SYSTEM FOR INTEGRATION INTO A FRUIT PROCESSING FACILITY
The system comprises one or more transportable bioreactors configured with the ability to conduct aerobic fermentation of fruit biomass. This system integrates three functionalities: transportation regulations, fermentation requirements and food safety/quality control requirements. The transportation design features of the system render the bioreactors transportable to a fruit processing facility, wherein they can be filled with fruit biomass. The transportable bioreactor and processes take into account the requirements of the bioreactor functionalities of the system, given the particular deployment specifications of the system tailored for a certain environment and fruit biomass. Moreover, the design of this system conforms to the minimal requirements for the food safety and quality regulations of the jurisdictions in which the ultimate products will be directly and/or indirectly sold (e.g., as a foodstuff, health supplement, and/or a food ingredient). The integration of these three types of functionalities (transport, bioreactor and sanitation) gives rise to a practical solution for addressing the various problems of wasted foodstuffs such as fruit biomass.
1 . A system comprising a transportable bioreactor configured for: a) transport via road, rail and/or a body of water, compliant with regulatory requirements; b) fermentation compliant with sanitation regulations; c) collecting fruit biomass at a fruit processing facility, and d) for initiating fermentation at a selected time starting after the fruit biomass is collected in the container, comprising:
a. a transportable bioreactor comprising a food-grade container configured for fermentation; accessibility for filling, emptying and monitoring and cleaning, further comprising:
i. means to exclude external contamination; and
ii. means to prevent spillage during transport.
2 . The system of claim 1 , further comprising means for introducing a microbial formulation to initiate fermentation of the biomass in the transportable bioreactor at a selected time.
3 .- 6 . (canceled)
7 . The system of claim 1 , wherein the fruit processing facility is a winery.
8 . The system of claim 1 , further comprising system monitoring means.
9 . A process for collecting fruit biomass at a fruit processing facility within a transportable aerobic bioreactor, comprising the steps of:
providing a transportable aerobic bioreactor at a fruit processing facility;
transferring fruit biomass into the transportable aerobic bioreactor at the fruit processing facility;
inoculating the fruit biomass within the bioreactor with a microbial formulation;
aerobically fermenting the inoculated biomass in the bioreactor until the acidity is at or below pH 4.0;
transporting the bioreactor at a selected time after aforesaid step b, from the fruit processing facility to a processing facility for further processing into a product.
10 . The process of claim 9 , wherein the microbial formulation comprises Acetobacter , and/or Gluconobacter.
11 . The process of claim 9 , wherein the microbial formulation comprises one or more strains of yeast that can ferment under aerobic, microaerophilic and/or anaerobic conditions.
12 . The process of claim 9 , wherein enzymes are added to the bioreactor.
13 . The product produced by the process of claim 9 .
14 . The process of claim 9 , wherein the fruit processing facility is a winery.
15 . The process of claim 9 wherein the fruit biomass comprises marc with berries and the process additionally incorporates lees derived from a winemaking process, further comprising the steps of:
a. grinding the hydrated fruit biomass comprising marc in the bioreactor to generate meal;
b. inoculating the meal in the bioreactor with a microbial formulation;
c. fermenting the inoculated meal in the bioreactor to generate a fermenting meal.
16 . The process according to claim 15 , additionally, after step a, hydrating said fruit biomass comprising marc in the bioreactor until berries swell.
17 . The process according to claim 15 , additionally
introducing lees into the bioreactor;
emulsifying the lees and fermenting meal in the bioreactor to generate a puree;
transporting the bioreactor to a processing facility where the puree is refined to generate a nutrient-rich product;
whereby methane emissions that would otherwise be caused by disposal of fruit biomass in landfills are significantly reduced or eliminated.
18 . The process of claim 17 , wherein the lees are first-rack lees.
19 . The process of claim 17 , further comprising the steps of inoculating the puree in the bioreactor and fermenting the inoculated puree to generate a fermented puree in the bioreactor.
20 . The process of claim 19 , further comprising the step of refining the fermented puree to generate a refined nutrient-rich product.
21 . The process of claim 20 , further comprising the steps of stabilizing the refined nutrient-rich product to generate a stabilized nutrient-rich product, and then packaging the stabilized nutrient-rich product.
22 . The process of claim 17 , wherein the microbial formulation comprises acetic acid bacteria and/or fungus inoculant.
23 . The process of claim 22 , wherein the microbial formulation comprises Acetobacter , and/or Gluconobacter.
24 . The process of claim 15 , wherein enzyme is added to the fermenting meal.
25 - 34 . (canceled)