brewer's grains in biogas production. The limitation to the use of this technology is the volume of grain produced sufficient for economically viable gas production.

- A method for processing brewer's grains by hydrolysis to obtain solutions of sugars and their subsequent use, for example, to obtain xylitol (invention patent RU 2109059 C1). The limitation of using this method is the complexity of organizing the technological process.

The proposed invention for the production of molded products from beer grains solves three important problems at once:

1. Disposal of beer production waste, which, when placed in a landfill, decomposes for more than 50 years, causing significant harm to the environment

2. Production of biodegradable disposable tableware that does not harm the environment, which is a replacement for plastic polymer products for the same purpose

3. Use of cheap and available raw materials. Beer is produced in almost all countries of the world, so spent grains as a raw material are found everywhere. And the very low demand for spent grains in industry, and as a consequence the lack of high demand for it, makes this raw material accessible and cheap.

This method for producing disposable tableware according to the invention can use used ground coffee as a raw material, resulting in the recycling of this type of waste.

Example 1.

Both parts of the mold are heated to a temperature of 140°C, after which beer grains are added in an amount of 3% of the mass without preliminary preparation, the rest of the grain, pre-dried to a moisture content of 9%, is immediately poured in, the mold is closed while simultaneously heating to a temperature of 150°C, pressing occurs with a force of 25 t/cm2. The compression lasts 3-5 seconds, after which the mold opens and the finished product is taken out.

Example 2.

Both parts of the mold are heated to a temperature of 140°C, after which used ground coffee is added in an amount of 6% of the mass without preliminary preparation, the rest of the used coffee dried to a moisture content of 7% is immediately poured in, the mold is closed while simultaneously heating to a temperature of 190°C occurs pressing with a force of 25 t/cm2. Pressing continues for 3-5 seconds, after which the mold opens and the finished product is taken out.

Claims (3)

1. A method for manufacturing a biodegradable molded product with the creation of water vapor pressure inside the composite mold, in which beer production waste is used as a raw material - beer grains, which are divided into two uneven parts, and the first part in a smaller size is used without treatment - natural humidity, the second a larger part is subjected to a drying process to a moisture content of 0.1 to 20%, while the first part in an amount of 1 to 10% of the measured volume is placed in the lower part of the mold heated to 140°C, then the second part of the material used is added there in the amount of the remaining volume, after which the upper part of the mold, heated to 140°C, is closed and pressing is performed for 3-7 seconds with a pressure from 1 to 100 t/ ^cm2 while simultaneously increasing the temperature of the mold in the range from 140 to 250°C , after which the mold is opened and the finished product is taken out. 2. The method of claim 1, wherein the biodegradable molded article is a biodegradable disposable tableware. 3. Application of the method according to claim 1 for the disposal of waste, which is beer grains.