U.S. patent application number 15/289699 was filed with the patent office on 2017-01-26 for method for separating lean beef and fat.
This patent application is currently assigned to SafeFresh Technologies, LLC. The applicant listed for this patent is SafeFresh Technologies, LLC. Invention is credited to Anthony J.M. Garwood.
Application Number | 20170020175 15/289699 |
Document ID | / |
Family ID | 48223860 |
Filed Date | 2017-01-26 |
United States Patent
Application |
20170020175 |
Kind Code |
A1 |
Garwood; Anthony J.M. |
January 26, 2017 |
METHOD FOR SEPARATING LEAN BEEF AND FAT
Abstract
A method for the separation of fat from meat. The method
includes transferring a mixture through a conduit, wherein the
mixture comprises lean particles with frozen water, fat particles,
and a fluid, allowing the frozen water in the lean particles to
thaw as the mixture travels through the conduit, and increases a
density of the lean particles, accumulating the lean particles with
non-frozen water at a first elevation in the conduit, and
accumulating fat particles at a second elevation in the conduit,
wherein the first elevation is lower than the second elevation.
Inventors: |
Garwood; Anthony J.M.;
(Mercer Island, WA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SafeFresh Technologies, LLC |
Mercer Island |
WA |
US |
|
|
Assignee: |
SafeFresh Technologies, LLC
Mercer Island
WA
|
Family ID: |
48223860 |
Appl. No.: |
15/289699 |
Filed: |
October 10, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13490222 |
Jun 6, 2012 |
9462824 |
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15289699 |
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13024178 |
Feb 9, 2011 |
9497985 |
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13490222 |
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61493876 |
Jun 6, 2011 |
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61302802 |
Feb 9, 2010 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A23L 13/60 20160801;
A22C 17/00 20130101; A23B 4/06 20130101; A22C 17/08 20130101; A23D
9/02 20130101; A23L 13/67 20160801; A23V 2002/00 20130101; A22C
17/04 20130101; A23D 9/00 20130101; A23L 13/00 20160801; A23B 4/08
20130101; A23B 4/09 20130101 |
International
Class: |
A23L 13/60 20060101
A23L013/60; A23D 9/02 20060101 A23D009/02; A22C 17/08 20060101
A22C017/08; A23B 4/09 20060101 A23B004/09 |
Claims
1. A method for separating lean from fat, comprising: (a)
transferring a mixture through a conduit, wherein the mixture
comprises lean particles with frozen water, fat particles, and a
fluid; (b) allowing the frozen water in the lean particles to thaw
as the mixture travels through the conduit, and increases a density
of the lean particles; (c) accumulating the lean particles with
non-frozen water at a first elevation in the conduit, and
accumulating fat particles at a second elevation in the conduit,
wherein the first elevation is lower than the second elevation.
2. The method of claim 1, further comprising transferring the
accumulated lean particles through a conduit branch connected to
the conduit, wherein the accumulated lean particles transferred in
the conduit branch comprise a majority of the lean particles in the
mixture.
3. The method of claim 1, further comprising transferring the
accumulated fat particles through a conduit branch connected to the
conduit, wherein the accumulated fat particles transferred in the
second conduit branch comprise a majority of the fat particles in
the mixture.
4. The method of claim 1, further comprising transferring a portion
of the mixture through a conduit branch connected to the conduit,
wherein the mixture in the conduit branch comprises a greater
percent by weight of fluid than fat and lean.
5. The method of claim 1, wherein the lean particles and the fat
particles in the mixture in the conduit prior to thawing of the
frozen water have a substantially similar density that prevents the
lean particles and the fat particles from accumulating at different
elevations.
6. The method of claim 1, further comprising adding carbonic acid
solution to the mixture before step (a).
7. The method of claim 1, wherein the fluid has a temperature
higher than the freezing point of water.
8. The method of claim 1, wherein the mixture further comprises
bones, and allowing the bones to separate from the mixture before
the thawing of water.
9. The method of claim 8, wherein the conduit comprises a vertical
section and a horizontal section, and the bones are separated at a
bend from the vertical section to the horizontal section.
10. The method of claim 1, further comprising, before step (a),
applying pressure to pieces of beef comprising both fat matter and
lean matter to produce the lean particles and the fat particles in
the mixture.
11. The method of claim 10, further comprising, before applying
pressure, chilling the pieces of beef to a temperature at which the
fat matter becomes brittle and can crumble and separate from the
lean matter upon the application of pressure.
12. The method of claim 1, further comprising emulsifying the
accumulated fat particles.
13. The method of claim 1, further comprising collecting the
accumulated lean particles and centrifuging the lean particles to
separate fluid.
14. The method of claim 1, wherein the conduit has an aspect ratio
defined as the cross-sectional width divided by the cross-sectional
height, and the aspect ratio decreases along the length of the
conduit from a proximal side to a distal side.
15. A method of separating a high vapor pressure fluid from beef,
comprising: (a) in an apparatus comprising a vessel, and a piston
disposed within the vessel, wherein a space is provided adjacent to
the piston, adding a high vapor pressure fluid with beef in the
space; and (b) moving the piston to compress the space to separate
the fluid from the beef, wherein the fluid is compressed at a
pressure to prevent evaporation and freezing of the beef.
16. The method of claim 15, wherein the apparatus comprises a
second piston, wherein the pistons are disposed opposite to each
other, and the pistons are moved together to compress the space to
separate the fluid from the beef.
17. The method of claim 15, wherein the high vapor pressure fluid
does not exist as a liquid at 1 atmosphere and 20.degree. C.
18. The method of claim 15, wherein the fluid is carbon
dioxide.
19. The method of claim 15, wherein the apparatus further comprises
a space behind the piston, wherein the space adjacent to and behind
the piston are in communication, and the fluid is transferred
behind the piston during compression.
20. A method for producing a beef product having a predetermined
fat content, comprising: (a) transferring a mixture through a
conduit, wherein the mixture comprises lean particles, fat
particles, and a fluid; (b) transferring a first portion of the
mixture having accumulated lean particles through a first conduit
branch connected to the conduit, wherein the portion of the mixture
transferred in the first conduit branch has a majority of the lean
particles in the mixture; (c) transferring a second portion of the
mixture having accumulated fat particles through a second conduit
branch connected to the conduit, wherein the portion of the mixture
transferred in the second conduit branch has a majority of the fat
particles in the mixture; (d) measuring the first portion of the
mixture having the accumulated lean particles in the first conduit
branch and determining a content of fat in the first portion; (e)
comparing the content of fat in the first portion with a target fat
content; and further performing (f1) or (f2): (f1) increasing the
massflow of the second portion of the mixture through the second
conduit branch to decrease the fat content of the first portion of
the mixture in the first conduit branch; or (f2) decreasing the
massflow of the second portion of mixture through the second
conduit branch to increase the fat content of the first portion of
the mixture in the first conduit branch.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. patent
application Ser. No. 13/490,222, filed Jun. 6, 2012 (now U.S. Pat.
No. 9,462,824), which claims the benefit of U.S. Provisional
Application No. 61/493,876, filed Jun. 6, 2011, and which is a
continuation-in-part of U.S. application Ser. No. 13/024,178, filed
Feb. 9, 2011, which claims the benefit of U.S. Provisional
Application No. 61/302,802, filed Feb. 9, 2010. All applications
are fully incorporated herein expressly by reference.
BACKGROUND
[0002] During the process of boning a carcass, and particularly a
beef carcass such as a steer or cow, the tallow and fat often
referred to as "trim" is removed. Other "trim" is cut from primal
beef portions during the slicing and disassembly process of
carcasses that is required during preparation of small cuts for
human consumption. During these processes, a significant amount of
lean beef can be cut from the carcass and carried away with the fat
and/or tallow. Lean beef comprises predominantly muscle protein,
although some amounts of fat and tallow are present, while fat and
tallow comprise predominantly glycerides of fatty acids with
connective tissue and collagen and are the predominant constituents
of plant and animal fat. The lean beef content in trim may be as
high as 45% to 50% by weight or higher. Presently, trim has little
use except for sausage production, or alternatively the fat may be
rendered.
[0003] A need therefore exists to more efficiently separate the
lower value tallow with fat from the higher value lean beef
contained in trim and to more effectively kill, reduce, or
completely remove the microbial pathogenic population and to
eliminate sources of cross contamination and recontamination, while
also producing a ground beef product of specific fat content.
SUMMARY
[0004] Disclosed are methods relating to the reduction in the
tallow content and/or the separation of tallow and/or fat from
materials, particularly in foods for human consumption, including
fresh, uncooked meats and in particular beef. Tallow comprises
natural proportions of fat, collagen, and connective tissue.
Disclosed herein is a method and apparatus for separating lean
matter from fat contained within the lean without destruction of
the muscle striations.
[0005] In one embodiment, the method includes reducing the
temperature of at least the fat component of the beef to a
temperature causing solidification of the fat and to a brittle
condition so that when a crushing action is applied to the
temperature-reduced pieces of beef, the crushing force is
sufficient to cause fracturing and the substantial disintegration
or fragmentation of the fat matter into small fat particles or
fragments that readily fall away from the lean, but without
significantly damaging the lean matter. The temperature-reduced and
crushed stream of fat and lean particles can then be transferred to
a vibratory separator, which can separate a portion of the fat
particles while agitating and shaking the larger lean pieces so as
to cause even more fat particles to separate from the larger lean
pieces. Then, the separated fat particles and larger lean pieces
can be combined with a fluid that comprises carbon dioxide and/or
water to form carbonic acid. The fat and lean matter with fluid are
transferred into to a vessel. The beef and the fluid are agitated
in the vessel to allow temperature equilibration above the freezing
point of water. The beef comprises relative lower amounts of less
dense (fat) and higher amounts of more dense (lean) matter, which
includes a greater quantity of frozen water. The heavy matter that
is predominantly lean beef when at least water partially unfreezes,
such that its density increases to a value above 62.4 lbs per cubic
foot and can then settle to the bottom of the fluid, and the light
matter that is predominantly tallow and fat can rise toward the
surface of the fluid. The separated matter comprising predominantly
lean beef can be removed from the fluid as a reduced tallow and fat
content beef product. The method can be practiced with any material
containing fat, not just beef, including plants and animals.
[0006] The fluid can include carbon dioxide and water. When
pressurized, the fluid can have a pH of about 3 or higher, or even
lower, such that when the beef is blended in the fluid for a period
of time, any bacteria that is present at the beef surfaces is
either killed or injured. Furthermore, the processing of the beef
in a substantially all carbon dioxide environment around the beef
extends the shelf life of the beef by at least displacing oxygen
from contacting the beef surfaces.
[0007] A first embodiment is related to a method for dividing a
quantity of food such as beef into components of fat and lean; and
may also separate bone fragments from the beef. The method includes
slicing, dicing, flaking and/or chipping beef into smaller beef
pieces and freezing the beef pieces, with or without bone
fragments, by reducing the temperature to below 29.5.degree. F. In
one embodiment, the temperature is low enough to freeze or
partially freeze the water in the beef, and in any event, the
temperature is low enough to cause the density of the beef to
decrease due to the expansion of water when chilled to a certain
temperature. The beef may be combined with fluid having a
temperature above 32.degree. F., in a vessel, allowing bone
fragments to sink to the bottom of the fluid before the temperature
of the beef increases to above the freezing point of water. In any
event, the bone fragments may be separated while the density of the
beef is less or nearly equal to the density of the fluid, such that
bone is capable of sinking in the fluid, but, not the beef. After
the bone has been separated, the temperature of the beef is allowed
to increase, and, with a temperature increase, the density of the
beef also increases due to the volume contraction, mainly by
thawing of water contained in the beef. At this point, the density
of the beef increases greater than the density of the fluid, such
that the denser lean particles sink to a lower region but above the
bone, while fat particles can rise to the upper region of the
fluid. Thereafter, once lean (beef) particles sink and fat
particles rise in the fluid, the respective particles are
collected, resulting in a beef product high in lean, a fat product
that can be rendered into tallow, and lean beef solids, through
emulsification, heating, pasteurization, and centrifugation.
[0008] A second embodiment is related to a method for separating
fat from lean in beef (meat) by fracturing frozen, size reduced,
beef pieces that comprise a fat component and a lean component. The
method includes providing a quantity of boneless beef and then
slicing, dicing, flaking and/or chipping the boneless beef pieces
into smaller beef pieces; chilling the beef pieces, by reducing the
temperature to below 29.degree. F.; transferring the size reduced
frozen beef pieces to a apparatus and applying a crushing force
across the frozen beef pieces so as to fracture the fat component
thereby enabling the fractured fat to detach from the lean
component of each piece of beef, to which the fat was previously
attached, to provide small pieces of separated fractured fat and
larger pieces of lean wherein all finished pieces of fat and lean
are smaller than the frozen pieces of beef prior to applying the
crushing pressure to the beef pieces.
[0009] A third embodiment relates to an apparatus for separation of
fat particles, lean particles, and, optionally, bone fragments
produced by the method of the third embodiment. The apparatus
includes a first, second, third, fourth, and fifth vessel, wherein
the first vessel is connected to the second and third vessel,
wherein the bottoms of the second and third vessels are at an
elevation higher than the bottom of the first vessel and means are
provided to seal the second and third vessels from the first
vessel; the fourth vessel is connected to the first vessel so that
the bottom of the fourth vessel is lower in elevation than the
bottom of the first vessel and means are provided to seal the
fourth vessel from the first vessel; the fifth vessel is connected
to the fourth vessel so that the bottom of the fifth vessel is
lower in elevation than the bottom of the fourth vessel and means
are provided to seal the fifth vessel from the fourth vessel; and
means to seal the bottom of the fifth vessel.
[0010] In the apparatus of the third embodiment, the bottom of the
third vessel is higher in elevation than the bottom of the second
vessel. In the apparatus of the fourth embodiment, fat or tallow is
collected in the second vessel.
[0011] In the apparatus of the third embodiment, a mixture of
carbon dioxide, fat, lean meat and bone are provided in the third
vessel and then allowed to settle.
[0012] In the apparatus of the third embodiment, bones or bone
fragments are collected in the fifth vessel.
[0013] In the apparatus of the third embodiment, lean meat is
collected in the fourth vessel.
[0014] In the apparatus of the third embodiment, carbon dioxide is
collected in the first vessel.
[0015] A fourth embodiment relates to a method for the separation
of fat from meat. The method includes providing individual pieces
of meat containing lean and fat; subjecting the individual pieces
of meat to chilling for a time sufficient to produce a difference
in temperature between the fat and lean, wherein the fat is chilled
such that the fat is brittle, or friable and can crumble into finer
particles when subjected to a pressure or crushing force and the
lean is chilled to a higher temperature than the fat and, the lean
is able to withstand a similar crushing force without substantially
crumbling into smaller pieces. At the described temperatures, the
beef pieces are subjected to pressure or crushing force to separate
particles of fat from the individual pieces of beef.
[0016] In the method of the fourth embodiment, after subjecting the
individual pieces of meat to chilling, the temperature at the
surface of the fat is 5.degree. F. to 10.degree. F.
[0017] In the method of the fourth embodiment, after subjecting the
individual pieces of beef to chilling, the temperature at the
surface of the lean is 16.degree. F. to about 34.degree. F.
[0018] In the method of the fourth embodiment, the time of chilling
the individual pieces of beef is approximately 2 minutes to 3
minutes.
[0019] In the method of the fourth embodiment, the method can
further comprise transferring the individual pieces of beef and
separated particles of fat to a vessel and filling the vessel with
a fluid comprising, at least, water, and allowing the particles of
fat to rise in the fluid and allowing the individual pieces of beef
to sink in the fluid, followed by collecting the fat and the
individual pieces of beef.
[0020] In the method of the fourth embodiment, the method may
further comprise allowing bone to sink in the fluid to a lower
elevation as compared to an elevation attained by the individual
pieces of beef.
[0021] In the method of the fourth embodiment, the method may
further comprise transferring the individual pieces of beef and
separated particles of fat within a conduit filled with a fluid
comprising, at least, carbon dioxide, and allowing the particles of
fat to rise in the fluid and allowing the individual pieces of beef
to sink in the fluid while the fluid travels in the conduit,
followed by collecting the fat and the individual pieces of
beef.
[0022] In the method of the fourth embodiment, the method may
further comprise subjecting the individual pieces of beef to a
crushing force produced by intermeshing teeth on rollers or a
continuous conveyor belt to separate particles of fat from the
individual pieces of beef.
[0023] In the method of the fourth embodiment, the method may
further comprise, after separating the particles of fat from the
individual pieces of beef, combining a measured portion of the fat
particles with a measured portion of the individual pieces of beef
to achieve a predetermined fat content for the beef.
[0024] In the method of the fourth embodiment, the method may
further comprise cutting raw beef to a size not exceeding 2 inches
in any dimension to produce the individual pieces of beef of step
(a).
[0025] In the method of the fourth embodiment, after producing the
individual pieces of beef, the pieces are chilled to minimize
agglomeration of pieces into frozen masses comprising a plurality
of pieces.
[0026] In the method of the fourth embodiment, the individual
pieces of beef produced after separation of the fat will comprise
predominantly lean beef.
[0027] In the method of the fourth embodiment, the method may
further comprise contacting the separate particles of fat and
individual pieces of beef with a flowing fluid comprising, at
least, water, in a conduit, and allowing frozen water in the
individual pieces of beef to thaw and increase in density which
causes the individual pieces of beef to fall in the flowing fluid,
while the fat particles are buoyant in the fluid, and collecting
the individual pieces of beef in a lower conduit of a manifold and
collecting the fat particles in an upper conduit of the
manifold.
[0028] In the method of the fourth embodiment, the method may
further comprise separating the fluid from the individual pieces of
beef and fat particles, weighing the fat, and combining a portion
of the fat with the individual pieces of beef to produce a beef
product of predetermined fat content.
[0029] In the method of the fourth embodiment, the method may
further comprise centrifuging the individual pieces of beef and fat
particles to remove the liquid, weighing the individual pieces of
beef in a first conveyor and, weighing the fat particles in a
second conveyor.
[0030] A fifth embodiment is related to a method for deactivating
pathogens in beef. The method includes transferring beef to a
vessel, wherein the vessel includes an enclosed elongated space
fitted with a first and a second piston within the interior of the
space at each of two opposing ends, and the pistons include a front
and back side; charging the vessel with carbon dioxide; moving the
first and second piston in a direction toward each other so as to
reduce the volume of the space and increase the pressure within the
space to create super critical carbon dioxide phase (carbon dioxide
above the critical pressure and the critical temperature) in the
space containing the beef; holding the super critical pressure of
carbon dioxide for a predetermined period of time; after holding
the super critical pressure for the predetermined period of time,
moving the first and the second pistons away from each other to
reduce the pressure in the space to a subcritical pressure of
carbon dioxide; holding the subcritical pressure of carbon dioxide
for a predetermined period of time; and after holding the
subcritical pressure of carbon dioxide, moving the first and second
pistons in a direction toward each other so as to reduce the volume
of the space while expelling the carbon dioxide from the space in
front of the pistons to spaces created at the back of the
pistons.
[0031] In the method of the fifth embodiment, the front side of the
first and the second piston is fitted with an impeller that rotates
as the first and second pistons move toward each other.
[0032] In the method of the fifth embodiment, the vessel includes a
central longitudinal axis, and the vessel is rotated back and forth
on the axis while the first and second pistons move toward each
other.
[0033] In the method of the fifth embodiment, the method may
comprise performing a plurality of super critical carbon dioxide
phases alternating with subcritical carbon dioxide phases before
expelling the carbon dioxide.
[0034] In the method of the fifth embodiment, the super critical
pressure produced is 1,500 psi or greater.
[0035] In the method of the fifth embodiment, the subcritical
pressure produced is 900 psi or less.
[0036] A sixth embodiment is related to a method for separating
lean from fat. The method includes: (a) transferring a mixture
through a conduit, wherein the mixture comprises lean particles
with frozen water, fat particles, and a fluid; (b) allowing the
frozen water in the lean particles to thaw as the mixture travels
through the conduit, and increases a density of the lean particles;
(c) accumulating the lean particles with non-frozen water at a
first elevation in the conduit, and accumulating fat particles at a
second elevation in the conduit, wherein the first elevation is
lower than the second elevation.
[0037] In the method of the sixth embodiment, the method further
comprises transferring the accumulated lean particles through a
conduit branch connected to the conduit, wherein the accumulated
lean particles transferred in the conduit branch comprise a
majority of the lean particles in the mixture.
[0038] In the method of the sixth embodiment, the method further
comprises transferring the accumulated fat particles through a
conduit branch connected to the conduit, wherein the accumulated
fat particles transferred in the second conduit branch comprise a
majority of the fat particles in the mixture.
[0039] In the method of the sixth embodiment, the method further
comprises transferring a portion of the mixture through a conduit
branch connected to the conduit, wherein the mixture in the conduit
branch comprises a greater percent by weight of fluid than fat and
lean.
[0040] In the method of the sixth embodiment, the lean particles
and the fat particles in the mixture in the conduit prior to
thawing of the frozen water have a substantially similar density
that prevents the lean particles and the fat particles from
accumulating at different elevations.
