Continuous Fermentation Process for Meat Curing Agents
In some aspects, the present disclosure provides an advantageous process for preparing meat curing agents. In some embodiments, a process for continuous conversion of plant-based nitrates to nitrites includes: inoculating a source material liquid comprised of nitrates with a bacterial culture capable of converting nitrates to nitrites; when nitrites in the source material liquid reach a desired concentration, harvesting a first harvest volume of the source material liquid at a harvest rate; and replenishing the harvested volume of the source material liquid with source material liquid comprising additional nitrates at a feed rate, wherein the harvest rate is higher than the feed rate.
1 . A system comprising:
a fermentation tank configured to hold a source material liquid comprising plant-based nitrates, the fermentation tank having an inlet configured to provide the source material liquid to the fermentation tank and outlet configured to withdraw the source material liquid from the fermentation tank;
a processor being programmed to:
receive a conversion data to monitor conversion of the plant-based nitrates to nitrites with a bacterial culture;
when nitrites in the source material liquid reach a desired concentration, cause a first harvest volume of the source material liquid to be harvested at a harvest rate; and
cause the first harvest volume of the source material liquid to be replenished with the source material liquid comprising additional plant-based nitrates at a feed rate, wherein the harvest rate is higher than the feed rate.
2 . The system of claim 1 , wherein the processor is further programmed to:
determine a rate of conversion of plant-based nitrates to nitrites;
calculate a time for desired conversion (Tconversion) of plant-based nitrates to nitrites based on an initial concentration of plant-based nitrates in the source material liquid and the rate of conversion;
calculate the first harvest volume based on a total volume of the source material liquid and T conversion; and
calculate the feed rate based on the first harvest volume and a harvest time.
3 . The system of claim 1 , wherein the processor is further programmed, if a concentration of plant-based nitrates in the first harvest volume is lower than the desired concentration of nitrites, to cause a decrease in the feed rate, cause a decrease in the first harvest volume, or cause an increase in harvest time.
4 . The system of claim 2 , wherein the processor is further programmed to cause an adjustment in one or more of the first harvest volume, harvest rate and feed rate to maintain a maximum conversion rate of plant-based nitrates to nitrites.
5 . The system of claim 1 , wherein the processor is further programmed to determine a rate of conversion of plant-based nitrates to nitrites and cause an allowance of the rate of conversion to become a maximum conversion rate of plant-based nitrates to nitrites for the bacterial culture before harvesting a first harvest volume.
6 . The system of claim 1 , wherein the harvest rate is between 5 and 50 times faster than the feed rate.
7 . The system of claim 1 , wherein the first harvest volume is between 40 and 60% of an initial volume of the source material liquid.
8 . A system for continuous production of a curing agent, the system comprising:
a fermentation tank configured to hold a source material liquid comprising plant-based nitrates, the fermentation tank having an inlet configured to provide the source material liquid to the fermentation tank and outlet configured to withdraw the source material liquid from the fermentation tank;
a processor being programmed to:
receive a conversion data to monitor conversion of plant-based nitrates in a source material liquid to nitrites using a bacterial culture;
when the nitrites in the source material liquid reach a desired concentration, cause a first harvest volume of the source material liquid to be harvested at a harvest rate; and
cause the first harvest volume of the source material liquid to be replenished with additional source material liquid comprising additional plant-based nitrates at a feed rate, wherein the harvest rate is between 3 and 100 times faster than the feed rate.
9 . The system of claim 8 , wherein the processor is further programmed to:
determine a rate of conversion of plant-based nitrates to nitrites;
calculate a time for desired conversion (Tconversion) of plant-based nitrates to nitrites based on an initial concentration of plant-based nitrates in the source material liquid and the rate of conversion;
calculate the first harvest volume based on a total volume of the source material liquid and T conversion; and
calculate the feed rate based on the first harvest volume and a harvest time.
10 . The system of claim 8 , wherein the processor is further programmed, if a concentration of plant-based nitrates in the first harvest volume is lower than the desired concentration of nitrites, to cause a decrease in the feed rate, cause a decrease in the first harvest volume, or cause an increase in harvest time.
11 . The system of claim 9 , wherein the processor is further programmed to cause an adjustment in one or more of the first harvest volume, harvest rate and feed rate to maintain a maximum conversion rate of plant-based nitrates to nitrites.
12 . The system of claim 8 , wherein the processor is further programmed to determine a rate of conversion of plant-based nitrates to nitrites and cause an allowance of the rate of conversion to become a maximum conversion rate of plant-based nitrates to nitrites for the bacterial culture before harvesting a first harvest volume.
13 . The system of claim 8 , wherein the harvest rate is between 5 and 50 times faster than the feed rate.
14 . The system of claim 8 , wherein the first harvest volume is such that at least 30% of the bacterial culture remains in the source material liquid.
15 . The system of claim 8 , wherein the first harvest volume is between 40 and 60% of an initial volume of the source material liquid.
16 . A system for continuous production of a curing agent, the system comprising:
a fermentation tank configured to hold a source material liquid comprising plant-based nitrates, the fermentation tank having an inlet configured to provide the source material liquid to the fermentation tank and outlet configured to withdraw the source material liquid from the fermentation tank;
a processor being programmed to:
receive a conversion data to monitor conversion of plant-based nitrates in a source material liquid to nitrites using a bacterial culture;
when the nitrites in the source material liquid reach a desired concentration, cause a first harvest volume of the source material liquid to be harvested at a harvest rate; and
cause the first harvest volume of the source material liquid to be replenished with additional source material liquid comprising additional plant-based nitrates at a feed rate, wherein the harvest rate is higher than the feed rate, and wherein the first harvest volume is such that at least 30% of the bacterial culture remains in the source material liquid.
17 . The system of claim 16 , wherein the processor is further programmed to:
determine a rate of conversion of plant-based nitrates to nitrites;
calculate a time for desired conversion (Tconversion) of plant-based nitrates to nitrites based on an initial concentration of plant-based nitrates in the source material liquid and the rate of conversion;
calculate the first harvest volume based on a total volume of the source material liquid and T conversion; and
calculate the feed rate based on the first harvest volume and a harvest time.
18 . The system of claim 16 , wherein the processor is further programmed, if a concentration of plant-based nitrates in the first harvest volume is lower than the desired concentration of nitrites, to cause a decrease in the feed rate, cause a decrease in the first harvest volume, or cause an increase in harvest time.
19 . The system of claim 17 , wherein the processor is further programmed to cause an adjustment in one or more of the first harvest volume, harvest rate and feed rate to maintain a maximum conversion rate of plant-based nitrates to nitrites.
20 . The system of claim 16 , wherein the processor is further programmed to determine a rate of conversion of plant-based nitrates to nitrites and cause an allowance of the rate of conversion to become a maximum conversion rate of plant-based nitrates to nitrites for the bacterial culture before harvesting a first harvest volume.
21 . The system of claim 16 , wherein the harvest rate is between 5 and 50 times faster than the feed rate.
22 . The system of claim 16 , wherein the first harvest volume is between 40 and 60% of an initial volume of the source material liquid.
23 . The system of claim 16 , wherein the harvest rate is based on the feed rate, a rate of replenishing the bacterial culture, or a combination thereof.