Process for producing a bio-inactve and shelf stable biomass matter derived from bioactive biomass feedstock
A process for producing a bio-inactive and shelf stable biomass matter derived from bioactive biomass feedstock includes processes that can be performed in an effective way with equipment that does not require large expenditures. The biomass feedstock may be dewatered and then stabilized to prevent degradation. The stabilized biomass may then be back blended with a dried back blending biomass having a water concentration of less than 10% and a particle size that produces back blended biomass that can be effectively processed by controlled agitation drying wherein the thickness is maintained at less than 100 mm while an airflow is formed over the back blended biomass and shear mechanical energy is imparted. The entire process may be performed in less than 12 hours to produce a shelf-stable dried biomass.
1 . A process for producing a bio-inactive and shelf stable biomass matter derived from bioactive biomass feedstock comprised of the following:
a) providing said bioactive biomass feedstock comprising:
i) an original protein concentration of between 2.5% and 66% by weight of the bioactive biomass feedstock;
ii) an original fat concentration of between 2.5% and 66% by weight of the bioactive biomass feedstock; and
iii) an original water concentration of between 20% and 90% by weight of the bioactive biomass feedstock;
b) stabilizing the bioactive biomass feedstock by adding an antioxidant at a dosing concentration of 2.0 to 20,000 parts per million by weight of the bioactive biomass feedstock to said bioactive biomass feedstock to produce a stabilized biomass wherein the fat is stabilized to prevent oxidation and to minimize free fatty acid creation to less than 50% by weight of the original fat concentration of the bioactive biomass feedstock;
c) providing a blending dried biomass, having a particle size between 10 and 20,000 microns;
d) back blending the stabilized biomass by mixing with the back-blending dried biomass at a back blending ratio by weight of said blending dried biomass to said stabilized biomass to produce a back blended biomass having a water concentration by weight that is 75% or less than said original water concentration of the bioactive biomass feedstock so that the biological activity does not consume the bioactive biomass feedstock via aerobic degradation processes and
e) controlled drying of the back blended biomass by producing controlled drying environment conditions including producing an airflow over the back blended biomass, maintaining a humidity level of between 5% and 100%, and maintaining a temperature of the back blended biomass between 10° C. (50° F.) and 71.1° C. (160° F.) over at least 50% of the drying time to produce said bio-inactive and shelf stable biomass matter having a final water concentration of no more than 10% by weight;
wherein a total duration time for processing said bioactive biomass feedstock in step a) to said bio-inactive and shelf stable biomass matter in step e) is controlled to less than 12 hours so that the bioactive biomass feedstock is not consumed by aerobic degradation processes.
2 . The process of claim 1 , wherein the controlled drying of the back blended biomass further includes agitation of the back blended biomass by imparting shear mechanical energy while producing said controlled drying environment conditions.
3 . The process of claim 2 , further comprising providing a shear aerator and wherein the shear mechanical energy is imparted to the back blended biomass using said shear aerator.
4 . The process of claim 1 , further comprising bulk dewatering the bioactive biomass feedstock to reduce the original water concentration of the bioactive biomass feedstock to no more than 75% by weight of the original water concentration of the bioactive biomass feedstock.
5 . The process of claim 4 , wherein bulk dewatering includes decanting the bioactive biomass feedstock to remove water from the bioactive biomass feedstock.
6 . The process of claim 4 , wherein bulk dewatering includes centrifuging the bioactive biomass feedstock to remove water from the bioactive biomass feedstock.
7 . The process of claim 4 , wherein bulk dewatering includes pressing the bioactive biomass feedstock to remove water from the bioactive biomass feedstock.
8 . The process of claim 4 , wherein bulk dewatering includes adding dewatering compounds to the bioactive biomass feedstock to remove water from the bioactive biomass feedstock.
9 . The process of claim 4 , wherein bulk dewatering includes exposing the bioactive biomass feedstock to electro-coagulation to remove water from the bioactive biomass feedstock.
10 . The process of claim 1 , wherein the blending dried biomass has an average particle size of between 100 and 10,000 microns.
11 . The process of claim 1 , wherein the controlled drying of the back blended biomass includes spreading the back blended biomass on a surface forming a spread thickness of the back blended biomass of no more than 15 cm.
12 . The process of claim 11 , wherein the surface is configured within a non-planar enclosure and wherein the controlled drying environment conditions are controlled within said enclosure.
13 . The process of claim 11 , wherein the surface is a radiant surface comprising a heating element to heat said radiant surface.
14 . The process of claim 1 , wherein the airflow during the controlled drying is maintained between 15.24 m/min (50 fpm) and 305 m/min (1000 fpm).
15 . The process of claim 1 , wherein the airflow during the controlled drying is maintained between 10° C. and 149° C. (50° F. and 300° F.).
16 . The process of claim 1 , wherein the airflow during the controlled drying is turbulent airflow.
17 . The process of claim 1 , wherein the airflow during the controlled drying consists substantially of nitrogen, having at least a 90% concentration of nitrogen by volume.
18 . The process of claim 1 , wherein the bioactive biomass feedstock comprises an animal-based feedstock stream.
19 . The process of claim 1 , wherein the bioactive biomass feedstock comprises a plant-based coproduct stream.
20 . The process of claim 1 , wherein the controlled drying includes particle sizing through acoustic or ultrasonic pulses.
21 . The process of claim 1 , wherein the controlled drying includes using scavenged heat from the controlled drying.