[0041] In the method of the sixth embodiment, the method further
comprises adding carbonic acid solution to the mixture before step
(a).
[0042] In the method of the sixth embodiment, the fluid has a
temperature higher than the freezing point of water.
[0043] In the method of the sixth embodiment, the mixture may
further comprise bones, and allowing the bones to separate from the
mixture before the thawing of water.
[0044] In the method of the sixth embodiment, the conduit comprises
a vertical section and a horizontal section, and the bones are
separated at a bend from the vertical section to the horizontal
section.
[0045] In the method of the sixth embodiment, the method further
comprises, before step (a), applying pressure to pieces of beef
comprising both fat matter and lean matter to produce the lean
particles and the fat particles in the mixture.
[0046] In the method of the sixth embodiment, the method further
comprises, before applying pressure, chilling the pieces of beef to
a temperature at which the fat matter becomes brittle and can
crumble and separate from the lean matter upon the application of
pressure.
[0047] In the method of the sixth embodiment, the method further
comprises emulsifying the accumulated fat particles.
[0048] In the method of the sixth embodiment, the method further
comprises collecting the accumulated lean particles and
centrifuging the lean particles to separate fluid.
[0049] In the method of the sixth embodiment, the conduit can have
an aspect ratio defined as the cross-sectional width divided by the
cross-sectional height, and the aspect ratio decreases along the
length of the conduit from a proximal side to a distal side.
[0050] A seventh embodiment is related to a method for separating
fat from beef pieces, including: (a) chilling beef pieces
comprising fat matter and lean matter for a time and at a
temperature that results in uneven chilling of surfaces of the fat
matter and lean matter, wherein the lean matter is chilled to a
temperature to cause freezing of water in the lean matter, and the
surface temperature of the fat matter is lower than the surface
temperature of the lean matter; and (b) applying pressure to the
beef pieces to break the fat matter from the beef pieces while
leaving the lean matter intact.
[0051] In the method of the seventh embodiment, the method may
further include, wherein in step (b) the surface temperature of the
fat matter is lower than the surface temperature of the lean matter
by at least 5.degree. F.
[0052] In the method of the seventh embodiment, the method may
further include, wherein in step (b), the surface temperature of
the lean matter is 26.degree. F. or less, and the surface
temperature of the fat matter is 5.degree. F. or greater, and the
surface temperature of the fat matter is lower than the surface
temperature of the lean matter.
[0053] In the method of the seventh embodiment, the method may
further include passing the beef pieces between a pair of parallel,
adjacent, non contacting, driven rollers, each roller having
alternating recesses and protrusions around the perimeter, wherein
the rollers are arranged to position a recess of one roller
opposite to a protrusion of the second roller, without the rollers
being in contact.
[0054] An eighth embodiment is related to a method of separating a
high vapor pressure fluid from beef, including: (a) in an apparatus
comprising a vessel, and a piston disposed within the vessel,
wherein a space is provided adjacent to the piston, adding a high
vapor pressure fluid with beef in the space; and (b) moving the
piston to compress the space to separate the fluid from the beef,
wherein the fluid is compressed at a pressure to prevent
evaporation and freezing of the beef.
[0055] In the method of the eighth embodiment, the apparatus may
comprise a second piston, wherein the pistons are disposed opposite
to each other, and the pistons are moved together to compress the
space to separate the fluid from the beef.
[0056] In the method of the eighth embodiment, the high vapor
pressure fluid does not exist as a liquid at 1 atmosphere and
20.degree. C.
[0057] In the method of the eighth embodiment, the fluid can be
carbon dioxide.
[0058] In the method of the eighth embodiment, the apparatus may
further comprise a space behind the piston, wherein the space
adjacent to and behind the piston are in communication, and the
fluid is transferred behind the piston during compression.
[0059] A ninth embodiment is related to a method for producing a
beef product having a predetermined fat content. The method
includes: (a) transferring a mixture through a conduit, wherein the
mixture comprises lean particles, fat particles, and a fluid; (b)
transferring a first portion of the mixture having accumulated lean
particles through a first conduit branch connected to the conduit,
wherein the portion of the mixture transferred in the first conduit
branch has a majority of the lean particles in the mixture; (c)
transferring a second portion of the mixture having accumulated fat
particles through a second conduit branch connected to the conduit,
wherein the portion of the mixture transferred in the second
conduit branch has a majority of the fat particles in the mixture;
(d) measuring the first portion of the mixture having the
accumulated lean particles in the first conduit branch and
determining a content of fat in the first portion; (e) comparing
the content of fat in the first portion with a target fat content;
and further performing (f1) or (f2); (f1) increasing the massflow
of the second portion of the mixture through the second conduit
branch to decrease the fat content of the first portion of the
mixture in the first conduit branch; or (f2) decreasing the
massflow of the second portion of mixture through the second
conduit branch to increase the fat content of the first portion of
the mixture in the first conduit branch.
[0060] In the method of the ninth embodiment, the method may
further comprise measuring the massflow of the first portion of the
mixture and determining a density, and correlating the density to
the fat content of the first portion of the mixture.
[0061] In the method of the ninth embodiment, the method may
further comprise, reducing the mass flow of the second portion of
the mixture flowing through the second conduit branch and
maintaining a constant mass-flow until the fat content of the first
portion of the mixture reaches a high target value, and then
increasing the mass-flow of the second portion of the mixture
through the second conduit branch and maintaining a constant
massflow until the fat content of the first portion of the mixture
reaches a low target value, wherein the high target value and the
low target value are not the same.
[0062] A tenth embodiment is related to a method for inactivating
pathogens present on pieces of beef. The method includes: (a)
introducing into an apparatus, pieces of beef, and a fluid
comprising water and carbon dioxide; (b) raising a pressure within
the apparatus above a critical pressure of carbon dioxide without
elevating a temperature within the apparatus above a temperature to
damage the beef; and holding the pressure and temperature for a
selected period of time; (c) reducing the pressure within the
apparatus, and increasing a density of the fluid to suspend and
separate the pieces of beef in a suspension to enable surfaces of
the beef to be in contact with low pH fluid to result in death of
pathogenic microorganisms on the surfaces of the beef.
[0063] In the method of the tenth embodiment, the method may
further comprise adjusting the density of the fluid where the beef
becomes buoyant to allow spacing apart of beef.
DESCRIPTION OF THE DRAWINGS
[0064] The foregoing aspects and many of the attendant advantages
will become more readily appreciated as the same become better
understood by reference to the following detailed description, when
taken in conjunction with the accompanying drawings, wherein:
[0065] FIG. 1 is a flow diagram illustrating a process for the
separation of fat from lean;
[0066] FIG. 2 is a diagrammatical illustration of apparatus for the
separation of fat from lean;
[0067] FIG. 3 is a diagrammatical illustration of apparatus for the
separation of fat from lean;
[0068] FIG. 4 is a diagrammatical illustration of apparatus for the
separation of fat from lean;
[0069] FIG. 5 is a diagrammatical illustration of apparatus for the
separation of fat from lean;
[0070] FIG. 6 is a diagrammatical illustration of apparatus for the
separation of fat from lean;
[0071] FIG. 7 is a diagrammatical illustration of apparatus for the
separation of fat from lean;
[0072] FIG. 8 is a diagrammatical illustration of apparatus for the
separation of fat from lean;
[0073] FIG. 9 is a diagrammatical illustration of apparatus for the
separation of fat from lean;
[0074] FIGS. 9A, 9B, 9C, and 9D are diagrammatical illustrations of
cross sections of the apparatus shown in FIG. 9;
[0075] FIG. 10 is a diagrammatical illustration of apparatus for
the separation of fat from lean;
[0076] FIG. 11 is a diagrammatical illustration of apparatus for
the homogenization and/or emulsification of fat;
[0077] FIG. 12 is a diagrammatical illustration of apparatus for
the homogenization and/or emulsification of fat;
[0078] FIG. 13A is a diagrammatical illustration of apparatus for
breaking fat;
[0079] FIG. 13B is a diagrammatical illustration of apparatus for
breaking fat;
[0080] FIG. 14 is a diagrammatical illustration of apparatus for
producing product having a desired fat content;
[0081] FIG. 15 is a diagrammatical illustration of apparatus for
pathogen deactivation;
[0082] FIG. 16 is a diagrammatical illustration of apparatus for
the separation of fat from lean;
[0083] FIGS. 17A and 17B are diagrammatical illustrations of
apparatus for the separation of fat from lean and for the
separation of fluid from lean and fat;
[0084] FIGS. 18A and 18B are diagrammatical illustrations of
apparatus for the separation of fat from lean and for the
separation of fluid from lean and fat; and
[0085] FIGS. 19A and 19B are diagrammatical illustrations of
apparatus for the separation of fat from lean and for the
separation of fluid from lean and fat.
DETAILED DESCRIPTION
[0086] The term "fat" as used herein can mean fat and tallow when
used in reference to animal matter. Throughout the description
"beef" may be used as a representative material that can be used in
the disclosed methods. However, it is to be appreciated that the
disclosed methods can be practiced not only on beef, but on any
meat, such as from poultry, pork, and seafood.
[0087] FIG. 1 illustrates a flow diagram for the processing of
animal matter that is a combination of fat and lean matter. A
representative animal matter may be high fat trim byproduct from
beef slaughterhouses. In one embodiment, the source materials can
comprise a combination of what is commonly known as 50's and 65's
boneless beef, or any other suitable boneless beef. However, in
other embodiments, the beef may combine bone and cartilage.
[0088] The method begins with block 2. In block 2, any animal
matter may be used. In one embodiment, the animal matter will be
beef, such as high fat content beef trimmings and other low value
beef products. From block 2, the method enters block 4.
[0089] In block 4, pathogen deactivation is performed on the animal
matter. A number of different pathogen deactivation technologies
may be employed in block 4. For example, in some embodiments, any
of the pathogen deactivation technologies well known in the art may
be used. In other embodiments, the pathogen deactivation process
disclosed herein in association with FIG. 15 may be used in block
4. From pathogen deactivation block 4, the method enters block
6.
[0090] Block 6 is for dicing and/or cutting the generally larger
sections of animal matter into smaller pieces. Dicing and/or
cutting may be done manually and/or alternatively, with dicing
machines. From block 6, the method enters block 8.
[0091] Block 8 is for chilling the diced animal matter or beef
pieces from block 6. In one embodiment, liquid carbon dioxide,
block 10, may be used for chilling in block 8. The chilled animal
matter has both fat and lean matter. The chilling method of block 8
results in differences in temperature between the fat and the lean
matter, such that the fat is at a temperature that can be separated
from the lean by the application of pressure and can break free of
the lean matter, and the lean is at a temperature that is pliable
and does not result in the lean matter breaking free through the
same application of pressure. However, the lean matter is chilled
to a temperature at which water within the lean matter can freeze
and expand, thus, reducing the density of such lean matter
particles. For example, in one embodiment, the temperature of the
beef pieces should be not more than 29.degree. F. and preferably
not less than 0.degree. F. but most preferably about 15.degree. F.
to about 24.degree. F. From block 8, the method enters block
12.
[0092] Block 12 is for breaking the fat matter free from the lean
matter. The product of block 12 comprises particles essentially
being all fat and particles comprising a majority of lean matter,
but, fat may still be present in a minority quantity.
[0093] From block 12, the method may optionally enter block 14. If
performed, block 14 is for separation of the small and large
particles of fat. After separation, the small particles, block 16,
may be combined with any other lean meat, such as pork or beef,
block 18. The combination of lean pork or beef with the small
particles of fat can be used to produce a product having a desired
percentage of fat in block 20. The larger particles of fat are
retained with the lean particles in block 14.
[0094] If block 14 is not performed, then, from block 12, the
method enters block 22. Block 22 is for introducing a selected
amount of a combination of both lean particles and fat particles.
In one embodiment, a rotary valve may be placed at the bottom of a
hopper as further described below.
[0095] From block 22, the method enters block 30. Before entering
block 30, the contents from block 22 are combined with carbonic
acid from block 24. A separate carbonic acid generation unit may be
provided in block 24. The amount of carbonic acid is measured using
a measuring instrument in block 26. In one embodiment, the
temperature of the carbonic acid fluid (suspension or buoyancy
medium) should be not less than about 40.degree. F. and not greater
than about 60.degree. F., but most preferably at about 50.degree.
F., before being mixed with the lean particles and fat particles.
Carbonic acid is mixed with the combination of lean particles and
fat particles and the mixture is measured in block 28. The mixture
of carbonic acid, beef particles, and fat particles is pumped or
may otherwise be transferred under gravity flow to a separation
apparatus, block 30.
[0096] Block 30 separates, at least, a portion of the mixture that
comprises the majority of the lean particles and a portion of the
mixture that comprises the majority of the fat particles. Various
embodiments of apparatus may be used for separation and are
described below in further detail. Any one embodiment of a
separator disclosed herein may be used in block 30. In one
embodiment, separation block 30 may also separate a portion of the
mixture comprising bone with some of the liquid in block 34. The
liquid may be separated from the bone, and further processed. For
example, any liquid containing carbonic acid may undergo processing
to recover carbon dioxide.
[0097] Separation block 30 results in at least two streams. First,
a mixture of lean particles and liquid, block 32, and, second, a
mixture of fat particles and liquid, block 36. It is to be
appreciated that small quantities of fat matter is still present in
the lean particles. The fat matter may be attached to the lean
particles, or some of the fat particles may have been entrained
with the lean particles. The fat particles may also include a small
quantity of lean matter, either as lean matter directly attached to
fat or as separate lean particles. The liquid containing lean
particles is measured in block 38. The liquid containing fat
particles is measured in block 40. Such measurements can include
flow rate and density from which fat content as a weight percent of
the total flow may be calculated.
[0098] From block 32, the liquid containing lean particles is sent
to the liquid separation apparatus, block 42. In block 42,
liquid/solid separation can be carried out via a centrifuge or a
sedimentation vessel. However, in another embodiment, a separation
vessel with one or two opposed pistons is described below in
association with FIG. 15. The liquid containing fat particles,
block 36, is sent to liquid separation, block 48. In block 48,
liquid is separated, in one embodiment, via a centrifuge, and, in
another embodiment, via a sedimentation tank, and, in still another
embodiment, with the liquid separation vessel of FIG. 15.
[0099] If a sedimentation vessel is used as the liquid separator in
block 48, then, the liquid from liquid separation, block 42, may be
sent to the sedimentation vessel used in block 48. Furthermore,
liquid separated from bone in block 34 may also be sent to the
sedimentation vessel of block 48. From block 48, in one embodiment,
the liquid is sent to a carbon dioxide recovery apparatus, block
56. The carbon dioxide recovery apparatus results in carbon dioxide
gas, block 58, and waste water, block 60. The carbon dioxide, block
58, can be sent to a storage vessel (not shown) and recirculated to
use throughout the various processes, such as in block 22, or used
to create carbonic acid in block 24. The waste water, block 60, can
be discarded or treated. In another embodiment, liquid from liquid
separation block 48 and liquid separation block 42 may be sent
directly to waste water block 60.
[0100] The essentially liquid free lean particles, block 44, and
the essentially liquid free fat particles, block 60, are produced
having a controlled amount of fat, and may be used as such for any
purpose. The essentially liquid free lean particles, block 44, and
the essentially liquid free fat particles, block 60, are considered
herein to be the first and second portions, respectively, separated
from the mixture of fluid, lean particles, and fat particles
entering the separation, block 30. In one embodiment, after
separation of the liquid from the lean and fat, the lean is not
produced having a controlled amount of fat. In that case, the lean
and the fat, blocks 44 and 50 respectively, are weighed on weigh
conveyors, 46 and 52, and proportioned according to weight to
achieve a combined lean/fat product of desired fat conduct in block
54. For example, each respective conveyor can move at a speed that
results in a specified proportion of lean to fat. However, in other
embodiments, using the measuring instruments, blocks 26, 28, 38,
and 40, the amount of liquid with fat that is sent to block 36 can
be increased or decreased, which causes a corresponding decrease or
increase of the fat that is carried with the lean particles to
block 32. Thus, the weigh conveyors 46 and 52 are optional.
[0101] The ability to measure the fat content of beef matter within
a fluid is based on the realization that the density of a fluid
with solid matter correlates to a fat percentage. The fat content
of any beef matter, regardless whether the beef is predominantly
lean matter or fat matter, can be determined by knowing the density
of the combined fluid and solid matter. In one embodiment, a
correlation table can be created that correlates density with fat
percent. The table may be created empirically after conducting
numerous trials. The table may be stored in a storage device, such
as computer memory, or databank. In one embodiment, the instruments
that measure density are known as coriolis instruments. Coriolis
measuring instruments, as used herein, are capable of measuring
massflow, density and temperature. Instead of using a single
measurement of massflow, an average may be taken of a plurality of
measurements over a time period. Density is determined from
massflow by dividing the massflow by a known volume in the
instrument. Accordingly, since massflow includes the mass of the
fluid and of any solids, the density is not the density of the
fluid or solids, but the density of the mixture of fluid with
solids. Once the density is known, the fat content can be
ascertained through a correlation table. It is to be appreciated
that the fluid has no fat content; thus, the fat content that is
ascertained refers to the fat content of the solid matter within
the fluid. Accordingly, once the fluid is separated, the fat
content remains the same.
[0102] In FIG. 1, between the rotary valve block 22 and the
separation block 30, the temperature of the beef matter, including
fat and lean particles, will initially be low enough such that the
lean and fat particles will float (but not the bone matter) in the
fluid; however, the temperature and volume of the fluid from block
24 is such that the frozen water content of the lean will unfreeze
and the density will increase accordingly. Separation of the
lean/liquid stream, block 32, from the fat/liquid stream, block 36,
in this way results in a lean content of the lean stream of about
92% and a lean content of the fat stream of about 20%. By dividing
the fat stream further into two streams of almost pure (fatty
adipose tissue) and a stream of higher lean content fat, the almost
pure fat stream will comprise at least 12% lean and the higher fat
content stream could be about 30% lean.
[0103] The massflow of fluid, e.g. carbonic acid, is measured in
block 26. The fluid can be carbonic acid or any other acid or high
pH value alkali liquid, such as ammonium hydroxide. The combined
massflow of fluid with beef matter is also measured in block 28.
Therefore, the massflow of beef solids, including fat and lean
particles, can be known by subtraction of the measurement of block
26 from the measurement of block 28. The massflow of lean/liquid
leaving the separation block 30 is measured in block 38. Therefore,
density of the lean/liquid is known and a correlation table is used
to ascertain the fat content. The massflow of fat/liquid leaving
the separation block 30 is measured in block 40. Therefore, density
of the fat/liquid is known and a correlation table is used to
ascertain the fat content.
[0104] The massflow of the fat/liquid stream, block 36, is
controlled by a pump that is controlled with a variable frequency
drive electric motor that can operate in the following manner. The
lean/liquid stream, block 32, is measured to determine a fat
content (which may be 8%); then, if the target is to produce 85%
lean, the fat/liquid stream massflow is restricted so that more of
the fat/liquid stream must flow into the lean/liquid stream to add,
say an additional 8% fat, and when this lower target value (84%
lean) is measured by measuring instrument block 38 (based on the
density/fat correlation table), the pump is opened to allow more
fat to be transferred away from the lean/liquid stream. When a
higher target value, say 86% lean, is measured by the measuring
instrument block 38, the pump is opened so as to add just 6%
additional fat. In this way, a harmonic motion or cycle can be
created wherein the upper limit fat content is 16% and the lower
limit fat content is 14% and this cycle can be continuously
repeated.
[0105] The process blocks of FIG. 1 are not limited to being
performed in any particular sequence. For example, pathogen
deactivation may occur after blocks 42 and 48 or any time before
then. Some steps may be omitted and substituted for one or more
steps, or that perform the similar function, or are arranged in a
different sequence to perform the similar function. Some steps may
be omitted that are merely ancillary, or embraced as a subsystem of
the illustrated steps.
[0106] The blocks discussed above will now be described in more
detail with reference to specific figures.
[0107] 1. Blocks 2, 4, 6, 8, 12, and 14
[0108] Equipment for performing the process blocks 2 (beef input),
4 (pathogen deactivation), 6 (dicing), 8 (chilling), 10 (liquid
carbon dioxide), 12 (bond breaking), and 14 (particle separator) of
FIG. 1 are more specifically shown in FIG. 2.
[0109] Referring now to FIG. 2, the section shown between item
number 1002 through item number 1046 represents the beef pathogen
deactivation and particle preparation systems. The pathogen
deactivation apparatus identified as 1022 can be substituted with
the high pressure super critical carbon dioxide pathogen
deactivation process described in association with FIG. 15.
