Method for producing hydrolysed keratinaceous material
The invention relates to a method for producing digestible keratinaceous material comprising the steps of hydrolysing keratinaceous material in the presence of water in a hydrolyser at elevated temperature and at a pressure between about 2 bar and about 15 bar, and drying the resultant hydrolysed keratinaceous material comprising at least partly insoluble material in a dryer at a temperature/time/pressure combination which limits the drop in pepsin and/or ileal digestibility by less than 10%, and/or such that the pepsin and/or ileal digestibility remains higher than 85%, or such that the pepsin and ileal digestibility remains higher than respectively 75% and 85%. Preferably, the drying of the resultant hydrolysed partly soluble keratinaceous material is performed in a dryer at a temperature such that the keratinaceous material remains at a temperature below 90° C., preferably below 80° C.
1. A method for producing digestible keratinaceous material, comprising the steps of hydrolysing keratinaceous material in the presence of water, in a hydrolyser with heat and at a pressure between about 2 bar and about 15 bar, and drying the hydrolysed keratinaceous material comprising at least partly insoluble material in a dryer at a temperature/time/pressure combination which limits the drop in pepsin and/or ileal digestibility by less than 10%, and/or such that the pepsin and/or ileal digestibility remains higher than 85%, or which limits the drop in pepsin and/or ileal digestibility by less than 10%, wherein the pepsin and ileal digestibility remain higher than respectively 75% and 85%, wherein an amount of more than about 2 tons of keratinaceous material is processed per hour and the drying method is not a non-stirred/non-moving drying method, and wherein the amount of insoluble material is 60 wt% or more if 100 g keratinaceous material is dissolved in 1000 mL of water at 20° C. and stirring for 15 min.
2. A method for producing digestible keratinaceous material, comprising the steps of hydrolysing keratinaceous material in the presence of water, in a hydrolyser with heat and at a pressure between about 2 bar and about 15 bar, and drying the hydrolysed keratinaceous material comprising at least partly insoluble material in a dryer at a temperature such that the keratinaceous material remains at a temperature below about 90° C., wherein an amount of more than about 2 tons of keratinaceous material is processed per hour and the drying method is not a non-stirred/non-moving drying method, and wherein the amount of insoluble material is 60 wt% or more if 100 g keratinaceous material is dissolved in 1000 mL of water at 20° C. and stirring for 15 min.
3. The method according to claim 1 , wherein the hydrolysis is performed in a continuous hydrolyser.
4. The method according to claim 1 , wherein the keratinaceous material is supplied to the hydrolyser with a moisture content of about 30 to about 80 wt% relative to the weight of moisture plus keratinaceous material.
5. The method according to claim 1 , wherein the dryer is a disc dryer processing at a pressure between about 10 and about 500 mbar (abs).
6. The method according to claim 1 , wherein the drying is performed in a flow of hot air.
7. The method according to claim 1 , wherein the dried digestible keratinaceous material has a moisture content of below about 12 wt%.
8. The method according to claim 2 wherein the drying step is performed at a temperature/time/pressure combination which limits the drop in pepsin and/or ileal digestibility by less than about 10%, and/or such that the pepsin and/or ileal digestibility remains higher than about 85%, or which limits the drop in pepsin and/or ileal digestibility by less than 10%, wherein the pepsin and ileal digestibility remain higher than respectively about 75% and about 85%.
9. The method according to claim 1 , wherein the drying step is performed at a temperature/time/pressure combination which limits the drop in pepsin and/or ileal digestibility by less than about 7%, and/or such that the pepsin and/ ileal digestibility remains higher than about respectively 80% and 90%.
10. The method according to claim 1 , wherein said method comprises separating a liquid phase containing solubilized proteins from the insoluble material in a press, and drying separately the liquid phase to obtain a product in powder form, having an ileal and/or pepsin digestibility of more than about 95%.
11. The method according to claim 1 , wherein said method comprises separating a liquid phase from the insoluble material in a press, centrifuging the liquid phase to separate an aqueous phase containing solubilized proteins, a fat phase and residuals solids, reincorporating the defatted aqueous phase and the residuals solids into the keratinaceous material and further drying the material to produce a low fat highly digestible feather meal.
12. The method according to claim 2 , wherein the hydrolysis is performed in a continuous hydrolyser.
13. The method according to claim 2 , wherein the keratinaceous material remains at a temperature below about 80° C.
14. The method according to claim 1 , wherein the drying is performed in a fluidized bed dryer, ring-type dryer, or rotating flash dryers with a flow of gas at a temperature of about 150° C. or lower.