NUTRIENT RICH COMPOSITIONS
This invention relates to processes and systems for converting fresh food waste into nutrient rich hydrolysates and particulate compositions. The invention also relates to the hydrolysates and compositions useful, for example, as fertilizers, feedstock or other nutrient supplements.
1 . A process for producing a nutrient rich composition from fresh food waste comprising the steps of:
(a) providing fresh food waste using a highly efficient and effective collection system;
(b) grinding the fresh food waste using a first grinder and optionally a second grinder to produce a fresh food waste particle slurry;
(c) incubating the fresh food waste particle slurry under constant agitation by adding to said fresh food waste particle slurry a combination of enzymes comprising at least one enzyme to digest proteins, at least one enzyme to digest fats and lipids, at least one enzyme to digest cellulosic material and at least one enzyme to digest other carbohydrates and incubating the mixture at two or more temperatures ranging between about 100° F. and 130° F., to match the temperature performance curves of the enzymes wherein a third grinder, comprising a high shear mixer, is used to create shear during at least part of the incubating, whereby a hydrolysate comprising incubated fresh food waste particles is produced;
(d) pasteurizing the hydrolysate to kill pathogens; and
(e) separating the hydrolysate into a liquid hydrolysate and incubated fresh food particles using a coarse screen and a fine screen.
2 . The process of claim 1 , wherein the combination of enzymes comprises at least one protease, at least one cellulase, at least one pectinase, at least one lipase, and α-amylase.
3 . The process of claim 1 , wherein step (d) further comprises adding a first enzyme combination comprising at least one cellulase, and at least one lipase to the particulate fresh food waste to form an incubating mixture and increasing the temperature to a first temperature between about 100° F. and 130° F.
4 . The process of claim 3 , wherein step (d) further comprises adding a second enzyme combination to the incubating mixture, comprising at least one pectinase, at least one protease, and α-amylase to the incubating particulate fresh food waste and increasing the temperature to a second temperature of about 110° F. to 130° F. to form a hydrolysate.
5 . The process of claim 4 , wherein the first enzyme combination comprises endocellulase, exocellulase and lipase, the first temperature is between about 100° F. and 130° F., and the incubating mixtures is held at the first temperature for at least about 30 minutes to about 1.5 hours.
6 . The process of claim 5 , wherein the incubating at the first temperature is about 30 minutes.
7 . The process of claim 5 , wherein the second temperature is between about 100° F. and 130° F. and is held for at least about 1.5 to 3 hours.
8 . The process of claim 5 , wherein the incubating at the second temperature is about 1.5 hours.
9 . The process of claim 1 , wherein the third grinder is an in-line grinder comprising a high shear mixer.
10 . The process according to claim 1 , wherein step (e) produces a liquid hydrolysate that is greater than about 85% by weight relative to the weight of the input incubating fresh food waste.
11 . The process according to claim 10 , wherein the separating of step (e) produces a liquid hydrolysate that is about 85% to about 95% by weight relative to the weight of the input incubating fresh food waste.
12 . The process according to claim 1 , wherein the grinding of step (c) produces particles in the particulate fresh food waste with an average size of less than about 1/16th of an inch.
13 . The process of claim 1 , wherein the first grinder is a rotary knife grinder.
14 . The process of claim 1 , wherein the second grinder is a low RPM/high torque grinder.
15 . The process according to claim 1 , wherein the separating of step (e) produces incubated fresh food particles greater in size than can pass through the coarse screen.
16 . The process according to claim 1 , wherein the fresh food particles produced in step (e) is used as an animal feedstock.
17 . The process according to claim 1 , further comprising the steps of:
(f) stabilizing and preserving the hydrolysate, using acid and/or preservatives, or using organic acids and/or organic preservatives allowed for use in the production of a certified organic hydrolysate;
(g) emulsifying the stabilized hydrolysate using an ultra-high-shear mixer to produce a stabilized, emulsified hydrolysate; and
(h) blending the emulsified hydrolysate in large storage tanks with circulation pumps, to assure the consistency of the finished product;
wherein the pH of the stabilized liquid hydrolysate is less than 4.0.
18 . The process according to claim 17 , wherein the emulsified hydrolysate produced in step (g) has an average particle size of less than or about 30 μm.
19 . The process according to claim 18 , wherein the emulsified hydrolysate produced in step (g) has an average particle size of about 30 μm.
20 . The process according to claim 17 , wherein the stabilizing of step (f) comprises addition and mixing of the liquid hydrolysate with an acid source consisting of one or more of hydrochloric, sulfuric, phosphoric, carbonic, acetic, stearic, propionic, tartaric, maleic, benzoic, succinic acids, lactic, or citric acid and one or more preservatives or organic preservatives.
21 . The process according to claim 17 , wherein the pH of the liquid hydrolysate is less than 4.0.
22 . The process according to claim 17 , wherein the pH of the stabilized liquid hydrolysate is about 2.5 to about 3.5
23 . The process according to claim 17 , wherein the pH of the stabilized liquid hydrolysate about 3.0.
24 . The process of claim 1 , wherein pathogens are inactivated.
25 . A method of processing fresh food waste as in claim 1 that generates negligible amounts of emissions, effluent, solid waste, and nuisance odors, and is conducted within a warehouse in a commercial and/or industrial zoned area, so that such facility may obtain all necessary government and regulatory permits and approvals to be able to operate in an urban area.
26 . An efficient and effective method of collecting fresh food waste before such material becomes putrescent, to allow processing the fresh food waste as in claim 25 , eliminating a long distance haul typical of hauling food waste to landfills.
27 . A method of processing fresh food waste as in claim 14 that generates negligible amounts of emissions, effluent, solid waste, and nuisance odors, and is conducted within a warehouse in a commercial and/or industrial zoned area, so that such facility may obtain all necessary government and regulatory permits and approvals to be able to operate in an urban area.