[0110] Equipment 1002 represents a vat dumper which may unload any
quantity of animal matter containing fat and lean, such as for
example, the unloading of containers of approximately 2,000 lb of
beef onto an inspection section followed by size reduction
equipment 1004. Combo dumpers can dump raw beef onto an inclined
conveyor which delivers the beef to size reduction equipment and
optionally a cutting table arranged to provide for manual cutting
and reduction in size of beef pieces that are too large to be
processed by the size reduction equipment 1004. Beef may be
boneless or may include bone and cartilage matter as well. Size
reduction equipment 1004 may reduce the beef to pieces of
approximately not bigger than 12'' in any dimension. The inspected,
size reduced beef is them transferred to accumulation hopper 1014
via conveyor 1008. From hopper 1014, the beef may be transferred
via the application of vacuum through conduit 1016 to the pathogen
deactivation system 1022. One particular embodiment of a pathogen
deactivation system is described in association with FIG. 15, which
uses carbon dioxide that is then drawn out from pathogen
deactivation system 1022 via conduit 1020. In another embodiment,
an autoclave is used as the pathogen deactivation system.
[0111] After treatment to reduce pathogens, the beef is transferred
from the pathogen deactivation system 1022 via conduit. 1026 to
dicing equipment 1028. Transfer of beef at this stage may be via
pump 1024. Pump 1024 is designed to transfer a continuous
substantially void free stream of pressurized beef within the
conduit 1026, which may include a measuring instrument, such as a
mass flow meter or coriolis meter. Coriolis meters can measure
density, mass flow, and temperature of the material transferred
therethrough. For example, the proportion of water contained in the
beef transferred therethrough can be determined and recorded for
comparison with similarly measured beef after processing. The
moisture content of the beef is recorded, and moisture content
throughout processing of the beef can be achieved by measuring the
water content prior to processing, during the process to check on
any variation, and after processing to confirm the "natural" water
content of the beef is not exceeded. The data collected by coriolis
measuring instruments is recorded automatically on computer disc or
memory as the beef advances throughout the process.
[0112] From dicing equipment 1028, beef pieces are transferred on
conveyor 1032 through a tunnel freezer 1036. Tunnel freezer 1036
may use carbon dioxide as the chilling medium. Carbon dioxide is
admitted and extracted through either of conduits 1034 or 1040
depending on whether the chilling operation is conducted concurrent
or countercurrent with the flow of beef. The dicing equipment 1028
is designed to slice and dice the beef and reduce beef to a
particle size preferably about 1 inch in cross section by 2 inches
or less. While not limiting, the particles are size reduced to
approximately not more than about 1 inch wide and 2 inches long
strips or 2 inch cubes. The individual particles of diced beef may
still contain an amount of fat and an amount of lean. The input
temperature of the beef particles to the tunnel 1036 (block 8 of
FIG. 1) may be about 32.degree. F. to 40.degree. F., but preferably
about 32.degree. F. The temperature of the beef before the tunnel
freezer 1036 may be controlled, in general, by adjusting the
temperature of the room in which the beef is being diced. Owing to
the differences of heat transfer between fat and lean in each beef
piece, and respective amounts of water in lean versus fat matter,
the chilling tunnel 1036 results in different temperatures of fat
and lean within each beef particle.
[0113] It has been realized that the temperature of the individual
particles that exit the chilling tunnel 1036 is not uniform
throughout the particles. Because of the different heat transfer
rates of fat and lean as well as the different percentages of water
within lean and fat, the temperature of the lean will be higher
than the temperature of the fat, even of the same particle. The
temperature reduction is carried out to result in lean matter that
remains flexible due to the cohesive properties of muscle tissue,
while the fat is cooler at the surface and is in a brittle and
friable condition due to the lower temperature. However, because
the lean contains greater amounts of water than fat, the water is
frozen or partially frozen.
[0114] In one embodiment, flooding the tunnel 1046 enclosure with
100% carbon dioxide gas displacing what would otherwise be air is
advantageous. In this way, carbon dioxide gas can be recycled
through the evaporators. Another purpose in the use of carbon
dioxide is to displace air (and therefore atmospheric oxygen),
thereby inhibiting the formation of oxymyoglobin from the
deoxymyoglobin exposed at the cut lean surfaces of each dice or
beef particle when diced or sliced.
[0115] The temperature of the quickly frozen beef particles when
exiting the tunnel 1036 is controlled such that lean matter
comprising substantially muscle striations, will freeze the water
and all naturally fluids. Water represents about 70% of lean matter
and thus the freezing and expansion of water when frozen
contributes a significant increase in volume with a corresponding
decrease in density of the lean matter. The beef particles are in a
solid phase but in such a way that the physical characteristics and
properties of the lean matter is pliable and "rubbery" in texture,
while the fat matter is friable such that it fractures when
subjected to compressive and twisting actions and will crumble
readily into small particles and be freed from the lean matter. The
temperature to which the beef particles are reduced needs to alter
the physical condition of the beef particles so as to facilitate
the flexing of the muscle striations of the lean matter without
causing it to fracture and break into smaller pieces, while
simultaneously rendering the fat matter friable such that it will
fracture, crumble, and break into smaller separate particles. In
this way, the friable fat having broken away from the lean when it
is flexed, crushed, bent, or twisted, thereby reduces the fat
matter into small separated particles. Hence, these are referred to
herein as fat particles. The part of the beef pieces remaining are
relatively larger comprising mostly lean matter (because they are
generally not broken into small particles). Hence, these are
referred to herein as lean particles. The change in physical
breakdown of the beef particles into two types of particles is
caused by lowering the temperature thereof followed by physical
disruption of the bond, which fixes the fat and lean matter
together in an attached state, and results in a size difference
between the larger lean particles compared to smaller fat
particles.
[0116] It has been found that by reducing the temperature of the
beef particles with fat to a range of between less than 29.degree.
F. and above 26.degree. F., the process described above will
facilitate separation by providing friable fat fractures permitting
the fat to crumble into small particles, leaving the lean as larger
particles.
[0117] The tunnel freezer 1036 may be a cryogenic freezer using
nitrogen or carbon dioxide as the refrigerant, such that upon
transfer out of the freezing tunnel 1036 (or other style of
freezer) the temperature of the fat (at its surface) is lower than
the temperature of the lean in each particle or separate piece of
beef. In one embodiment, the beef particles are temperature reduced
by transfer through tunnel freezer 1036 such that the surface
temperature of the fat matter is lower (approximately 5.degree. F.)
than the surface temperature of the lean matter, which is shown to
be about 29.degree. F., immediately following discharge from the
freezer. The temperature at the surface of fat may be at about
5.degree. F. or less and up to 10.degree. F. or more such that it
can be friable and crumble upon application of pressure, while the
temperature of the lean may be 16.degree. F. to about 34.degree.
F., or alternatively below 29.degree. F., which makes the lean
flexible and not frozen into a "rock-hard" condition immediately
after removal from the freezing process.
[0118] The above description of creating friable fat prone to
crumble is attributed to the respective differences in the heat
transfer ability of fat compared to lean. Table 2 shows
representative temperatures of fat and lean exiting a tunnel
freezer. Referring to TABLE 2, the temperature of the lean and fat
matter is separately plotted against elapsed time. As can be seen,
the temperature of the lean matter is above the temperature of the
fat matter for about 5 minutes subsequent to discharge from the
freezer and at about 6 minutes (after discharge from the freezer)
the lean temperature is lower than the fat temperature.
[0119] In one embodiment, immediately after leaving the tunnel
freezer, the fat can be at a temperature of 5.2 F. (at the
surface), while the lean is at a temperature of 29 F. This
difference in temperature is attributed to the respective heat
conductive properties of fat versus lean. The individual pieces of
beef containing both fat and lean are exposed to the freezer on the
order of minutes, generally, between 2 and 3 minutes to create
friable fat matter prone to crumble under a crushing force, whereas
the lean remains pliable, flexible and not prone to crumble under a
similar crushing force. The temperatures will then begin to
converge to equilibrium; therefore, it is useful to process the
particles of beef in the bond breaking compression device 1042
before the fat is no longer friable and easy to crumble.
TABLE-US-00001 TABLE 2 Temperature Difference of Fat and Lean
Temperature Date Time delta T' delta T Fat Lean 1 Aug. 3, 2010
3:31:00 PM 0:00 0:00 5.2 29.0 2 3:37:00 PM 0:06 0:06 27.9 26.6 3
3:43:00 PM 0:06 0:12 29.5 26.9 4 3:50:00 PM 0:07 0:19 30.9 27.8 5
3:58:00 PM 0:08 0:27 29.7 28.6 6 4:03:00 PM 0:05 0:32 30.6 28.9 7
4:14:00 PM 0:11 0:43 31.0 29.5 8 4:22:00 PM 0:08 0:51 32.8 29.8 9
4:31:00 PM 0:09 1:00 33.3 30.0 10 4:36:00 PM 0:05 1:05 35.3
30.0
[0120] The stream of temperature reduced beef particles can then be
immediately, without storing in containers or otherwise that could
allow temperature equilibration of the fat and the lean matter, or
on an extended conveyor, be transferred through a bond breaking
process during which the beef particles are "flexed" or bent by
distortion and partially crushed as they are transferred between,
for example, a pair (two) of parallel rollers manufactured from any
suitable stainless steel such SS316 or SS304 grades, but wherein
the beef particles are not completely flattened as would occur if
placed on a hard surface and rolled upon with a very heavy roller
(steam/road roller for example). This bond breaking compression
process is intended to cause breakage of the friable fat matter
into smaller pieces of, in the majority of instances, approximately
100% fatty adipose tissue (fat) and smaller than the fat matter was
before transfer through the bond breaking process and much more so
than the lean matter which remains in most cases intact but without
any more than about 10% fat, or less, remaining attached to the
majority of lean matter after transfer through the bond breaking
process. In other words, the fat in the beef particles will
"crumble", fracture, and break into small pieces and separate from
the lean in a continuous stream of what becomes small (smaller than
before transfer through the crushing process) fat particles and
lean particles that still comprise some fat, but are approximately
more than 90% lean beef.
[0121] Following temperature reduction in tunnel 1036, and while
the fat and lean maintain different temperatures, as discussed
above, the beef particles still containing fat and lean are
transferred to a bond breaking compression device 1042 that clamps
and flexes the particles so as to cause the friable fat to crumble
and break away from the flexible lean component of the beef. Device
1042 may comprise at least one or more pairs of horizontally
disposed and opposed specially manufactured rollers, such as
rollers 1043 and 1045, arranged so that one pair is above the
other, such that the stream of beef particles spread out across the
full width of the tunnel conveyer are dropped in a waterfall effect
between the upper pair of rollers which clamp the particles and
flex so as they are transferred between the clamping rolls without
crushing and in this way cause the friable fat matter attached to
any flexible lean matter to break away in small particles. One
embodiment of a profile of a pair of rollers is described in
association with FIGS. 13a and 13b. After processing between the
upper pair of rollers, the stream of beef particles drops between
the second pair of similarly arranged rollers driven by a suitable
electric motor to ensure processing of all particles which are then
transferred to accumulation hopper 1044 and by vacuum transfer are
conveyed via conduit 1046 into hopper 1054 mounted above the inlet
to the separation manifold 1072. From the description above,
embodiments for separating lean from fat are possible by chilling,
followed by the application of pressure or a crushing.
[0122] In one embodiment, a method for the separation of fat from
meat includes: (a) providing individual pieces of meat containing
lean and fat; (b) subjecting the individual pieces of meat to
chilling for a time sufficient to render the fat into a brittle
condition; and (c) with a machine, and with the fat in the brittle
condition, subjecting the individual pieces of meat to a crushing
force to separate particles of fat from the individual pieces of
meat.
[0123] The method may further include rendering the fat particles
into beef tallow. The method may further include exposing the
individual pieces of meat after crushing to carbon dioxide at or
above the critical temperature and critical pressure. The method
may further include centrifuging the fat particles after being
separated from the individual pieces of meat. The method may
further include emulsifying the fat particles after being separated
from the individual pieces of meat. The method may further include
extracting lean from the fat particles. The method may further
include separating fat from lean in a centrifuge. In the method,
the lean matter can be chilled to a temperature to cause freezing
of water in the lean, and the temperature of the fat is lower than
the temperature of the lean. In the method, during step (c), the
lean can be left intact. In the method, in step (b), the surface
temperature of the fat can be lower than the surface temperature of
the lean by at least 5.degree. F. In the method, in step (b), the
surface temperature of the lean can be 26.degree. F. or less, and
the surface temperature of the fat can be 5.degree. F. or greater,
and the surface temperature of the fat can be lower than the
surface temperature of the lean. The method may further include
passing the pieces of meat between a pair of parallel, adjacent,
non-contacting, driven rollers, each roller having alternating
recesses and protrusions around the perimeter, wherein the rollers
are arranged to position a recess of one roller opposite to a
protrusion of the second roller, without the rollers being in
contact. In the method, the meat can be beef.
[0124] A method for the separation of fat from meat can include:
(a) providing individual pieces of meat containing lean and fat;
(b) subjecting the individual pieces of meat to chilling for a time
sufficient to produce a difference in temperature between the fat
and lean, wherein the fat is chilled such that the fat is friable
and crumbles into finer particles when subjected to a crushing
force and the lean is cooled to a higher temperature than the fat
and the lean is able to withstand a similar crushing force without
substantially crumbling into smaller particles; and (c) with the
fat and lean at the temperatures produced in step (b), subjecting
the individual pieces of meat to a crushing force to separate
particles of fat from the individual pieces of meat.
[0125] In the method, after subjecting the individual pieces of
meat to chilling, the temperature at the surface of the fat can be
5.degree. F. to 25.degree. F. In the method, after subjecting the
individual pieces of meat to chilling, the temperature at the
surface of the lean can be 16.degree. F. to about 34.degree. F. In
the method, the chilling time of the individual pieces of meat can
be approximately 2 minutes to 3 minutes. The method may further
include transferring the individual pieces of meat and separated
particles of fat to a vessel and filling the vessel with a fluid
comprising, at least, water, and allowing the particles of fat to
rise in the fluid and allowing the individual pieces of meat to
sink in the fluid, followed by collecting the fat and the
individual pieces of meat. The method may further include allowing
bone to sink in the fluid to a lower elevation as compared to an
elevation attained by the individual pieces of meat. The method may
further include transferring the individual pieces of meat and
separated particles of fat within a conduit filled with a fluid
comprising, at least, water, and allowing the particles of fat to
rise in the fluid and allowing the individual pieces of meat to
sink in the fluid while the fluid travels in the conduit, followed
by collecting the fat and the individual pieces of meat. The method
may further include subjecting the individual pieces of meat to a
crushing force produced by intermeshing teeth to separate particles
of fat from the individual pieces of meat. The method may further
include, after separating the particles of fat from the individual
pieces of meat, combining a measured portion of the fat particles
with a measured portion of the individual pieces of meat to achieve
a predetermined fat content for the meat. The method may further
include cutting raw meat to a size not exceeding 2 inches in any
dimension to produce the individual pieces of meat of step (a). In
the method, after producing the individual pieces of meat, the
pieces can be chilled to minimize agglomeration of the pieces into
frozen masses. In the method, after crushing, the individual pieces
of meat in step (c) can comprise predominantly lean meat. The
method may further include contacting the separate particles of fat
and individual pieces of meat of step (c) with a flowing fluid
comprising, at least, water, in a conduit, and allowing frozen
water in the individual pieces of meat to thaw and increase in
density, which causes the individual pieces of meat to fall in the
flowing fluid, while the fat particles are buoyant in the fluid,
and collecting the individual pieces of meat in a lower conduit of
a manifold and collecting the fat particles in an upper conduit of
the manifold. The method may further include separating the fluid
from the individual pieces of meat and fat particles, weighing the
fat, and combining a portion of the fat with the individual pieces
of meat to produce a meat product of predetermined fat content. The
method may further include centrifuging the individual pieces of
meat to remove the fluid after separating the fat particles.
[0126] Following the bond breaking compression device 1042, the
beef particles, once a combination of lean and fat matter, are now
smaller particles of predominantly all fat and predominantly all
lean owing to the breaking of the fat. The lean particles and the
fat particles are next separated. Separation may be done in cycles.
The lean particles and the fat particles are accumulated in hopper
1054 until a sufficient amount has been collected to provide for
the next separation cycle in the separation equipment. A vacuum
source draws the stream of crushed particles into hopper 1054.
Carbon dioxide gas can be fed into the bond breaking compression
device 1042 to displace air and provide the gas by which the vacuum
source enables transfer through an enclosed conduit 1024 to hopper
1054.
[0127] A rotary valve at the bottom of hopper 1054 discussed in
association with FIG. 1 is used to provide a selected quantity of
lean and fat particles to separation equipment.
[0128] Referring to FIG. 1, it is optional to include a small
particle separation in block 14. The small particle separator if
used would be placed directly following the bond breaking
compression device 1042 and hopper 1044. In one embodiment, a
particle separator system comprises a large particle separator and
a small particle separation. The large particle separator applies
pressure to the large particles of beef by way of a horizontally
disposed assembly of parallel stainless steel bars mounted to a
drive means at one end via a stainless steel disc end plate and to
a bearing at the opposite end also via a stainless steel disc; the
horizontally disposed assembly of bars can rotate in the lower
section of a horizontal trough having a lower profile that follows
the underside profile of the rotating bars. The trough material is
stainless steel and is perforated with holes of a selected size
such that when the rotating assembly of bars is positioned so as to
have little clearance between it and the lower section of the
perforated trough, any particles of greater size than the
perforations will be size reduced by crushing until the reduction
in size allows the particles to fall through the perforations. The
size reduced particles are then returned to the large particle
separator and added to the beef particles and then transferred to a
second particle size reduction and from there via screw conveyor or
vacuum transfer conduit to transfer to hopper 1054 before
separation equipment.
[0129] 2. Blocks 22, 24, 26, 28, 30, 32, 34, 36, 38, 40
[0130] Blocks 22, 24, 26, 28, 30, 32, 34, 36, 38, 40 of FIG. 1 will
now be described with reference to FIGS. 2, 3, 4, 5, 6, 7, 8, 9,
10, 11, and 12.
[0131] The section shown in FIG. 2 between hopper 1054 and hopper
1111 is arranged to separate the lean particles from the fat
particles produced in the bond breaking compression device
1042.
[0132] In general, separation of the fat particles from the lean
(having some fat) particles is done by way of buoyancy separation
in a fluid that has a density lower than that of the lean
particles, when the water in the lean particles is not frozen.
Separation may also be conducted with a fluid that has a density
greater than that of the fat particles. Separation may also be
conducted with a fluid that has a density in the range between the
fat particles and the lean particles. The fluid can include water,
or water with carbon dioxide, which results in the production of
carbonic acid. At the temperatures required for bond breaking
discussed above, when fluid is first mixed with the lean and fat
particles, the particles will float including the lean particles,
and be suspended at the uppermost space available in the fluid and
just below a surface of the fluid or suspended within the fluid. As
the temperature of the fluid and fat and lean particles begins to
equilibrate, which involves the initial lower temperature of the
lean particles increasing, corresponding with the decreasing
temperature of the fluid, the buoyancy of the lean particles will
start to "fail" until the lean particles sink toward the base of
the fluid leaving the fat particles floating at the fluid surface
or uppermost available space in the fluid. An increase in the
density of the lean particles is seen as the lean and water thaw,
which reduces the volume of lean particles and correspondingly
increase in density. Fat having a lower content of water does not
experience as great an increase in density due to water
thawing.
[0133] Before and during the lean particles and fat particles have
reached equilibrium with the fluid, any bone chips that may be
present will sink when mixed together with the fluid, thereby
providing a convenient means of separating bone chips first, which
will most preferably be arranged to occur immediately after
blending the lean and fat particles with the fluid and before
temperature equilibration of the particles or when the lean
particle temperature has increased so as to thaw the lean/water
content of the lean matter upon which shrinkage of the lean will
occur causing it to sink in the fluid. The fat particles, frozen or
not, will remain floating at the fluid surface. By lowering the
fluid temperature relative to the temperature of the lean
particles, complete thawing and temperature equilibration will be
delayed and, accordingly, the lean particles will remain suspended
for a longer period and this can assist with UVc pathogen
deactivation as described below.
[0134] The lean and fat particles suspended in an anti-microbial
fluid of carbon dioxide and water (at a suitable ratio of fluid to
particles in the range of 1:1 to 5:1, or 10:1 to 1:10 by weight)
can be treated by exposure to UVc light, which is lethal to
pathogens when the exposure is sufficient. The suspension of frozen
lean and fat particles in sufficient anti-microbial carbonic acid
fluid (or water) can be transferred at a steady rate of transfer
through an enclosed/sealed internally polished (preferably
stainless steel) tube within which an elongated, tubular profiled,
UVc light source is mounted, in parallel with the enclosing SS
tube. As the temperature of the mixture steadily equilibrates, the
outer surface of the lean and fat particles thaw, if pathogens are
present, the single celled organisms will be at the surface of the
beef particles or suspended in the fluid but, in any event, at
locations readily accessible to the direct "line of sight" of the
UVc light source given that the particles revolve while suspended
in the fluid. UVc is lethal to such pathogens as E. Coli 0157:H7
and Salmonellas and such pathogen contamination can be deactivated
by adequate exposure to UVc. The particles suspended in the fluid
revolve randomly as the mixture is transferred through the UVc
apparatus. Pathogens are quickly deactivated when exposed to the
UVc light source.
[0135] In one embodiment, the process of separating fat from lean
is achieved within enclosed conduits. After separation of
predominantly lean particles from predominantly fat particles
simultaneously in two streams including a first high percentage
lean content stream (comprising for example 93%+/-<1.0% lean
with the balance being fat) and a second initial fat stream of high
fat content (comprising about 85% fat with the balance being lean).
The two streams are transferred within first and second enclosed
conduits, in such a way that the separated lean and fat travel
along the respective first and second conduits at approximately the
same velocity (up to about 10 feet per second) to each other. The
conduits in which the respective streams of fat particles and lean
particles travel can be measured by flow measuring instruments,
such as coriolis instruments. The separated second stream of fat,
although separate from the first stream of lean, is in relative
close proximity to the lean stream from which it was separated. In
this way, the fat stream can be divided, yet again, into third and
fourth stream divisions wherein at least one of the fat stream
divisions can be a measured third stream division of the initial
second stream of fat. The mass of the measured third stream
division can be adjusted by varying the quantity transferred in the
third stream and continuously measured and/or weighed on a
continuous weighing, variable speed conveyor belt.
[0136] The measured third stream of fat, or any other stream, can
then be recombined with the entire first stream of lean such that
the relative proportions of fat and lean after recombining provide
a single recombined stream with fat and lean content proportions
according to a selected ratio. In other words, for example, by
accurately measuring the fat stream division, the resultant lean
content of the recombined stream can be any value less than the
lean content (93%+/-<1.0% lean) of the first lean stream. A
recombined stream lean content of 81%, 85%, 90% or any other value
can be produced in this way.
[0137] Referring to FIG. 2, the stream of still partially frozen
particles (mostly/only fat and mostly/only lean) is drawn in to
hopper 1054 through vacuum, or otherwise. The bottom of hopper 1054
is connected to a vertical column (seen best in FIGS. 6, 7, and 8).
The vertical column then connects to the separation manifold 1072,
of which there are several embodiments, any of which may be used
and are interchangeable. Furthermore, the separation equipment need
not be a manifold. As an alternative to a manifold, a separation
vessel may be used, such as the one shown in FIG. 5. The stream
traveling through the vertical column is combined with a
pressurized stream of liquid carbonic acid (H2CO3) that is
temperature and massflow controlled, at about 70 psia (but the
pressure could be up to about 50 Bar (725 psia)). The liquid
carbonic acid is measured, such as with a coriolis instrument. In
other embodiments, liquid carbonic acid may be substituted with
water, or other fluids. The liquid carbonic acid that is injected
in the vertical column may be generated by combining recovered and
stored carbon dioxide, as described below, with water. In FIG. 2,
vessel 1048 is a storage vessel for carbonic acid fluid.
[0138] As described further below, the mixture comprising lean
particles, fat particles, and liquid carbonic acid (or other fluid)
are separated into components. The fat is separated and extracted
from the fluid and processed, optionally, through a particle size
reducing apparatus such as a bowl chopper or even an emulsifier
used to break the cell walls but at this stage in the separation
process, the fat particles in the fat stream will be size reduced,
but not to the extent of breaking cell walls, but only so as to
ensure all red and white colored lean still present with the fat is
recovered.
[0139] Additionally, the lean particles are separated from the
fluid and then optionally combined with the fat stream after the
fat stream has been processed via a size reduction apparatus such
as, but not limited to a bowl chopper.
[0140] In one embodiment, the combined lean and fat streams
including a reduced quantity of carbonic acid (or carbon dioxide
and water), altogether in a single stream is then transferred into
a decanter style centrifuge. The decanter style centrifuge
separates the lean, liquid water and carbonic acid, and fat in
typical fashion into layers according to density with the heaviest
(lean) forming a layer around the inner surface of the centrifuge
barrel. The water, carbon dioxide and fat together are separated
from the lean in two entirely separate streams.
[0141] The first of several embodiments of a separator following
the bond breaking compression device, including the separation
manifold will be described referring to the schematic illustration
of FIG. 3, which includes equipment similar to FIG. 2. The
temperature reduced stream of fat and lean particles from the
tunnel freezer 1502 is transferred in the direction shown by arrow
1508 to hopper 1510 with rotary valve, which facilitates transfer
of the particle stream from ambient pressure to the pressurized
conditions within the separation manifold 1512. Simultaneously, a
temperature and mass flow controlled, measured quantity of carbonic
acid (H2CO3) is also transferred from pressure vessel 1526, through
coriolis measuring instrument 1528, and along a conduit represented
by arrow 1544 into manifold 1512.
[0142] The two mass flow and temperature controlled streams of
particles and carbonic acid fluid are blended together in the
vertical column connected to the bottom of hopper 1510 and the
temperatures begin to equilibrate. Initially, however, the frozen
condition of the lean and fat result in both lean and fat solids,
floating. Any heavy, bone fragments, which are unaffected by the
water freezing temperatures, of the fat and lean solids sink
immediately to the lowermost location in the manifold it can fall
to, which, in one embodiment, is arranged to be located at the base
of the vertical column located directly beneath the hopper 1510 and
rotary valve. From the vertical column, the conduit may be diverted
horizontally. In one embodiment, for example, the bone matter may
be collected at a bend from the vertical column to the horizontal
conduit.
[0143] As the mixture of solids and liquid carbonic acid are
transferred along the horizontal conduit ("manifold"), temperature
equilibration between the solids and liquid increases the density
of the high-water-content lean matter as the formerly frozen water
thaws and shrinks. The lean and fat solids quickly separate as
temperature equilibration occurs, causing the density of lean to
increase causing the fat and lean solids to diverge as they are
carried with the flow of low pH carbonic acid. The fat matter
remains buoyant, carried by the fluid at a higher elevation than
the lean matter and the lean particles fall to the lowermost
section of the conduit through which they are still propelled along
the horizontal conduit by the flow of liquid. The separation
manifold is constructed so that following temperature equilibration
of the particles, a conduit connected directly to the underside of
the horizontal separation manifold and extending downward, allows
the lean particles to be separated from the main fluid stream. An
opposing conduit, attached directly to the upper side of the
horizontal conduit, allows the fat particles to diverge upwardly
and in this way, the fat and lean particles are divided into two
streams, wherein the lean particles ("matter") follow a conduit
that becomes 1531 and the fat particles ("matter") follow a path
that connects directly to conduit 1514.
[0144] Enclosed conduit 1531 includes a coriolis measuring
instrument 1530 through which the entire stream of liquids and
solids carried by the conduit 1531 is transferred. Conduit 1531
connects directly to a positive displacement pump 1524, which
controls mass flow therethrough. The fat stream carried via conduit
1514 is transferred via coriolis measuring instrument 1513 and to
positive displacement pump 1515.
[0145] Two decanter style centrifuges 1532 and 1519 are
conveniently located so as to allow direct connection of 1531,
which is carrying the stream containing lean matter, to centrifuge
1532 and conduit 1514, which is carrying the stream containing fat
matter connects to centrifuge 1519. Centrifuge 1532 is positioned
to allow discharge of the lean matter, after separation from the
liquid portion of the stream, directly onto a continuous conveyor
1534, which also includes a weighing station. Similarly, centrifuge
1519 is positioned to allow discharge of the fat matter after
separation from the liquid portion of the stream, directly onto a
continuous conveyor 1521, which also includes a weighing station.
The de-liquefied lean matter is carried in the direction shown by
arrow 1536 and continuously weighed as it is carried toward the
collection conveyor 1550, and the de-liquefied fat matter 1520
carried by weighing conveyor 1521 is weighed as it is carried
toward the collection conveyor 1550. A coriolis measuring device
1538 is arranged to measure the quantity of liquid separated from
the lean matter carried by conduit 1531 and transferred through
discharge pipe 1522 by centrifuge 1532, and the liquid separated
from the fat matter carried by conduit 1514 and separated by
centrifuge 1519 is then transferred via conduit 1516 and measured
by coriolis measuring instrument 1517. Coriolis measuring device
1528 is arranged to measure the quantity of water with the carbonic
acid added to the combined stream transferred via separation
manifold 1512, and, in this way, the quantity of water remaining
with the lean matter discharged from centrifuge 1532 can be
determined by subtraction after measuring the content of the fat
matter carried by conduit 1514 with coriolis measuring instrument
1513 and the quantity of separated liquid discharged via 1516 and
through coriolis measuring instrument 1517, thereby enabling
determination of the lean content of the lean matter deposited by
centrifuge 1532 onto conveyor 1534.
[0146] Coriolis measuring instrument 1530 continuously measures
temperature, mass flow and water content of the stream carried by
conduit 1531 and coriolis measuring instrument 1513 continuously
measures temperature, mass flow, and water content of the stream
carried by conduit 1514.
[0147] The quantity of fat deposited onto conveyor 1521 is already
known by subtracting the quantity of liquids measured by coriolis
1517 from the mass flow of matter measured by coriolis measuring
instrument 1513. In this way, a measured quantity of fat can be
returned to the lean matter carried by conveyor 1534 by restricting
the quantity of fat (tallow) carried on conveyor 1521 with the
balance of fat matter discharged in the direction shown by 1518. In
this way, the recombined lean and fat streams can be measured so as
to produce a product of selected fat content boneless beef carried
along conveyor 1550.
[0148] Referring back to FIG. 2, the apparatus of FIG. 2 is similar
to the apparatus of FIG. 3.
[0149] As the mixture of solids and liquid carbonic acid are
transferred along the horizontal conduit 1072 ("manifold"),
temperature equilibration between the solids and liquid increases
the density of the high-water-content lean matter as the formerly
frozen water thaws and shrinks. The lean and fat solids quickly
separate as temperature equilibration occurs, causing the density
of lean to increase causing the fat and lean solids to diverge as
they are carried with the flow of low pH carbonic acid. The fat
matter remains buoyant, carried by the fluid at a higher elevation
than the lean matter and the lean particles fall to the lowermost
section of the conduit through which they are still propelled along
the horizontal conduit by the flow of liquid. The separation
manifold is constructed so that following temperature equilibration
of the particles, a conduit connected directly to the underside of
the horizontal separation manifold and extending downward, allows
the lean particles to be separated from the main fluid stream. An
opposing conduit, attached directly to the upper side of the
horizontal conduit, allows the fat particles to diverge upwardly
and in this way, the fat and lean particles are divided into two
streams, wherein the lean particles ("matter") follow a conduit
which becomes 1087 and the fat particles ("matter") follow a path
that connects directly to conduit 1085.
[0150] Enclosed conduit 1087 includes a coriolis measuring
instrument 1088 through which the entire stream of liquids and
solids carried by the conduit 1088 is transferred. Conduit 1088
connects directly to a positive displacement pump 1089, which
controls mass flow there through. The fat stream carried via
conduit 1085 is transferred via coriolis measuring instrument 1086
and to positive displacement pump 1101.
[0151] Two decanter style centrifuges 1090 and 1107 are
conveniently located so as to allow direct connection of conduit
1087, which is carrying the stream containing lean matter, to
centrifuge 1090 and conduit 1085, which is carrying the stream
containing fat matter connects to centrifuge 1107. Centrifuge 1090
is positioned to allow discharge of the lean matter, after
separation from the liquid portion of the stream, directly onto a
continuous conveyor 1098, which also includes a weighing station.
Similarly, centrifuge 1107 is positioned to allow discharge of the
fat matter after separation from the liquid portion of the stream,
directly onto a continuous conveyor 1105, which also includes a
weighing station. The de-liquefied lean matter is carried in the
direction shown by arrow 1103 and continuously weighed as it is
carried toward the collection conveyor 1110, and the de-liquefied
fat matter carried by weighing conveyor 1105 is weighed as it is
carried toward the collection conveyor 1110. A coriolis measuring
device is arranged to measure the quantity of liquid separated from
the lean matter carried by conduit 1087 and transferred through
discharge pipe 1100 by centrifuge 1090, and the liquid separated
from the fat matter carried by conduit 1085 and separated by
centrifuge 1107 is then transferred via conduit 1131 and measured
by coriolis measuring instrument. Coriolis measuring device 1064 is
arranged to measure the quantity of water with the carbonic acid
added to the combined stream transferred via separation manifold
1072, and, in this way, the quantity of water remaining with the
lean matter discharged from centrifuge 1090 can be determined by
subtraction after measuring the content of the water of the fat
matter carried by conduit 1085 with coriolis measuring instrument
1086 and the quantity of separated liquid discharged via 1131 and
through coriolis measuring instrument, thereby enabling
determination of the lean content of the lean matter deposited by
centrifuge 1090 onto conveyor 1098.
[0152] Coriolis measuring instrument 1088 continuously measures
temperature, mass flow and water content of the stream carried by
conduit 1087 and coriolis measuring instrument 1086 continuously
measures temperature, mass flow, and water content of the stream
carried by conduit 1085.
[0153] The quantity of fat deposited onto conveyor 1105 is already
known by subtracting the quantity of liquids measured by coriolis
in line 1131 from the mass flow of matter measured by coriolis
measuring instrument 1086. In this way, a measured quantity of fat
can be returned to the lean matter carried by conveyor 1098 by
restricting the quantity of fat (tallow) carried on conveyor 1105.
In this way, the recombined lean and fat streams can be measured so
as to produce a product of selected fat content boneless beef
carried along conveyor 1111.
[0154] After the production of a selected fat content boneless beef
through any one of the embodiments described herein there is
downstream from member 1111, conduit 1130 arranged to transfer a
stream of boneless beef having a selected fat content into a vacuum
dehydration and storage vessel 1136. Vessel 1136 is mounted on
three load cells 1134, 1114, and 1120 and is arranged to enable a
moisture adjustment by way of vacuum dehydration. For example,
moisture can be extracted under very low vacuum (below 4.7 torr) to
ensure the moisture content of the finished beef corresponds with
the input stream prior to separation. After moisture content
correction, processed beef is transferred via conduit 1122 to an
enclosed carbon dioxide flooded hopper 1124, such as by Handtmann,
mounted directly above and to the vacuum stuffer 1138, such as by
Handtmann.
[0155] An inline grinder 1126 can be used optionally as the beef is
transferred to chub packing machine 1128 (Poly Clip FCA 160 chub
packaging system).
[0156] Referring now to FIG. 4, a second embodiment of equipment
for manufacturing boneless beef having a selected fat content and
produced from any suitable grade of boneless beef, is illustrated.
As with the embodiment illustrated in FIGS. 2 and 3, the embodiment
of FIG. 4 is one of several embodiments of equipment that may
follow the bond breaking compression device, block 12 of FIG. 1.
Any of the embodiments described herein for equipment following the
bond breaking process of block 12 of FIG. 1 is interchangeable with
each other embodiment.
[0157] FIG. 4 also includes equipment to carry out the process of
liquid separation from lean matter, block 42 of FIG. 1, liquid
separation from fat matter, block 48 of FIG. 1, carbon dioxide
recovery, block 56 of FIG. 1, carbon dioxide collection, block 58
of FIG. 1, and waste water treatment, block 60 of FIG. 1. The
blocks just described are also adaptable to be used with other
embodiments for separation of fat and lean, and are not limited to
being used solely with the separation configuration of FIG. 4.
[0158] The manifold includes three "in-put" ports at 1706, 1726 and
1610 which connect via a series of manifolds and valves to a "main
line" conduit 1766, which collectively provides a means to separate
a mixture of carbonic acid and beef particles into the following:
(1) a stream of high lean content boneless beef; (2) a stream of
beef fat; (3) a stream of recovered, pressurized carbon dioxide;
and, (4) a stream of waste water.
[0159] A stream of particle size and temperature reduced boneless
beef including fat particles and lean particles, such as produced
from the bond breaking compression device, is transferred from its
place of production via vacuum conveyor 1706 in the direction shown
by arrow 1700. A vacuum generator (such as a Gardner Denver 4512
blower) is connected directly to conduit 1704 so as to facilitate
pressure reduction in space 1709 by evacuation. Suitably
pressurized carbon dioxide gas is transferred into port and conduit
section 1720, and through flow regulator 1724 and coriolis
measuring instrument 1722, and then directly into column 1716 via
1720. The purpose of providing carbon dioxide into the sections of
vertical column shown as 1716 and 1730 is to maintain a carbon
dioxide gas atmosphere for that section of vertical column 1716 and
1730.
[0160] A third fluid stream of carbonic acid is provided under
selected pressure of at least 70 psia via conduit 1610 in the
direction shown by arrow through heat exchanger 1692 and into
conduit section 1744 which communicates directly with coriolis
measuring instrument 1740 via regulator 1742. The flow of carbonic
acid transferred via heat exchanger 1692 is thereby temperature
controlled to a selected temperature within a tight tolerance of
not more than + or -5.degree. F. The temperature controlled flow of
carbonic acid can be directed via conduit 1738 in the direction
shown by arrow 1737 or, alternatively, via conduit 1748 in the
direction shown by arrow 1750 or a proportion of the flow of
carbonic acid can be divided according to any selected proportions
via both conduits 1738 and 1748 in the direction shown by arrows
1737 and 1750, respectively. In this way, a continuous stream of
mass flow selected carbonic acid is transferred into conduit
sections 1730 and 1756 with a carbon dioxide gas atmosphere filling
section 1716 of the vertical column. The flow of carbonic acid is
generally in the direction shown by arrow 1718, through segments
1730, 1756, and onto section 1766.
[0161] Particles of temperature controlled beef, including lean
particles and fat particles, are transferred into vertical column
1716 via rotary valve 1712 wherein the particles are transferred
from fully enclosed hopper 1708 and in particular from space 1709
and the direction shown by arrow 1710. The lean particles and fat
particles are transferred into space 1709 in the direction shown by
arrow 1700 by inducing a lower gas pressure within the free space
of hopper 1708 enclosed and sealed by hopper cover 1714. Gas from
within space 1709 is transferred via conduit 1704 in the direction
shown by arrow 1702 by way of a suitable Rootes blower or similar
gas evacuation pump that is attached to the extension (not shown)
of conduit 1704. When a lower gas pressure has been induced within
the free space 1709, frozen beef particles comprising the lean
particles and fat particles from the place of production are
transferred to the hopper 1708, via a conduit extended from 1706 to
the source of the particles. Said temperature controlled particles
are held within space 1709 for a relatively short period of time
prior to being transferred via rotary valve 1712 and into the
carbon dioxide gas filled column 1716. Accordingly, the temperature
controlled particles which comprise substantially either all lean
beef or all beef fat having been processed to break any bond that
held the fat matter and lean matter together. Therefore, the
temperature controlled particles transferred into vertical column
1716 will fall in the direction shown by arrow 1718 and combine
with the liquid carbonic acid transferred into the lower part of
vertical column section 1730 and, after mixing, will be carried by
the rapidly flowing stream of carbonic acid through a 90 degree
conduit section 1756 and toward the horizontal coriolis measuring
instrument 1760 via variable frequency drive controlled Waukesha
positive displacement pump 1758.
[0162] Prior to transfer through pump 1758, any very dense bone
pieces or fragments, being more dense than the particles suspended
in the stream of carbonic acid, will fall to the lower part of any
containment such as the conduit 1756 through which the particles
and any bone fragments contained therewith is traveling. A vertical
section of conduit 1752 communicates directly between a liquid
filled container with space 1754 and the underside of a horizontal
section of conduit immediately following conduit bend 1756. In this
way, the heavy bone particles or fragments will fall via conduit
1752 and into contained space 1754 within which liquid carbonic
acid has been provided. Following separation of bone fragments by
transfer through conduit 1752, the remaining particles which are
suspended in the liquid carbonic acid, are carried into the inlet
port of Waukesha positive displacement pump 1758 and the combined
flow of carbonic acid with suspended particles is pumped via
Waukesha pump 1758 and through coriolis measuring instrument
1760.
[0163] The temperature of carbonic acid is controlled prior to
transfer into the separation manifold comprising conduit sections
1756, 1766 and toward the confluence 1764 of what becomes conduit
branches 1822, and 1771. Positive displacement pump 1758 is
controlled to the extent that the fluid with suspended solids
carried therein ensures a suitable pressure required to minimize
and substantially eliminate any bubbles or voids in the combined
stream as it is transferred through coriolis measurement instrument
1760. After measurement by coriolis 1760, the combined stream is
transferred into conduit section 1766 and toward confluence 1764.
The temperature of beef particles and the temperature of the liquid
carbonic acid within which the beef particles are suspended, are
arranged such that rapid equilibration can occur around the outer
surfaces of each particle. At any event, equilibration of the
temperature of the lean particles occurs before the confluence
1764, such that the density of the lean particles is increased
before the confluence and will fall to the lower section of the
conduit 1766, so that the majority of lean particles will flow into
conduit 1771. The beef particles and the liquid carbonic acid will
ultimately be of the same temperature, however, time is required to
enable the temperature equilibration and the disclosed method
provides the conditions in which the fat particles will tend to
float and the lean particles will tend to sink when suspended in
the liquid carbonic acid. Furthermore, the method provides the
conditions wherein the fat particles and the lean particles can be
separated rapidly and within less than about 5 seconds after
combining together.
[0164] The density of the lean particles is approximately 66
lbs/cubic foot when not frozen however when frozen, the density
decreases by greater than 9 percent which is due to the expansion
of water within the lean particles. Conversely, the fat particles,
which contain a low percentage of water of about 11 percent, are
not so much affected by temperature as are the lean particles. The
density of the fat particles is approximately 61 lbs/cubic foot
whereas the density of the carbonic acid is greater than 62.3
lbs/cubic foot. Accordingly, the fat particles will float whether
frozen or not, but the lean particles will float only when frozen,
and when not frozen, lean particles having a density of
approximately 66 lbs/cubic foot cannot be suspended by the carbonic
acid and will therefore sink. However at a point in the temperature
equilibration process between the conditions of lean being either
completely frozen or on the other hand completely above the frozen
condition temperature of about 28.5.degree. F., the average density
of the lean particle will be greater than the density of the liquid
within which it is suspended. In this condition, the center or core
regions of each lean particle can be still frozen or a low
temperature and the outer regions close to the surfaces of each
particle will not be frozen. However, the average density will be
greater than that of the liquid in which they are suspended and
accordingly those lean particles will sink to a lower location
within the carbonic acid. The disclosed methods provide the
conditions to enable the separation of fat particles from the lean
particles in a continuous stream but allow the separation of lean
particles to occur when, at least, part of the particles remain in
a frozen condition while the remaining part of the particle is an
unfrozen condition and to then as quickly as can be achieved,
separate the lean particles from the liquid carbonic acid which
carries the lean particles along the low elevation conduit branch
1771 shown in FIG. 4.
[0165] After transfer through coriolis measuring instrument 1760,
the combined stream of carbonic acid and particles is transferred
through conduit section 1766 and, as the transfer occurs, fat
particles and lean particles separate such that the fat particles
occupy an upper region of any section of the conduit section 1766,
whereas the lean particles occupy a lower region of the carbonic
acid within which the particles are suspended and, to the extent
that the combined stream of fat particles and lean particles
suspended in the carbonic acid become arranged in such a manner
that the fat particles occupy the upper section and the lean
particles occupy the lower section of the conduit such that when
the combined stream is transferred into the region 1768, the fat
particles can be directed in the direction shown by arrow 1784 in
branch conduit 1822, whereas the lean particles are suspended in a
portion of the carbonic acid and transferred into branch conduit
1771 that is lower in elevation with respect to branch conduit 1822
in the direction shown by arrow 1770.
[0166] A variable frequency drive controlled Waukesha positive
displacement pump 1786 controls the flow of fat particles and fluid
into conduit 1822 before pump and conduit section 1788 after pump.
Pump 1786 achieves flow control by increasing or decreasing the
speed at which it operates which is controlled via a variable
frequency drive according to the coriolis instrument measured fat
content of the stream transferred via conduit 1788 and through 1790
to conduit section 1789 in the direction shown by arrow 1827. The
measured fat content is compared with lean content of that portion
of the combined lean and carbonic acid stream transferred via
conduit section 1771 and through coriolis instrument 1772 into
conduit section 1773 followed by Waukesha pump 1824, which is also
controlled by a variable frequency drive speed control. In this
way, the measurement data recorded of measurements by coriolis
instruments 1740, 1760, 1790, and 1772 are compared continuously.
The measurement of carbonic acid flow recorded after transfer via
coriolis measuring instrument 1740 is compared with the recorded
data for the same section of carbonic acid combined with the
particles transferred and combined with the carbonic acid via
rotary valve 1712. The mass flow, density, and temperature data
recorded according to coriolis 1760 is compared with the mass flow,
temperature, and density data recorded from measuring instrument
1740 and the difference between the two sets of data will show
precisely the amount of particles that have been transferred and
combined with carbonic acid stream through conduit 1610.
Additionally, data recorded of mass flow, density, and temperature
measurements measured by coriolis instruments 1790 and 1772 can
also be compared and by doing so, the lean content within the
stream transferred via conduit 1772 can be determined and the fat
content of stream transferred via 1790 can also be determined and,
if the lean content of the stream transferred via coriolis 1772 is
insufficient, the speed of Waukesha pumps 1786 and 1824 can be
adjusted to compensate for the lean content by reducing (or
increasing) the mass flow of fluid via section 1822 and the mass
flow of fluid via conduit section 1771 can be increased (or
decreased) and the inadequate proportion of fat compensated by the
addition of a greater quantity of suspended fat with the stream
transferred via conduit 1771. Therefore, it can now be seen that
the coriolis measuring instruments 1740, 1760, 1790, and 1772 can
be used to measure and control Waukesha pumps 1758, 1786, and 1824
so as to direct a fat stream or a lean stream in such a manner as
to enable the lean stream transferred via conduit 1826 in the
direction shown by arrow 1818 and into pressurized centrifuge 1838,
which rapidly removes the lean particles from the suspended
condition in the carbonic acid. The lean particles are then
transferred in a continuous stream via conduit section 1820 and in
the direction shown by arrow 1806 and into free space 1804 of
pressurized vessel 1802.
[0167] Vessel 1802 is suspended on load cells mounted on brackets
1808, 1793, and a third load cell not shown. In this way, the
contents 1800 of vessel 1802 can be weighed. The fat content of
lean beef 1800 can be controlled to within + or -1% lean content.
Space 1804 is pressurized to maintain a pressure within the
separation manifold and conduits of the system as required to
facilitate the retention of carbon dioxide in the fluid separated
by centrifuge 1838 and transferred via Waukesha positive
displacement pump 1812 in the direction shown by arrow 1816 via
conduit 1814 and through coriolis measuring instrument 1842 in the
direction shown by arrow 1844.
[0168] The separated liquid carbonic acid is transferred via
conduit 1846 and into free space 1950 within vessel 1944.
Additionally, the stream of carbonic acid and fat suspended therein
transferred via conduits 1822, 1788, 1789 and 1828 is also
transferred into space 1950, wherein the buoyant fat matter 1948
floats upward to form a segment of fat filling a portion of vessel
1944 and held between the upper horizontal plane 1938 and a lower
horizontal plane 1946. Vessel 1944 is pressurized and provides the
means for fat particles to accumulate in stratum 1940 and to be
transferred through conduit 1928 having an open end 1942 arranged
to enable the pressurized fat particles to be transferred
therethrough and through conduit 1928 and 1932 in the direction
shown by arrow 1930.
[0169] Fat stream transferred there through is then transferred
into emulsifier 1934 and after emulsification in the direction
shown by arrow 1936, which communicates directly with a heat
exchanger followed by decanter centrifuge which separates the oil
from any remaining solids in the stream. Vessel 1944 comprises an
elongated vertically disposed cylindrical tube with a dome closing
the upper end of a tube and a cone at the lower end. A gate valve
is provided at the lower end of the lower cone and a section of,
for example, 6 inch diameter stainless steel tube 1924 is mounted
at the upper end to enable the transfer of carbon dioxide gas via
conduit 1904 and in the direction shown by arrow 1902.
[0170] Liquid carbonic acid from the separation process of the
centrifuge 1838 and liquid carbonic acid containing fat particles
is transferred to the lower section of the pressure vessel 1944,
and the two streams are allowed to combine and any suspended solids
separate by stratification, wherein a small amount of lean matter
1840 may still accumulate at the lowermost section of the vessel
1944 while carbonic acid is allowed to accumulate in a space 1950
at the middle section of the vessel 1944. Fat segment 1940 can
therefore accumulate by flotation to the upper surface of carbonic
acid liquid 1950. The location of inlet ports (2) and outlet ports
(4) is arranged to facilitate the removal of accumulated and
stratified fat via port 1942, stratified lean 1840 via conduit
1830, liquid carbonic acid via conduit 1926 in the direction shown
by arrow 1848. Gas is transferred from space 1864 via conduit 1924,
1904 in the direction shown by arrow 1902 and conduit section 1876
in the direction shown by arrow 1878.
[0171] The stream of carbonic acid discharged from space 1950
within vessel 1944 is transferred into heat exchanger 1918 via
conduit 1906, wherein the temperature of the carbonic acid stream
is increased by at least 30.degree. F. with a heating medium
entering exchanger 1918 via 1914, such that the carbonic acid will
decompose into water and carbon dioxide. The stream of decomposing
heated fluid is transferred into vessel 1872 via conduit 1908 and
port 1870 into space 1877 in the direction shown by arrow 1912.
Carbon dioxide gas is then free to form bubbles and ascend upwardly
in the direction shown by arrow 1874 and to accumulate in space
1898 and 1896 of vessel 1872. Carbon dioxide gas can then be
transferred via conduit 1894 in the direction shown by arrow 1892
to Blackmer compressor 1888 and after compression to about 300 psia
into heat exchanger 1882, via conduit 1890, and then via conduit
1886 in the direction shown by arrow to a suitable storage vessel
prior to reuse. The shell side of tube in shell style heat
exchanger 1882 is filled with chilled fluid transferred therein via
conduit 1884 and the spent fluid returned to its source via conduit
1880 in the direction shown by arrow 1881, in order to cool the
compressed carbon dioxide gas after compression.
[0172] Referring again to FIG. 4 and in particular vessel 1802.
Lean beef 1800 accumulates in the lower portion of the vessel while
carbon dioxide gas pressurized to a selected pressure but most
preferably around 70 psia accumulates in space 1804 and 1810.
Carbon dioxide gas is transferred into space 1804 with the lean
stream and excess gas is released via conduit 1794 in the direction
shown by arrow 1819 wherein said conduit 1794 communicates directly
with conduit 1900 in the direction shown by arrow 1910 to connect
with the carbon dioxide gas exiting vessel 1944. Excess gas
accumulating in space 1864 and 1924 of vessel 1944 above the fluid
surface 1938 is transferred through conduit 1904 in the direction
shown by arrow 1902 and arrow 1878 communicating directly with
conduit 1894, thereby enabling transfer of excess gas from vessels
1872, 1944, and 1802 to carbon dioxide compressor 1888, which
elevates the gas supplied thereto at a pressure of greater than 25
psia compressing the carbon dioxide gas supply to around 300 psia
which is then transferred via conduit 1890 and heat exchanger 1882
to suitable storage vessels (not shown) in the direction shown by
arrow 1886. Arrows 1884 and 1881 represent the introduction of a
cooling medium in the heat exchanger 1882 for cooling the carbon
dioxide gas following compressor 1888.
[0173] Lean 1800 in vessel 1802 is progressively transferred via
bottom port 1798 along conduit 1796 and 1792 in the direction shown
by arrows to port 1780 and into enclosed hopper 1776. Enclosed
hopper 1776 with cover 1778 is sealed and may be pressurized to any
suitable pressure up to around 70 psia or ambient pressure however
lower flange 1782 communicates directly with a vacuum filler such
as a Handtmann VF620 and boneless beef having a predetermined fat
content can thereby be transferred from holding hopper 1776 to any
selected subsequent process such as chub packaging or anoxic case
ready packaging in the direction shown by arrow 1774.
[0174] Heat exchanger 1918 is arranged to provide a means of
heating the liquid carbonic acid transferred therein via conduit
1906. Hot fluid heated to a selected temperature of not more than
200.degree. F. is transferred into the shell side of shell and tube
heat exchanger 1918 so as to circulate around the tube side through
which carbonic acid is transferred. Spent heating fluid is then
discharged and returned to its source via conduit in the direction
shown by arrow 1920 while the heated fluid carbonic acid, carbon
dioxide gas and water, is transferred via conduit 1908 into space
1879 of vessel 1872. Waste water is discharged via port 1868 along
conduit 1866 to a suitable disposal such as a sewer in the
direction shown by arrow 1865.
[0175] 3. Separators
[0176] This section more particularly describes the separators. As
used herein, a separator is the equipment arranged to separate from
a mixture containing fluid, fat particles, and lean particles, at
least one stream of fluid and lean, and preferably separate two
streams one of lean matter and one of fat matter. Particles of fat
are formed, as discussed above, through a bond breaking process
that breaks frozen fat from beef particles, leaving mostly lean on
the remaining particle. The first stream contains fluid and the
majority of the lean particles, and the second, contains fluid and
the majority of the fat particles. The fluid can be carbonic acid,
or a mixture of water and carbon dioxide, or other fluids mentioned
herein. It is to be appreciated that at this stage of separation,
small amounts of lean particles may be entrained in the fluid
stream of fat particles, and small amounts of fat may be entrained
in the fluid stream of lean particles. Indeed, the retention of
some fat, and preferably a desired content of fat content in the
fluid stream of lean particles is desirable to produce a lean
product of desired fat content. The fat may also be present on lean
particles that fails to separate from the lean matter during the
bond breaking process. The first and second fluid streams mentioned
correspond to blocks 32 and 36 of FIG. 1.
[0177] It has been determined that the fat matter of a frozen,
diced piece of beef (or other meats) can be separated from the lean
matter by crushing the frozen beef so as to fracture the fat (fatty
adipose tissue).
[0178] The fat matter behaves quite differently to the lean matter,
particularly when frozen to a temperature below about 25.degree. F.
to about 10.degree. F. or lower, but not to such a low temperature
that will cause the lean to become brittle. When reduced size beef
pieces are frozen in this way, the fat can be shattered and will
crumble providing a suitable means of separating the fat matter
from the lean matter initially present in the beef pieces.
Typically, this method of separation produces much smaller
particles of fat while the lean particle size remains largely
unaffected. It is therefore possible to separate lean from fat by
freezing, shattering the fat matter, and then transferring the
resultant stream of material through a vibratory sieve, which will
allow the small fat particles to pass through a sieve while
transferring the larger lean pieces to another hopper; however, the
sieve is not as cost effective as using the method of flotation in
an anti-microbial carbonic acid.
[0179] The separation of bone fragments, lean and fat relies not
only on the respective densities of bone (cartilaginous matter or
bone), fat, lean, and fluid carbonic acid to cause separation when
all are maintained at a similar temperature, above the freezing
point of water, but also when the water-containing lean and bone
fragments are at a temperature below the freezing point of
water.
[0180] Table 1 (below) lists the densities of; firstly, several
beef components including bone, lean beef, fat and cartilaginous
bone, at both above and below the respective frozen condition; and
also carbonic acid and water. It can be seen that the densities of
the frozen, water-containing beef components of lean and fat have
lower densities compared to their respective unfrozen condition.
This physical variation is because water expands when it freezes.
The temperature at which beef freezes is at about 29.degree. F. or
below. Beef fat will float in water or carbonic acid whether it is
in frozen condition or not but, as can be seen in Table 1, frozen
lean beef having a density of about 59 lbs per cubic foot will
float in water and/or carbonic acid which have densities of about
the same value, about 63 lbs per cubic foot; however, when the lean
beef is not frozen, its density increases to about 65 lbs per cubic
foot and therefore will sink when suspended in water or carbonic
acid. Furthermore, the introduction of initially frozen
water-containing beef into such fluids at a higher temperature than
the frozen beef will cause suspension or floating of the beef
initially. As the temperatures equilibrate, this causes thawing of
the water in the beef with an attendant decrease in volume and
increase in density, which will cause the beef or lean to sink in
the fluid. Neither bone nor cartilaginous bone contain significant
quantities of water and their respective densities are not
significantly affected by freezing followed by thawing; both are
more dense than fat or lean beef.
[0181] The separation methods described herein employ the density
variations described above to provide an effective method of
dividing a quantity of beef into fractions comprising the separated
components of bone, lean beef and beef fat. Beef is used only for
purposes of illustrating the various embodiments, it is to be
appreciated that other meats, including pork, chicken, and fish may
also be used in the disclosed methods. Furthermore, bone or
cartilaginous bone may or may not be present in some
embodiments.
TABLE-US-00002 TABLE 1 APPROXIMATE DENSITIES & WATER CONTENT OF
SPECIFIED MATTER Physical Density % Water Density Matter @
4.degree. C. Content when frozen Bone 118.6 lbs/cu' 0% 118.6
lbs/cu' Cartilage 80 lbs/cu' 0% 80 lbs/cu' Lean Beef 64 lbs/cu' 59%
59.6 lbs/cu' Lean Beef 64 lbs/cu' 73% 58.6 lbs/cu' Carbonic Acid 63
lbs/cu' 70% 58 lbs/cu' Water 62 lbs/cu' 100% 57 lbs/cu' Ice 57
lbs/cu' 100% 57 lbs/cu' Beef Fat 55 lbs/cu' 11% 54.5 lbs/cu'
[0182] Low pH carbonic acid can be manufactured in block 24 of FIG.
1 by combining a quantity of carbon dioxide vapor/gas with clean
pure filtered water at a ratio of weight equal to about 1 part
carbon dioxide to two parts water at a pressure of up to about 150
psia which will provide carbonic acid having a pH of about 2.6
units. Pressure of about 125 psia to 150 psia results in a pH value
of the carbonic acid in the order of between 3.4 and 2.6 pH. The
carbonic acid may be used as a fluid in which to separate the
respective components of beef.
Embodiment 1
[0183] One embodiment for separating respective streams of lean and
fat particles may use the vessel illustrated in FIG. 5. FIG. 5
shows an apparatus 500 designed for the separation of bone
fragments, lean beef and fat particles.
[0184] The arrangement of the vessel 500 illustrated in FIG. 5
comprises an arrangement of 5 pressure vessels, 501, 502, 503, 504,
and 505 that are connected together to provide an assembly of
pressure vessels and configured to allow communication between the
vessels but also having valves 511, 512, 513, 514, 515, and 516
provided at the juncture between any two vessels so as to
facilitate communication between the vessels or the isolation of
each vessel as desired.
[0185] Spaces 510 and 590 have a combined volume sufficient to
accommodate a full charge of beef (meat) pieces, wherein the charge
has a volume and/or mass equal to the maximum quantity of beef
pieces that can be processed in one cycle of the apparatus 500.
[0186] The space 508 is equal to approximately 4 times the combined
space of 510 and 590, and the space 509 is approximately equal to
the maximum quantity of beef fat that can be processed by the
separation apparatus 500.
[0187] The arrangement of vessel 500 as shown in FIG. 5 is
constructed with vessel 502 at the upper end of a vertically
disposed arrangement with vessel 503, which is centrally located.
Vessels 504 and 505 are also vertically disposed below vessel 503,
and loading vessel 501 is mounted above and to the side of the main
separation vessel 503.
[0188] The sequence of operation is as follows:
[0189] With valves 511 open and valve 513 closed, a charge of
carbonic acid, lean particles, and fat particles, and bone, frozen
to below 29.5 F and most preferably below 27 F and as low as 15 F,
are transferred into space 510, after which valve 511 is closed.
Carbon dioxide gas is provided into voids remaining in space 510 up
to a pressure of about 150 psia. With valves 512, 513, and 514
closed, space 508 is pressurized to about the same pressure as
space 510 with carbon dioxide and valve 513 is opened such that
aperture at 521 is fully open, thereby allowing the contents of
space 510 to transfer by gravity feed into the lower region of
space 508, after which valve 513 is fully closed. Space 510 can be
now reloaded in readiness for the next loading cycle of space
508.
[0190] Carbonic acid, water, filtered water, distilled water,
potable water, water having been transferred through reverse
osmotic treatment to produce potable water, or any suitable
antimicrobial organic acid or alkali having a density of about
62-63 lbs per square foot at a temperature of about 40 F to 60 F is
transferred into space 509, the remaining space in 508 and spaces
556 and 506 under pressure at about 150 psia. The antimicrobial
fluid is recycled through ports 550, 584, 542, 544, and 592 at such
a rate of flow so as to create turbulence and agitation of the
mixture of particles which are now suspended in the antimicrobial
fluid that fills the entire inner spaces of vessels 502, 503, 504,
and 505. The valves 512, 514, and 515 are opened while the beef
particles remain substantially frozen and the agitation is stopped
so as to allow bone fragments to settle by sedimentation into the
lowermost space 505. Before the temperature of the beef particles
within vessels 502, 503, 504, and 505 equilibrates with the
antimicrobial fluid in which it is suspended to an equilibrated
temperature of above 32 F, the valve 515 is closed to isolate all
bone particles or chips in space 506. When the temperature of lean
and fat matter of the beef particles transferred into space 508 is
below the freezing temperature of the water contained within the
particles, both fat and lean particles will remain suspended in the
fluid because the density of the particles is less than the density
of the antimicrobial fluid; however, when the temperature of the
fluid and particles equilibrates, the lean particles will sink into
space 504 and below valve 514 at which time valve 514 is closed so
as to isolate spaces 508 and 504. Fat particles float upward into
space 509 after which valve 512 is closed so as to isolate space
509.
[0191] The quantity of fat particles at about 34 F or more, which
are now enclosed within space 509, is extracted, most preferably by
vacuum, via port 594 and through conduit 532 in the direction shown
by arrow 536.
[0192] Bone chips and unwanted cartilaginous bone is removed via
port 564 and/or via aperture 517 after valve 516 is opened.
[0193] Lean beef (meat) is extracted via port 518 in valve 515 and
through port 517 in valve 516, and then through conduit 566 and
port 568, and transferred for further processing into edible
food.
[0194] Fluids can be extracted through spaces 558, 570, after
passing through holes 554, 572, 560, and also via ports 562 and
564, for water and carbon dioxide recovery for subsequent recycling
prior to removal of solids as described above. Vessel 504 can
include an outer cylindrical shell that tapers to a smaller
diameter at the bottom. Within the vessel 504 are provided a series
of frustoconically shaped vessels numbered 576, 574, 575 and 507
from top to bottom, wherein the wider "bases" are oriented towards
the upper portion of vessel. The side with the smaller diameter of
the frustoconically shaped vessel fits within the side of the
larger diameter of an adjacent vessel. This difference in diameter
allows the placement of annular screens with holes 554, 572, and
560 in the annular space between the frustoconical vessels.
Furthermore, the frustoconical shape creates spaces between the
frustoconically shaped vessels and the interior of the outer shell
of vessel 504.
Embodiment 2
[0195] A manifold as used herein when referring to a separator
takes the from of a conduit that branches from a main conduit
transferring the mixture of fluid, fat and lean particles into at
least two or more conduit branches. The two or more conduit
branches are, respective to each other, different in elevation, so
that matter that is lower in the main conduit may be transferred to
the low conduit branch, while matter that is higher in the main
conduit is transferred to the higher conduit branch.
[0196] Referring to FIG. 6, a manifold 122 used as a separator is
arranged between a feed hopper 86 at ambient pressure, and rotary
valve 92 (block 22 of FIG. 1) with driver 88 on the in-put end of
the manifold assembly and the spent liquid centrifuges 162 and 180
at the output. The manifold separator 122 may be used as the
separator block 30 of FIG. 1.
[0197] Hopper 86 is loaded most preferably by way of an enclosed
conduit with frozen beef particles in the direction shown by arrows
80 from the bond breaking compression device. The frozen beef
particles refer to the fat and lean particles produced by the bond
breaking compression device, block 12 of FIG. 1. Hopper 86 is
attached directly to the upper side of a rotary valve 92 which
provides the means of transferring the frozen beef particles from
hopper 86 into vertically disposed column conduit 106 when the
pressure within conduit 106 is maintained at a constant elevated
pressure such as 50 psia or 70 psia. If required, carbon dioxide
gas is injected into hopper 86 via connection tube 82 with on/off
valve 84 in the direction shown by arrow 90.
[0198] Conduit 106 is attached directly to the underside of rotary
valve 92 via a connection member 94 into which carbon dioxide gas
can be injected via tubes 100 and 98 in the direction shown by
arrows 102 and 96 respectively. Frozen beef particles 104 including
fat and lean particles are shown descending in the direction shown
by arrow 200 toward mixing section 116 between carbonic acid
injection ports 112 and 110 via which carbonic acid is injected in
the directions shown by arrows 114 and 108. The blended beef
particles including fat and lean particles and carbonic acid fluid
118 continue downward through reducing conical member 120 and
around radius 122 in the direction shown by arrow 124.
[0199] Immediately after the 90 degree bend in the conduit 122 at
the lowermost underside point, tube 119 is attached and
communicates directly with pressurized vessel 123 filled with fluid
117. In one embodiment, the tube 119 is configured to be at or
approximately tangent to the lowermost end of the bend 122. However
in other embodiments, the tube 119 can be placed at a horizontal
run of conduit, wherein the tube 119 branches at an angle less than
or equal to 90 degrees. The purpose of tube 119 and vessel 123 is
to allow the heavy bone fragments that occasionally occur in
boneless beef to be separated by following conduit 119 into vessel
123 and accumulating therein as bone or cartilage matter 121
thereby being removed from the boneless beef. It is to be
appreciated that the frozen or partially frozen lean particles by
the time they pass above tube 119 have not yet thawed sufficiently
to cause their density to increase and fall to the lower side of
conduit 122 and are still suspended in the mixture. Thus, this
avoids the lean particles being carried with bone and cartilage
into tube 119 and vessel 123.
[0200] The temperature of the carbonic acid injected via inlet
ports 112 and 110 must be sufficient to elevate the temperature of
the boneless beef particles including fat and lean particles such
that any water contained therein will thaw. The temperature of the
water contained within the boneless beef particles should be on the
order of 32-34.degree. F. after equilibration. The proportion of
carbonic acid expressed as a ratio to the frozen beef particles
including fat and lean particles should be in the range of not less
that 1:1 and not more than 6:1, wherein, with a ratio of 1:1, the
quantities are equal or not more than six parts carbonic acid and
one part beef particles.
[0201] Density of beef tallow or fat is approximately 55 lbs/cubic
foot whereas the density of lean beef is approximately 66 lbs/cubic
foot when not frozen. When frozen, lean beef has a density of
around 60 lbs/cubic foot and beef fat around about 54 lbs/cubic
foot. Given that carbonic acid has a density of approximately 62.4
lbs/cubic foot when frozen, both lean beef and beef fat will float
after immersion in carbonic acid. However lean beef with a density
of 66 lbs/cubic foot when not frozen will therefore sink when no
longer frozen. The apparatus shown in FIG. 6 is arranged to take
advantage of these variations in density by allowing bone fragments
to be separated from the mixture via conduit 119, while both beef
fat and lean 128 are still frozen and therefore will flow following
the upper side of conduit 130. As the mixture of carbonic acid and
beef particles including fat and lean particles flow through
conduit 130 in the direction shown by arrow 126, lean particles
increase in temperature such that the water contained therein will
begin to thaw and is no longer frozen. As this occurs, the density
of the lean particles increases so that the lean particles fall to
the lower side of the conduit 130, thus, facilitating the
separation of the lean particles via a low elevation branch conduit
140 in the direction shown by arrow 136 and the lighter fatty
particles follow in the direction shown by arrow 132 through a
higher elevation branch conduit 134. However, any particles that
remain suspended in the carbon dioxide will continue in the
direction shown by arrow 202 through a third middle elevation
branch conduit 138. The third middle elevation branch conduit 138
then branches, so that one branch reconnects with the higher
elevation conduit branch 138, and one branch from middle branch 138
reconnects with the lower elevation branch conduit 140. Middle
elevation branch conduit 138 provides additional length for fat
particles and lean particles to diverge into upper and lower spaces
in the conduit.
[0202] High and low elevation conduits 134 and 140 then connect
with respective pumps 144 and 154, which then feed respective
centrifuges 162 and 180. High and low elevation conduits 134 and
140 may include respective measuring instruments, such as coriolis
flow meters, to measure flow rate, density and temperature to
derive a fat or water content, and these measurements may be used
to adjust the flow rate of pumps 144, 154. A fourth branch conduit
113, optionally, of smaller diameter than branch conduit 134
communicates at a 45 degree disposition with positive displacement
pump 115. Conduit 113 branches from conduit 134 at the end of a
bend before conduit 134 returns to a horizontal run. Positive
displacement pump 115 controls the amount of fluid with suspended
solids that travel in the direction shown by arrow 107. As the
lighter fatty particles change direction following the conduit 134
and shown by arrow 142, the lightest smallest fat particles are
drawn into conduit 113 and in this way substantially pure fat
particles substantially excluding protein or connective tissue can
be drawn into conduit 113 in the direction shown by arrow 107. The
remaining lighter particles but still heavier than particles in
conduit 113 continue in the direction shown by arrow 142 and into
positive displacement pump 144 which controls the mass flow of
suspended solids and fluid into centrifuge 162.
[0203] The heavier lean particles and carbonic acid flow along
conduit 140 in the direction shown by arrow 150 and into positive
displacement pump 154 which controls the mass flow of the solids
and fluids into centrifuge 180. Both centrifuges are arranged to
remove the spent carbonic acid from the streams of solids which are
discharged via separate ports. Thus, these fulfill the function of
blocks 42 and 48 of FIG. 1. However, other liquid separators
described herein may be substituted for the centrifuges 162 and
180, such as buoyancy separators. The liquid carbonic acid
separated from the solid fat particles in centrifuge 162 is
discharged via a port in the direction shown by arrow 158 and the
liquid carbonic acid separated from the solid lean particles in
centrifuge 180 is discharged via port 155 in the direction shown by
arrow 156. The fat particles are discharged via a port at the
opposite end of the centrifuge in the direction shown by arrows 170
and 174 and the lean particles are discharged via port 184 in the
direction shown by arrows 186 and 182. Because the fat content of
lean particles traveling in conduit 140 has been measured and
adjusted through the control of pumps withdrawing a greater or
lesser volume of the fat particles, the separated lean particles
may be produced having a desired fat content. Alternatively, the
liquid free fat and lean particles exiting centrifuges may be
weighed and combined in desired proportions to arrive at a desired
fat content product. The liquid carbonic acid discharged from
centrifuges may be sent to a carbon dioxide recovery process as
described above, and any carbon dioxide gas vented from any
equipment may be directed to a carbon dioxide gas treatment process
and compression as described above to be reused to make carbonic
acid or as the carbon dioxide gas injected into the bottom of
rotary valve 92 through ports 98 and 100.
Embodiment 3
[0204] Referring to FIG. 7, a manifold used as a separator is
arranged between a feed hopper 1300 at ambient pressure, and rotary
valve 1300 (block 22 of FIG. 1) with driver 1302 on the in-put end
of the manifold assembly and the spent liquid centrifuges 1362 and
1386 at the output. The manifold separator may be used as the
separator block 30 of FIG. 1.
[0205] The assembly and operation of the apparatus shown in FIG. 7
is similar to the operation of the apparatus shown in FIG. 6,
however the fat stream is processed differently in the apparatus
shown in FIG. 7.
[0206] As can be seen in FIG. 7, the process is similar to FIG. 6
up to the 90 degree bend following the introduction of carbonic
acid fluid through ports 1326 and 1330. After the 90 degree bend
1348, the horizontal conduit 1410 with fluid being transferred in
the direction shown by arrow 1414, diverges into two conduits with
a lower branch conduit 1354 and an upwardly disposed branch conduit
1352. In this way, lean particles and a proportion of carbonic acid
are directed in the direction shown by arrow 1404 through
downwardly inclined branch conduit 1354 and then horizontally in
section 1402. However, the fat particles and a proportion of
carbonic acid is transferred upwardly and then in the direction
shown by arrow 1336 to positive displacement pump 1334 which pumps
under pressure the fat with fluid in the direction shown by arrow
1332, via conduit 1342 and into "emulsifying" device 1344. Device
1344 is described herein in association with FIGS. 11 and 12 and is
constructed for the purpose of separating any fat matter that
remains connected to connective tissue. The fluid and fat in the
fat stream diverted and processed by pumping via device 1344 is
subjected to an explosive force when transferred through a narrow
annular slot which "scrapes" fat from other more pliable and tough
matter. The processed stream is then transferred via a conduit in
the direction of arrows 1346 and 1412 through a horizontal conduit
1350. Horizontal conduit 1350 transferring emulsified fat particles
and other tissue, then branches into three branches of high,
middle, and low elevations.
[0207] The high elevation branch conduit 1338 connects to pump 1358
followed by centrifuge 1362. The middle elevation branch conduit
1339 has a short horizontal run and then branches into an upwardly
inclined high branch 1406 that reconnects with high elevation
branch 1338, and a downwardly inclined low branch 1396 that
reconnects with initial branch 1402 carrying the lean particles.
The low elevation branch 1408 from conduit 1350 connects to branch
1402 carrying lean particles 1402 at a location before the
connection from middle elevation conduit downwardly inclined branch
1396. In this way, the emulsified materials are connected with the
separation manifold upstream of upward and downward conduits which
allow heavier lean components to sink into conduit 1392 and lighter
fat particles to conduit section 1338 and forward to respective
centrifuges 1362 and 1384.
[0208] High and low elevation branch conduits 1364 and 1400 before
pumps 1358 and 1390 may include respective measuring instruments,
such as coriolis flow meters, to measure flow rate, and density to
derive a fat content, and these measurements may be used to adjust
the flow rate of pumps 1358 and 1390 that feed centrifuges 1362 and
1386. Both centrifuges 1362 and 1386 are arranged to remove the
spent carbonic acid from the streams of solids which are discharged
via separate ports. Thus, these fulfill the function of blocks 42
and 48 of FIG. 1. However, other liquid separators described herein
may be substituted for the centrifuges 1362 and 1386, such as
buoyancy separators. The liquid carbonic acid separated from the
solid fat particles in centrifuge 1362 is discharged via a port in
the direction shown by arrow 1358 and the liquid carbonic acid
separated from the solid lean particles in centrifuge 1386 is
discharged via a port in the direction shown by arrow 1388. The fat
particles are discharged via a port at the opposite end of the
centrifuge 1362 in the direction shown by arrows 1374 and 1372 and
the lean particles are discharged via a port 1382 in the direction
shown by arrows 1380 and 1384. Because the fat content of lean
particles traveling in conduit 1400 has been measured and adjusted
through the control of pumps withdrawing a greater or lesser volume
of the fat particles, the separated lean particles may be produced
having a desired fat content. Alternatively, the liquid free fat
and lean particles exiting centrifuges may be weighed and combined
in desired proportions to arrive at a desired fat content product.
The liquid carbonic acid discharged from centrifuges may be sent to
a carbon dioxide recovery process as described above, and any
carbon dioxide gas vented from any equipment may be directed to a
carbon dioxide gas treatment process and compression as described
above to be reused to make carbonic acid or as the carbon dioxide
gas injected into the bottom of rotary valve 1309 through ports
1398 and 1318.
Embodiment 4
[0209] Referring now to FIG. 8, another embodiment of a separation
manifold 1600 is illustrated. The separation manifold 1600 can be
used as the separator block 30 mentioned in association with FIG.
1. In this embodiment, the apparatus is intended to enable the
continuous flow of a stream in the direction shown by arrow 1658
within conduit 1616 and in to manifold 1662, wherein the stream
comprises solids introduced via rotary valve 1608, which allows a
controlled flow of solids from hopper 1606 and contents 1684 and
into space 1714, immediately above fluid introduced via conduit
1654, 1620, and 1648, in the direction shown by arrows 1645 and
1618.
[0210] Fluid introduced into vertical column at 1712, such as
carbonic acid, is measured by a coriolis measuring instrument 1652.
Controlled flow of carbon dioxide vapor is introduced via conduits
1636 and 1610 and the total can be measured by a coriolis measuring
instrument 1640. An additional coriolis instrument provided in
Section 1708 (but not shown) measures the combined stream
comprising carbonic acid fluid, lean particles, and fat particles,
flowing in the direction 1658. The proportion of fluid, solids, and
carbon dioxide gas are adjusted to achieve optimal operation of the
apparatus. If too much carbon dioxide is present it will not
dissolve in the fluid and will affect the accuracy of coriolis
measuring instruments, therefore, the flow of carbon dioxide vapor
and carbonic acid transferred through conduits 1636 and 1654
respectively must be measured and controlled accurately to ensure
any gas introduced via conduit 1636 and 1610 will dissolve.
[0211] Solids at 1714 combine with the carbon dioxide vapor which
acts as a barrier between the fluid entering at 1712 through ports
1618 and 1644 to ensure that the fluid cannot come into contact
with the underside of rotary valve 1608. The combined stream within
conduit 1616 is measured by coriolis measuring instrument installed
at space 1708, followed by a large diameter coriolis measuring
instrument.
[0212] In this embodiment, the manifold is a large diameter conduit
1624 having a series of horizontal plates. The horizontal plates
are aligned parallel to each other within the conduit 1624. The
higher a plate is in elevation, the more the plate is located
forward of the adjacent plate lower in elevation. Thus, each
horizontal plate has a forward end (or proximal side) that
terminates closer from the entrance of conduit 1624, than a
horizontal plate below it.
[0213] The solids introduced into the conduit 1624 enter space 1622
after transfer through a positive displacement pump and coriolis
(both not shown) inserted in space 1708. Within space 1622, the
lean solids particles have preferably reached equilibrium of
temperature with the fluid to allow the increase in density that
comes with the thawing of frozen water within the lean matter. The
pump delivers the fluid mixture with suspended solids at a
controlled rate into the space 1622 so as to enable the fat content
to elevate and stratify up against the underside of the upper
section of manifold 1624 whereas the heavier solids such as lean
will sink and accumulate at the lower section near location
1662.
[0214] The series of horizontal plates within manifold 1624 are
provided to ensure lateral flow does not facilitate mixing of the
separated stratified particles. The distal side of manifold 1624
branches into three conduit branches, including high conduit branch
1694 which is highest in elevation, low conduit branch 1672, which
is lowest in elevation, and middle conduit branch 1682, which is
between the low and high conduit. One horizontal dividing plate
1683 can extend distally to completely separate the low conduit
branch 1672 form the middle conduit branch 1684. The dividing plate
1683 separates the horizontal plates into an upper array and a
lower array. The lower array feed into low conduit branch 1672
only, while the upper array variously feeds both the high 1694 and
middle 1682 branch conduits.
[0215] Within manifold 1624, a pivoting plate 1770 is provided. A
horizontal and stationary dividing plate 1696 is located distal to
the pivoting plate 1700. The horizontal plate 1696 separates the
high conduit branch 1694 from the middle conduit branch 1682. The
proximal end of pivoting plate 1770 can be positioned at the end of
any of the distal ends of the horizontal plates that comprise the
upper array of horizontal plates above the dividing plate 1683. The
pivoting plate 1770 thus can be positioned so that one or more of
the upper array horizontal plates feed into the high conduit branch
1694, while the remaining horizontal plates of upper array feed
into the middle conduit branch 1684. As illustrated, the fluid with
solid particles collected in space 1702 above the plate 1700 will
flow toward the high conduit branch 1694, while the fluid with
solid particles collected in space 1680 below the plate 1700 will
flow toward the middle conduit branch 1682. It is believed that the
higher a particle is in fat content, the higher in elevation the
fat particle will float in the fluid. Thus, the higher the pivoting
plate 1770 is positioned, the higher the fat percentage will be the
stream collected in the high conduit branch 1694.
[0216] Plate 1700 can be positioned as shown by movement indicated
by arrows 1704 and 1706. High conduit branch 1694 has a coriolis
measuring instrument 1692. Middle conduit branch 1682 has a
coriolis measuring instrument 1688. Low conduit branch 1672 has a
coriolis measuring instrument 1674. In this way, fat content of
suspended solids flowing along high conduit branch 1694 can be
either increased or decreased according to measurements recorded by
coriolis measuring instrument 1692 or 1688. Coriolis measuring
instruments 1674, 1688, and 1692 can also control fat content of
each of the streams represented by arrows 1690, 1686, and 1678 when
positive displacement pumps are connected directly inline with
conduits 1694, 1682, and 1672.
Embodiment 5
[0217] Referring to FIG. 9, the side elevation of a manifold 2528
is shown with four cross section views A-A, B-B, C-C, and D-D taken
along the length. The embodiment of a manifold 2528 illustrated in
FIG. 9 may be applied to anyone of the manifold separators
illustrated in FIGS. 2, 3, 4, 6, 7, and 8.
[0218] The manifold 2528 is arranged to enable the separation of a
single stream of particles suspended in a fluid such as carbonic
acid wherein particles, some of which are approximately 100% fat,
some are approximately 100% lean, and others are a combination of
fat and lean in varying percentages between 100% lean and 100% fat.
Arrows 2522 show the direction in which the stream with suspended
particles is flowing within the conduit 2528 under selected
pressure such as 70 psi or several hundred psi such as 200, 300,
400 or more. The manifold separator 2528 includes a changing
cross-sectional profile as the separation manifold approaches the
diverging conduit branches. The manifold 2528 cross-sectional
aspect ratio (the width divided by the height) decreases from a
proximal to distal position. This decrease in the aspect ratio
assists to provide better separation.
[0219] At cross section A-A shown as 2508, the separation manifold
2528 has a circular profile 2556. At cross section B-B shown as
2510, the separation manifold 2528 is elongated in the vertical
direction as shown in 2562. At cross section C-C shown as 2512, the
separation manifold 2528 is elongated even further, and at cross
section D-D, the separation manifold 2528 is even more so.
[0220] The diameter of cross section A-A 2556 may be in the order
of 6 inches whereas the width at section D-D of the manifold may be
1 inch to 11/2 inches by approximately 6-8 inches in height and the
manifold profile between section A-A and D-D gradually changes in
such a way that no sharp corners are created. The fluid stream with
suspended particles in carbonic acid represented by arrows 2522 is
transferred through manifold 2528 and divided into three streams in
three conduit branches, 2538, 2544, and 2552, represented by arrows
2540, 2542, 2554.
[0221] Referring to circular cross section A-A, in the lower
section, particles 2502 higher in lean content stratify by
sedimentation, whereas the particles 2556 higher in fat content are
stratified at the upper inner side of the circular conduit, which
are the lighter, less dense particles. At the central section 2558,
the density of particles suspended in the fluid is between the
upper and lower extremes. As stream 2522 travels under controlled
positive displacement pump flow, the manifold profile gradually
changes and at cross section B-B represented by member 2510,
stratified suspended particles are shown to be located at the upper
2562 and lower 2566 extremes with space 2564 generally containing
few particles. As the profile changes moving further down the
manifold 2528 to the cross section 2512, the light particles 2568
located at the upper extreme of manifold 2528 are now further away
from the denser particles 2572 which are located at the lower end
of the elongated cross section. Cross section D-D shows even
greater separation of the lighter particles 2578 in the upper
section 2516 from the more dense particles in the low section at
2574 with middle section 2576 carrying the least accumulation of
particles.
[0222] A pump is attached to the conduit 2538. The mass flow of
fluid with suspended particles extracted in the direction shown by
arrows 2540 within conduit branch 2538 is controlled by the
positive displacement pump driven by variable frequency drive speed
control. Similarly a positive displacement pump is attached to
conduit branch 2544 so as to control mass flow of the fluid with
suspended particles passing through conduit 2544 in the direction
shown by arrows 2542. It is not necessary to install a positive
displacement pump attached at conduit branch 2552 since the flow
control of stream 2544 is determined by the combined flow of
streams represented by arrows 2540 and 2542. By adjusting the mass
flow of one or both of the streams 2540, and 2542, the fat content
and the lean content of each stream can be adjusted. For example,
by slowing mass flow through conduit branch 2538, fat content in
the lower streams will increase, and by increasing mass flow
through conduit 2538, the fat content of the lower streams shown by
2542 and 2554 will be reduced. Although the embodiment just
described may have mass flow control on the high conduit branch
2538 and the middle conduit branch 2544, the pump on either can be
omitted and placed on the lower conduit branch 2552. In general,
for X number of conduit branches, X-1 pumps can be used to control
the flow of all conduit branches, so that the flow through the
conduit branch without a pump, is controlled as a result of control
of the other flows.
Embodiment 6
[0223] Referring to FIG. 10, an embodiment of a separation manifold
1970 is illustrated. The separation manifold 1970 can be used as
the separator block 30 mentioned in association with FIG. 1. The
separation manifold illustrated in FIG. 10 may be substituted for
any of the previous embodiments of separation manifolds illustrated
in FIGS. 2, 3, 4, 6, 7, 8, and 9. The separation manifold 1970
includes that portion of the manifold that receives an inlet fluid
comprising fat particles and lean particles and produces at least
two fluid streams, respectively of high fat and high lean content.
One fluid stream includes essentially fat particles, while the
second fluid stream includes lean particles and a generally desired
content of fat particles so that the majority of the particles are
lean particles. The remaining solids are determined to result in a
desired concentration of fat.
[0224] In FIG. 10, the inlet fluid stream 1900, shown as arrows,
enters inlet 1902. The fluid 1900 includes fat particles and lean
particles in a fluid mixture. The fluid passes through an interior
centrally disposed nozzle 1986, which outlets at 1984. The purpose
of nozzle 1986 will be described further below. In one embodiment,
as the inlet fluid passes the nozzle 1986, the manifold enters a
convergent section 1946. In the convergent section 1946, the
diameter of the inlet 1902 can reduce to a smaller diameter, which
has the effect of increasing the speed of the inlet fluid 1980
together with the fluid 1982 exiting the nozzle 1986. After
entering the convergent section 1946 and passing into the small
diameter of the convergent section 1946, the separation manifold
may be constructed from a block 1970.
[0225] Block 1970, the separation manifold, can be described as
follows. From the small diameter following the convergent section
1946, the separation manifold expands in diameter. At its greatest
diameter, the manifold branches into four distinct separate
conduits. The separation manifold gradually expands in diameter to
reach a maximum diameter. At or approximately at the largest
diameter, the separation manifold branches into four conduit
branches, each conduit branch being a smaller diameter than the
maximum diameter prior to the conduit branches. The first conduit
branch 1964 is highest in elevation, and as described before, the
highest elevation of the fluid contains substantially all fat
particles, denoted by arrow 1956. The fluid that is drawn into
branch conduit 1964 enters pump 1966, which transfers the fluid and
fat particles denoted as arrow 1968 to the fat/liquid separation,
block 48, illustrated in FIG. 1. The lowest elevation conduit
branch 1910 carries a majority of lean particles and may further
carry a desired proportion of fat particles. The lowest conduit
branch 1910 does not have a pump and exits through outlet 1912 and
the fluid with the majority of lean particles and a desired or
minor proportion of fat solid particles 1914 can be transferred to
liquid/separation, block 42 illustrated in FIG. 1. Two middle
conduits, respectively 1928 and 1962, are intermediate in elevation
between the high elevation conduit branch 1964 and the low
elevation conduit branch 1910. The middle branch conduits 1962 and
1928 rejoin each other at the inlet for pump 1922. Upper middle
branch 1962 and lower middle branch 1928 essentially collect fluid
with minimal solid matter from the central portion of the manifold.
From pump 1922, the fluid is transferred through pump outlet 1920
and then into coriolis measuring instrument 1916 and to conduit
1906. The fluid then enters device 1904, which is generally an
emulsifier of fat that further separates any remaining fat from
connective tissue. Following emulsifier 1904, the fluid is injected
in the middle of the inlet stream 1900. The emulsification of any
fat and connective tissue allows for the separation and collection
of additional fat.
[0226] The separation manifold 1970 includes a divider 1942 placed
in the path of the stream at 1978. The divider 1942 includes an
injection port 1940, which injects clear fluid, denoted by arrows
1938 into the separation manifold and with the direction of flow of
the fluid. The divider 1942 may have a singular point at the
proximal edge and two distal points at the distal end, appearing to
be two mirror image chevrons. Clear fluid is dispensed between the
distal points and with the flow of the fluid. The clear fluid will
generally flow into the upper and lower middle conduit branches
1962 and 1928. The clear fluid provides a layer of fluid that
allows any fat that gets entrained in the lower section of the
separation manifold to migrate through the clear fluid in the
center of the stream in the direction shown by arrow 1932, and to
combine with the fat particles flowing in the direction of arrow
1972 to enter into the higher elevation conduit 1964. Similarly,
any lean particles that become entrained and are transferred in the
flow stream above the divider 1942 will migrate across the clear
fluid stream in the direction of arrow 1974 to rejoin the
essentially all-lean stream 1930 and exit through the lower branch
conduit 1910. The fat particles that are entrained in the flow
below the divider 1942 will cross the clear fluid boundary layer
and rejoin the flow of essentially all fat particles 1972 and exit
through the higher branch conduit 1964.
[0227] As can be appreciated there is one inlet stream to manifold
1970 and two outlet streams. A measuring instrument from which it
is possible to determine the fat content of a stream, such as a
coriolis measuring instrument, may be placed inline on the conduit
1968 from pump 1966, and on conduit 1912. The speed of the pump
1966 can control the amount of fat that leaves with the lean solid
particles through conduit 1910. For example, by slowing the pump
1966, more fat will enter the lean stream and leave through lower
conduit branch 1912. Conversely, speeding up the pump 1966 will
withdraw more fat from the system thus leaving less fat to exit
with the lean particle stream 1910 through lower conduit branch
1912. As can be appreciated the fat content of the flow through
conduit 1912 may be controlled to produce a product having a
desired fat content.
Embodiment 7
[0228] Referring to FIG. 16, another embodiment of a conduit used
as a manifold separator 3100 is illustrated. The manifold separator
3100 may be used as the separation block 30 in the method
illustrated in FIG. 1. The manifold separator 3100 comprises a
"triangular" shaped chamber defined by sides 3153 at the upper
right, 3133 at the lower right and 3143 at the upper left, and has
a rectangular cross section and is about 6 inches deep. The
separator 3100 is configured such that a corner where the sides
3153 and 3143 meet is positioned to be the highest in
elevation.
[0229] Ports are also provided at each lower corner. Thin gauge
plates such as 3142, 3144, 3140, 3162 are fixed in a vertical
disposition across the flat front and flat back of the separator
chamber. The vertical plates are spaced apart so as to restrict
fluid and suspended solids movement to a vertical direction such as
shown by arrow 3160. The vertical plates allow spaces between the
plates and the three sides 3153, 3133, and 3143, so that fluid and
lean and fat matter can be carried therethrough. Conduit 3110 is
the entry conduit for a "slurry" of treated beef particles (having
been chilled, transferred through the bond breaking device (block
12 of FIG. 1) and mixed with a measured (minimized) quantity of
fluid such as carbonic acid or water etc) in direction of arrow
3106. Jets of more temperature controlled fluid are transferred
into space 3119 via ports 3113 and 3117. Lighter fat particles will
separate and move upwards or float in the direction shown by arrows
3120, 3122, 3126, while heavier lean particles will sink in the
direction shown by arrows 3124, 3128, 3130 and will collect in
conduits 3133, 3132 in direction shown by arrows 3134.
[0230] Excess fluid is extracted via a port 3136 in the direction
shown by arrow 3138. Input and output streams may be mass flow
controlled by pumps such as WAUKESHA 3152, and 3192. Coriolis
measuring instrument 3100 and homogenizing member 3102 are arranged
to measure and treat the fat and lean stream transferred through
conduit 3198, 3196 in the direction shown by narrows 3194, 3104 and
mass flow controlled according to a "balanced" input and output
control system. Fat stream represented by stream 3190 is flow
controlled by Waukesha pump 3152 via port 3148.
[0231] The embodiment of FIG. 16 can minimize the amount of fluid
required by providing adequate fluid at the place of separation
only. For example, very little fluid will leave with the fat stream
represented by arrow 3196.
Embodiment 8
[0232] Referring to FIGS. 17A-17B, a method and an apparatus for
pathogen deactivation combined with separation are illustrated.
[0233] First and second vessels, 220 and 222, of similar capacity
are arranged in parallel at close proximity and at a common height.
A single direct connection between the vessels 220, 222, is located
at the highest altitude in each vessel and comprises a horizontal
conduit 218 with a valve 216 centrally located. The conduit 218
communicates at each end via a single port with each of the first
220 and second 222 vessels.
[0234] Both first 220 and second 222 vessels have a large diameter,
and upper and lower ports. Vessel 220 has upper port 240 and lower
port 230. Vessel 222 has upper port 226 and lower port 224. Each
port is fitted with a suitable valve. Each port is located at
opposite sides of the first and second vessels with a first
centrally located along the upper ridge of the vessel and a second
along the lower ridge of the vessel.
[0235] Each vessel 220 and 222 has a first and second piston. For
example, vessel 220 has pistons 208 and 210. Vessel 222 is
similarly fitted with two pistons. Each of the first and second
pistons are attached to first and second piston rods with each
piston fitted into opposing ends of each vessel. Suitably sized and
mounted hydraulic cylinders are arranged to drive each piston
independently or simultaneously toward or away from the
perpendicular centerline of each first 220 and second 222
vessels.
[0236] Diced beef is chilled and treated to break the friable fat
away from the lean matter as described above, and the beef pieces
201 comprising lean particles and fat particles are loaded into a
feed hopper 204 via port 202. The first vessel 220 is then filled
through port 240 to about 50% of vessel's 220 internal volume and
the remaining space is then filled with liquid carbon dioxide 212
through port 230 and pressurized to 495 psia+/-2 psia.
[0237] The second vessel 222 is filled with carbon dioxide vapor at
495 psia and connected directly, via conduit 218, with the space
232 of the first vessel 220 above the beef pieces 228 and in such a
way as to ensure constant (equal) pressure in first 220 and second
222 vessels.
[0238] At greater than 400 psia and 18.degree. F. (density of
carbon dioxide is 60.20 lbs/cubic foot) and less than 536 psia at
36.degree. F. (density of carbon dioxide is 56.92 lbs/cubic foot)
and most preferably at between 490 psia at 30.degree. F. (density
of carbon dioxide is 58 lbs/cubic foot) and at 505 psia at
32.degree. F. (density of carbon dioxide is 57.77 lbs/cubic foot).
The density of beef fat and beef lean, held at a temperature
ranging between 18.degree. F. to 36.degree. F. is about 55
lbs./cubic foot to 56 lbs./cubic foot for fat and between about 60
lbs./cubic foot and 66 lbs./cubic foot for lean beef and between
29.5.degree. F. to 32.degree. F. about 55 lbs./cubic foot for fat
and 66 lbs./cubic foot for lean beef (i.e., above temperature of
frozen water) lean has a density of about 66 lbs/cubic foot.
[0239] The contents of the first vessel 220 is then agitated
gently, so as to enable the buoyant fat 246 to float and the
heavier lean 244 to sink, steadily, as seen in FIG. 17B. The valve
216 on conduit 218 is then opened and the pistons 208, 210 in the
first vessel 220 are closed together until the buoyant fat 246,
having accumulated along the uppermost level along the inside of
the vessel 220, is transferred through connecting conduit 218 to
second vessel 222, as seen in FIG. 17B.
TABLE-US-00003 DENSITY (LBS/CU') AT SPECIFIED H2O TEMPERATURE
CONTENT Matter 18.degree. F. 36.degree. F. LBS/CU' 29.5.degree.
32.degree. F. 15% Fat 56 55 LBS/CU' 55 55 73% Lean 60 66 LBS/CU' 66
66 100% Water 57.41 62.4 LBS/CU' 62.4 100% Ice 57.41 LBS/CU'
57.41
[0240] All 4 pistons (2 in each vessel) may also be activated to
expand and contract the space within both vessels and compress
contents of first and second vessels to elevate carbon dioxide
pressure to above the critical pressure and temperature of carbon
dioxide. Supercritical carbon dioxide can be used reduce the
activity of any microorganisms are present on the lean or fat
matter. The pressure within vessels 220 and 222 can be cycled
between a low and higher pressure exceeding the critical pressure
and temperature a plurality of times until the microorganisms are
reduced to an acceptable level.
[0241] After transfer of the fat matter 246 to the second vessel
222, and optionally performance of cycling between a low
pressure/temperature and a high pressure above the critical
pressure and temperature of carbon dioxide, the pistons in each of
the respective vessels 220 and 222 can compress to separate carbon
dioxide fluid from the lean matter in vessel 220 and from the fat
matter in vessel 222.
[0242] As can be appreciated from the description of the separators
described above, the separators described above may be used in a
method for separating lean from fat. The method includes
transferring a mixture, the mixture comprising lean particles
comprising frozen water, fat particles, and a fluid, through a
conduit, allowing the frozen water in the lean particles to thaw as
the mixture travels through the conduit and increases the density
of the lean particles, accumulating the lean particles with
non-frozen water at a first elevation in the conduit and
accumulating fat particles at a second elevation in the conduit,
wherein the first elevation is lower than the second elevation, and
transferring a portion of the mixture having the accumulated lean
particles through a first conduit branch connected to the conduit,
wherein the portion of the mixture transferred in the first conduit
branch has a majority of the lean particles in the mixture. This
method further includes additional features and steps as step forth
below and as described in the embodiments that follow.
[0243] In one embodiment, the method may further include
transferring a second portion of the mixture having the accumulated
fat particles through a second conduit branch connected to the
conduit, wherein the mixture in the second conduit branch comprises
a greater percent by weight of fat particles compared to the
mixture in the first conduit branch.
[0244] In one embodiment, the method may further include
transferring a third portion of the mixture through a third conduit
branch connected to the conduit, wherein the mixture in the third
conduit branch comprises a greater percent by weight of fluid than
fat and lean.
[0245] In one embodiment, the method may further include, wherein
the lean particles and the fat particles in the mixture in the
conduit prior to thawing of the frozen water have a substantially
similar density that prevents the lean particles and the fat
particles from accumulating at different elevations.
[0246] In one embodiment, the method may further include adding
carbonic acid solution to the mixture before step (a), wherein the
carbonic acid solution has a temperature higher than the freezing
point of water to thaw the frozen water.
[0247] In one embodiment, the method may further include, wherein
the mixture comprises bones, and allowing the bones to separate
from the mixture before the thawing of water.
[0248] In one embodiment, the method may further include, wherein
the conduit comprises a vertical section and a horizontal section,
and bones are separated at a bend from the vertical section to the
horizontal section.
[0249] In one embodiment, the method may further include, wherein
the conduit comprises a vertical section and a horizontal section,
and carbonic acid solution is added at a point in the vertical
section.
[0250] In one embodiment, the method may further include, wherein
the conduit comprises a vertical section and a horizontal section,
and a hopper is connected to an upper end of the vertical section,
and carbon dioxide gas is added to the vertical section above the
point where the carbonic acid solution is added to prevent carbonic
acid solution from entering the hopper.
[0251] In one embodiment, the method may further include providing
a valve at the bottom of the hopper, and the valve is opened to
allow a predetermined amount of mixture into the vertical
section.
[0252] In one embodiment, the method may further include, before
step (a), crushing beef particles comprising both fat matter and
lean matter to produce the lean particles and the fat particles in
the mixture.
[0253] In one embodiment, the method may further include before
crushing beef particles comprising both fat matter and lean matter
to produce the lean particles and the fat particles in the mixture,
chilling the beef particles to a temperature at which the fat
matter can crumble and separate from the lean matter to produce fat
particles and lean particles.
[0254] In one embodiment, the method may further include, wherein
the amount of fluid by weight is at least equal to or greater than
the combined weight of fat particles and lean particles.
[0255] In one embodiment, the method may further include
transferring a third portion of the mixture through a third conduit
branch connected to the conduit, wherein the mixture in the third
conduit branch comprises a greater percent by weight of fluid than
fat and lean, wherein the third conduit branch is higher in
elevation than the first conduit branch.
[0256] In one embodiment, the method may further include
transferring a second portion of the mixture having the accumulated
fat particles through a second conduit branch connected to the
conduit, wherein the mixture in the second conduit branch comprises
a greater percent by weight of fat particles compared to the
mixture in the first conduit branch, and transferring a third
portion of the mixture through a third conduit branch connected to
the conduit, wherein the third conduit branch divides into an upper
branch to connect with the first conduit branch, and a lower branch
to connect with the second conduit branch.
[0257] In one embodiment, the method may further include
transferring a second portion of the mixture having the accumulated
fat particles through a second conduit branch connected to the
conduit, wherein the mixture in the second conduit branch comprises
a greater percent by weight of fat particles compared to the
mixture in the first conduit branch; and emulsifying the second
portion of the mixture and transferring the emulsified mixture
through a lower and upper branch conduits, wherein the lower branch
conduit connects to the first conduit branch.
[0258] In one embodiment, the method may further include
transferring the emulsified mixture through a lower, center and
upper branch conduits, wherein the lower branch conduit connects
with the first conduit branch, the center branch conduit connects
with the upper branch conduit and the first conduit.
[0259] In one embodiment, the method may further include separating
fluid from the portion of the mixture having the accumulated lean
particles via centrifugation.
[0260] In one embodiment, the method may further include
transferring a second portion of the mixture having the accumulated
fat particles through a second conduit branch connected to the
conduit, wherein the mixture in the second conduit branch comprises
a greater percent by weight of fat particles compared to the
mixture in the first conduit branch; and separating fluid from the
second portion of the mixture having the accumulated fat particles
via centrifugation.
[0261] In one embodiment, the method may further include
transferring a second portion of the mixture having the accumulated
fat particles through a second conduit branch connected to the
conduit, wherein the mixture in the second conduit branch comprises
a greater percent by weight of fat particles compared to the
mixture in the first conduit branch; and allowing fluid and fat
particles from the second portion of the mixture to stratify within
a vessel to produce a stratum comprising a majority of fat
particles and a stratum comprising a majority of fluid. This method
may further include collecting the stratified fat particles. This
method may further include, wherein the fluid comprises carbonic
acid, and further comprising collecting the stratified fluid with
carbonic acid and heating the fluid to produce carbon dioxide gas.
This method may further include collecting lean particles that
stratify at the bottom of the vessel, and returning the lean
particles to the mixture of step (a).
[0262] In one embodiment, the method may further include, wherein
the portion of the mixture transferred in the first conduit
comprises a minority of the fat particles in the mixture. This
method may further include, wherein the second portion of the
mixture transferred in the second conduit comprises a minority of
the lean particles in the mixture.
[0263] In one embodiment, the method may further include, wherein
the conduit comprises a chamber having a triangular shape with
three sides, a corner of the chamber formed by two of the sides is
at a first high elevation, and the chamber includes plates defining
passages leading from a lower elevation of the chamber to the first
high elevation. This method may further include, wherein the
triangular chamber comprises at least two exterior sides that are
not horizontal and not vertical with respect to a ground
surface.
[0264] In one embodiment, the method may further include providing
a plurality of horizontal plates in the conduit, wherein a
horizontal plate comprises a proximal end that terminates further
upstream in the conduit as compared to a proximal end of a
horizontal plate of lower elevation.
[0265] In one embodiment, the method may further include providing
a second branch conduit connected to the conduit at a higher
elevation than the first branch conduit, providing a third branch
conduit connected to the conduit at a higher elevation than the
second branch conduit, providing a plurality of horizontal plates
in the conduit, and juxtaposing a proximal end of a dividing plate
next to a distal end of a horizontal plate, and transferring a
portion of the mixture below the dividing plate to the second
branch conduit, and transferring a portion of the mixture above the
dividing plate to the third branch conduit, wherein the percent of
fat by weight of the mixture in the third conduit is higher than
the percent fat by weight of the mixture in the second conduit.
This method may further include, wherein the distal ends of the
horizontal plates define an arc, and the dividing plate is
pivotable to juxtapose a proximal end of the dividing plate next to
a distal end of a horizontal plate. This method may further include
providing a stationary dividing plate between the second and third
conduits, wherein the lower surface of the dividing plate leads to
the second branch conduit, and the upper surface of the dividing
plate leads to the third branch conduit, and the pivoting dividing
plate is proximally located to the stationary dividing plate.
[0266] In one embodiment, the method may further include, wherein
the conduit has an aspect ratio defined as the cross-sectional
width divided by the cross-sectional height, and the aspect ratio
decreases along the length of the conduit from a proximal side to a
distal side.
[0267] A method for separating fat matter from lean matter includes
transferring a mixture, the mixture comprising lean particles
comprising frozen water, fat particles, and a fluid, through a
conduit, allowing the frozen water in the lean particles to thaw as
the mixture travels through the conduit and increases the density
of the lean particles, accumulating the fat particles at a first
elevation in the conduit and accumulating the lean particles with
nonfrozen water at a second elevation in the conduit, wherein the
first elevation is higher than the second elevation, and
transferring a portion of the mixture having the accumulated fat
particles through a first conduit branch connected to the conduit,
wherein the portion of the mixture transferred in the first conduit
branch has a majority of the fat particles in the mixture. This
method may further include transferring a second portion of the
mixture through a second branch conduit that connects to the first
conduit branch, and the second branch conduit is higher in
elevation than the first branch conduit, and includes a greater
percentage of fat matter as compared to fat matter in the first
conduit branch.
[0268] One embodiment of a method is related to a method for
separating lean from fat. The method includes: (a) transferring a
mixture through a conduit, wherein the mixture comprises lean
particles with frozen water, fat particles, and a fluid; (b)
allowing the frozen water in the lean particles to thaw as the
mixture travels through the conduit, and increases a density of the
lean particles; (c) accumulating the lean particles with non-frozen
water at a first elevation in the conduit, and accumulating fat
particles at a second elevation in the conduit, wherein the first
elevation is lower than the second elevation.
[0269] In one embodiment, the method may further comprise
transferring the accumulated lean particles through a conduit
branch connected to the conduit, wherein the accumulated lean
particles transferred in the conduit branch comprise a majority of
the lean particles in the mixture.
[0270] In one embodiment, the method may further comprise
transferring the accumulated fat particles through a conduit branch
connected to the conduit, wherein the accumulated fat particles
transferred in the second conduit branch comprise a majority of the
fat particles in the mixture.
[0271] In one embodiment, the method may further comprise
transferring a portion of the mixture through a conduit branch
connected to the conduit, wherein the mixture in the conduit branch
comprises a greater percent by weight of fluid than fat and
lean.
[0272] In one embodiment, the lean particles and the fat particles
in the mixture in the conduit prior to thawing of the frozen water
have a substantially similar density that prevents the lean
particles and the fat particles from accumulating at different
elevations.
[0273] In one embodiment, the method may further comprise adding
carbonic acid solution to the mixture before step (a).
[0274] In one embodiment, the fluid may have a temperature higher
than the freezing point of water.
[0275] In one embodiment, the mixture may further comprise bones,
and allowing the bones to separate from the mixture before the
thawing of water.
[0276] In one embodiment, the conduit may comprise a vertical
section and a horizontal section, and the bones are separated at a
bend from the vertical section to the horizontal section.
[0277] In one embodiment, the method may further comprise, before
step (a), applying pressure to pieces of beef comprising both fat
matter and lean matter to produce the lean particles and the fat
particles in the mixture.
[0278] In one embodiment, the method may further comprise, before
applying pressure, chilling the pieces of beef to a temperature at
which the fat matter becomes brittle and can crumble and separate
from the lean matter upon the application of pressure.
[0279] In one embodiment, the method further comprises emulsifying
the accumulated fat particles.
[0280] In one embodiment, the method may further comprise
collecting the accumulated lean particles and centrifuging the lean
particles to separate fluid.
[0281] In one embodiment, the conduit can have an aspect ratio
defined as the cross-sectional width divided by the cross-sectional
height, and the aspect ratio decreases along the length of the
conduit from a proximal side to a distal side.
[0282] When the separators include coriolis measuring instructions
that are used to control the massflow via a flow controlled pump,
such as generally illustrated in FIG. 3, the separators may be used
in a method to achieve a product having a predetermined fat content
of the lean stream (i.e., blocks 42, 44, and 56 of FIG. 1).
Accordingly, the separators may be used in a method for producing a
beef product having a predetermined fat content, including: (a)
transferring a mixture comprising measured proportions of a first
stream of lean and fat particles with a second stream of fluid,
through a conduit; (b) transferring a first portion of the mixture
having accumulated lean particles through a first conduit branch
connected to the conduit, wherein the portion of the mixture
transferred in the first conduit branch has a majority of the lean
particles in the mixture; (c) transferring a second portion of the
mixture having accumulated fat particles through a second conduit
branch connected to the conduit, wherein the portion of the mixture
transferred in the second conduit branch has a majority of the fat
particles in the mixture; (d) measuring the first portion of the
mixture having the accumulated lean particles in the first conduit
branch and determining the content of fat in the first portion; (e)
comparing the content of fat in the first portion with a target fat
content, and further performing (f1) or (f2), wherein (f1) is
increasing the massflow of the second portion of the mixture
through the second conduit branch to decrease the fat content of
the first portion of the mixture in the first conduit branch, and
(f2) is decreasing the massflow of the second portion of mixture
through the second conduit branch to increase the fat content of
the first portion of the mixture in the first conduit branch.
[0283] In one embodiment, the method may further include measuring
the massflow of the first portion of the mixture and determining a
density, and correlating a density to the fat content of the first
portion of the mixture.
[0284] In one embodiment obtaining a plurality of measurements of
the massflow of the first portion of the mixture, and obtaining an
average of the measurements.
[0285] In one embodiment, the method may further include reducing
the mass flow of the second stream of the mixture flowing through
the second conduit branch and maintaining a constant mass-flow
until the fat content of the first stream of the mixture reaches a
high target value, and then increasing the mass-flow of the second
portion of the mixture through the second conduit branch and
maintaining a constant massflow until the fat content of the first
portion of the mixture reaches a low target value, wherein the high
target value and the low target value are not the same. This method
may further include measuring the fat content of the second portion
of the mixture and determining the constant massflow based on the
measured fat content of the second portion of the mixture.
[0286] In one embodiment, the method may further include separating
the mixture into three portions, wherein the third portion is lower
in fat content than the second portion.
[0287] Fat Emulsifier
[0288] Referring to FIG. 11, an emulsifying device is illustrated.
The device includes an inlet 2102 and an outlet 2152. Between the
inlet 2102 and the outlet 2152, a high shear-producing member is
placed in the path of fluid carrying particles comprising fat. The
fluid stream comprising fat particles, denoted by arrow 2100, is
introduced through the inlet 2102. A cone-shaped plug 2156 fits
within a cylinder. The plug 2156 rests on a piston 2122 that is
located at the bottom of the chamber. The piston 2122 includes
piston rings 2120, which provide sealing around the cylinder walls
2116. Thus, the piston with the cone-shaped plug 2156 can be moved
upwards and downwards within the cylinder 2116. An annular member
2104 creates the inlet 2102 of a specific diameter. The annular
member terminates at a lower end in a 90 degree edge that
approaches, but does not touch the circumference of the cone-shaped
plug 2156. The cone-shaped plug 2156 has a diameter at its base
that is larger than that the diameter of the inlet 2102. The
cone-shaped plug 2156 tapers as it rises within the inlet of the
annular member to the apex of the cone-shaped plug 2156.
Furthermore, the base of the cone-shaped plug 2156 may be encircled
by a depression 2114. Therefore, as can be appreciated, the piston
2122 and therefore the cone-shaped plug 2156 can create an annular
space between the circumference of the plug 2156 and the lower edge
of the annular member 2104. If the plug 2156 is brought
sufficiently close to the lower edge of the annular member 2104, a
very narrow annular space is created between the cone-shaped plug
2156 and the lower edge. As such, the velocity is increased and
very high shear forces will cause any fat to be scraped or removed
from the larger solid particles. The plug 2156 can be moved up or
down to change the width of the annular space, and thus, also
create a small or large pressure drop in passing the shear
zone.
[0289] After passing the shear zone, the solid fat particles travel
in the space 2113 around the cone 2156 and eventually exit through
the outlet 2154. In this manner, as can be seen, a high-pressure
will result in the emulsification of fat from solid particles.
[0290] Referring to FIG. 12, a second embodiment of a fat
emulsifier is illustrated. The fat emulsifier is incorporated into
a conduit 2910 of generally rectangular configuration. The inlet
2904 is for transferring a mixture of fluid, solid, fat and lean
particles, denoted by arrows 2900. From the inlet 2904, the conduit
2910 rapidly increases in diameter. This rapid increase in diameter
allows fat particles to flow upward, while the lean particles flow
downward. The lean particles 2908 follow a path along the lower
section of conduit 2910 due to the higher density, while the fat
particles 2958 generally flow upward and encounter a diverter 2970.
The stationary or movable diverter 2970 is positioned between a
first outlet conduit 2952 and a second inlet conduit 2940. The
diverter 2970 includes a wide base connected to a narrow stem on
top. The diverter 2970 projects downward from the top of the
conduit 2910, such that a sharp edge of the diverter 2970 is facing
in the direction of the oncoming fluid 2958, 2956 and the edge
directs the uppermost fluid to enter the conduit 2952. The diverter
2970 may be raised to create a narrow gap 2954. Such narrowing of
the gap 2954, increases the pressure drop and creates higher shear
forces on any particles passing through the gap 2954, which
provides for a way of separating fat from connective tissue.
[0291] The fluid with the entrained solid fat particles, which have
now been subjected to high shear forces, are diverted by the plug
2970 into the inlet conduit 2952 and are then directed to a pump
(not shown), which then returns the fluid through conduit 2940 into
the conduit 2910. The pump returns the mixture of fluid and fat
particles through the inlet nozzle 2940 on the distal side of the
diverter 2970.
[0292] Compared to the diameter of the inlet conduit 2904, the
diameter of the conduit 2910 is relatively three-fold, and this
causes the fluid carried in the center of the conduit 2910 to be
essentially clear fluid. The clear fluid allows the materials
separated from the fat and which are heavier than the fat to
immediately sink after exiting the distal side of the diverter 2970
through conduit 2940. The conduit 2910 has two distal outlets. The
higher elevation conduit branch 2926 will remove a mixture of fluid
with fat particles 2930. The lower conduit branch 2920 will remove
fluid with lean particles 2922 and any particles that have been
stripped from the fat particles. Such particles that were
previously attached with fat are shown as arrows 2932 and 2934
traversing downward across the clear fluid that fills the center
2912 of the conduit 2910 and are directed toward the lower conduit
branch 2920.
[0293] It should be noted that the end piece 2924 of conduit 2910
has a convex interior shape that assists with directing flow to
both high conduit branch 2926 and low conduit branch 2920.
[0294] Bond Breaking Compression Device
[0295] FIG. 13A shows the end view of a pair of rollers that may be
used in one embodiment of the bond breaking compression device,
block 12 of FIG. 1. A pair of shafts 5020 and 5010 are mounted in
bearings (not shown) with a timing belt drive arranged to rotate
roller 5022 and 5016 in opposite directions with roller 5016
rotating in a counter clockwise direction while 5022 rotates in a
clockwise direction. Rollers 5016 and 5022 are positioned relative
to each other such that diced and temperature-reduced beef product
as described earlier can be transferred there between in the
direction shown by arrows 5016 and 5014. The distance between the
perpendicular centerline of each roller is held in a selected
position such that protrusions 5015 and recess 5012 are adjacent to
each other as the rollers rotate and provide a gap 5026, as shown
in FIG. 13B of a hypothetical condition, wherein the surface of
each roller has been straightened and the recess 5008 and
protrusion 5004 are arranged opposite to the other roller such that
the protrusion is opposite a recess.
[0296] The length of the protrusion 5004 is less than the length of
the recess 5008 such that when the distance between the rollers
5016 and 5022 is as shown, a clamping force can be applied to the
beef pieces transferred therebetween but no damage such as cutting
the beef occurs. All corners are radiused heavily and this further
limits the capacity of the rollers to damage the beef product by
cutting while performing crushing to liberate the friable fat
matter from the beef pieces, leaving mostly lean matter and little
fat matter on the beef pieces.
[0297] The temperature of the individual beef pieces is controlled
such that the lean matter of the beef piece will remain flexible
and not be prone to breakage or shattering, while the fat matter is
friable and prone to breakage and will fracture and shatter into
small particles. In one embodiment, the bond breaking compression
device includes intermeshing teeth, either on opposed rollers, as
just described in associate with FIG. 13A, or on top and bottom
threads running parallel in a continuous manner. The spacing of the
teeth can be determined based on the size of the fat particles that
are shattered coming from the outlet of the bond breaking
compression device. If the fat particles are too large, the spacing
between the teeth can be decreased to reduce the size of fat
particles. If the fat particles are too small and/or lean is
combined with the fat, then the spacing of the intermeshing teeth
can be increased. From the bond breaking compression device
approximately 1,000 lbs., for example, can be accumulated in a
storage hopper and at the appropriate cycle time transferred to
separation equipment, wherein the beef and fat particles are
blended with a quantity of carbonic acid sufficient to fill the
separation equipment which is sealed and pressurized to
approximately 150 psia prior to the carbonic acid fluid transfer
therein.
[0298] As can be appreciated from the description above, the bond
breaking device of FIGS. 13A and 13B, may be used in a method for
separating solid fat from beef pieces.
[0299] The method includes (a) chilling beef pieces comprising fat
matter and lean matter for a time and at a temperature that results
in uneven chilling of surfaces of the fat matter and lean matter,
wherein the lean matter is chilled to a temperature to cause
freezing of water in the lean matter, and the surface temperature
of the fat matter is lower than the surface temperature of the lean
matter, and (b) applying pressure to the beef pieces to break the
fat matter from the beef pieces while leaving the lean matter
intact.
[0300] In one embodiment, the method may further include, wherein
in step (b) the surface temperature of the fat matter is lower than
the surface temperature of the lean matter by at least 5.degree.
F.
[0301] In one embodiment, the method may further include, wherein
in step (b), the surface temperature of the lean matter is
26.degree. F. or less, and the surface temperature of the fat
matter is 5.degree. F. or greater, and the surface temperature of
the fat matter is lower than the surface temperature of the lean
matter.
[0302] In one embodiment, the method may further include passing
the beef pieces between a pair of parallel, adjacent, non
contacting, driven rollers, each roller having alternating recesses
and protrusions around the perimeter, wherein the rollers are
arranged to position a recess of one roller opposite to a
protrusion of the second roller, without the rollers being in
contact.
[0303] Selected Fat Content
[0304] FIG. 14 shows a front elevation of an assembly of apparatus
arranged to produce a selected fat content boneless beef product
from the lean and fat streams separated in a separation system as
described herein in association with FIGS. 2-8. The apparatus can
provide for the liquid separation from lean solid particles and fat
solid particles shown as blocks 42 and 48 of FIG. 1, and further
provide for the combining of fat and lean to produce a product of
selected fat content represented by the blocks 42, 44, 46, 48, 50,
52, and 54. However, in other embodiments, the fat content that is
present with the lean stream can be controlled via the control of
the flow rate of the fat stream, such that more or less fat can be
added to the lean stream by controlling the amount of flow that is
withdrawn from the system, such as described, for example, in
association with FIGS. 3, 4, 6, 7, and 8.
[0305] In FIG. 1, all the mass flowing into the separation block 30
is measured as well as the mass flow of any stream leaving the
separation block. Therefore, a total mass balance can be performed
around the separator. The preferred measurement instrument is a
coriolis flow meter. A coriolis flow meter is able to measure the
mass flow per unit time and the density and temperature of the
fluid. From knowing the density, the volumetric flow may also be
determined. In the embodiment of FIG. 1, the total mass flow to the
separation block 30 is measured by block 28. Also, the carbonic
fluid that is added is also measured by block 26, therefore, by
subtracting the mass of the carbonic fluid, the mass of the beef
pieces, including fat and lean particles can be known. If more than
one stream is added to the inlet flow, then, every flow is measured
so that the mass of the combined lean and fat particles can be
known. The separation block 30 has at least two outlet flows,
including the lean matter with fluid, block 32 and the fat matter
with fluid, block 36. However, if additional flows, such as
illustrated in FIGS. 6 and 8 are present, then all outlet flows are
measured. All inlet or outlet flows are measured to determine the
mass flow, density and temperature. In FIG. 1, the bone matter and
fluid flow, block 34 is optional, but, if present, this flow may
also be measured. As discussed above, the fluid density influences
the degree of separation between fat and lean matter. Therefore,
fluid density can be related to the amount of fat with the lean
matter in block 32 because it has been found that for any given
fluid density, the lean matter will contain a predictable fat
content. A correlation table can be created that stores a
relationship between fluid density and a corresponding amount of
fat in the lean matter of block 32. Therefore, the density of the
flow of the lean matter and fluid of block 32 can be determined.
For example, prior to of each of the flows of blocks 32 and
36d.
[0306] In FIG. 14, the lean stream with carbonic acid fluid is
transferred in the direction shown by arrow 6000 via conduit 6004
and through coriolis measuring instrument 6002, from which the flow
rate, water content and/or fat content of the lean matter/fluid may
be determined, and continuing therefrom along conduit 6070 and into
centrifuge 6068 via port 6069. In this way, the apparatus as
arranged removes liquid carbonic acid and discharges the liquid via
conduit 6008 in the direction shown by arrow 6006. The solid, lean
matter is discharged via aperture manifold 6010 onto continuous
inline weighing conveyor 6016. A shield 6080 is arranged to provide
a suitable method of dividing the continuous stream of lean matter
deposited on conveyor 6016 into portions with spaces there between
and as can be seen with portions, such as 6018, a gap is shown
between them and indeed all other portions. This is provided to
enable the continuous weighing of the continuous stream divided
into portions with gaps by the weighing section 6016. Shield 6080
is attached to member 6062 mounted to a means of providing
horizontal movement shown by arrow 6066. The movement indicated by
arrow 6066 is in a horizontal plane and shield 6080 can be arranged
to shield strips of the conveyor such that gaps are provided as
required. Conveyor 6016 comprises a continuous belt which extends
horizontally and is held in position by a roller at each end 6012
and 6020. In this way, the continuous stream of lean matter is
weighed prior to transfer into accumulation hopper 6024 and in the
direction shown by arrows 6064 and 6060.
[0307] The fat stream with carbonic acid fluid separated in a
separator, such as a manifold arrangement upstream is transferred
in the direction shown by arrow 6043 and into conduit 6048 and
passes through coriolis measuring instrument 6044, from which the
flow rate, water and/or fat content of the fat/fluid may be
determined, and then is transferred into centrifuge 6046 via
centrally disposed port 6050. Solid fat matter is removed from the
stream and the spent carbonic acid is discharged via conduit 6054
in the direction shown by arrow 6072. A horizontally disposed
continuous weighing conveyor 6038 is arranged directly beneath the
discharge port of centrifuge 6046 such that a measured proportion
of fat matter deposited thereon is weighed as it is transferred in
the direction shown by arrow 60734. As can be seen, portions 6036
for example are shown with a gap between them similar to the
arrangement provided on continuous weigh belt 6016.
[0308] A shield 6076 is attached to a member mounted to a means of
providing horizontal movement. The shield 6076 can be arranged to
shield strips of the conveyor such that gaps are provided as
required. Conveyor 6038 comprises a continuous belt which extends
horizontally and is held in position by a roller at each end 6030
and 6040. In this way, the continuous stream of fat matter is
weighed prior to transfer into accumulation hopper 6024 and in the
direction shown by arrow 6076.
[0309] The flow of fat matter and flow measured via coriolis
measuring instrument 6044 is controlled such that the amount of fat
weighed and transferred into collection hopper 6024 is the amount
required to provide a selected fat content boneless beef when
combined with the lean stream weighed on conveyor 6016.
[0310] Pathogen Deactivation Vessels
[0311] A vessel includes a shuttling action that provides a
semi-continuous process wherein approximately 2,000 lbs of beef is
loaded into the shuttling basket and it is then immediately
transferred into the autoclave. A measured quantity of the raw beef
is accumulated in autoclave or alternatively in a hopper located
directly above the shuttling basket at the input end of the
autoclave and in such a way that the shuttling basket can be loaded
rapidly by opening a set of "bomb" doors arranged in the base of
the upper hopper, so as to provide a rapid loading of the basket.
The autoclave operates by processing batches of beef product and
when an amount of, for example 2,000 lbs, has been accumulated in
the shuttle basket, the autoclave is closed and all air removed by
displacement with carbon dioxide fluid transferred under pressure
from carbon dioxide gas vessel. After purging substantially all air
from autoclave, all ports are closed except for the connection to
vessel, which charges the autoclave to about 350 psia with carbon
dioxide gas. Communication with vessel is disconnected by closing a
valve, which is immediately followed with opening of valve
connection to vessel containing liquid carbon dioxide to facilitate
transfer of carbon dioxide fluid, which then fills autoclave with
950 psia fluid carbon dioxide. During the transfer of carbon
dioxide into autoclave, the beef contents enclosed within the
"shuttling basket" are agitated to ensure that all surfaces of
every piece of beef are exposed to sufficient liquid carbon dioxide
to elevate the temperature at the surface of the beef to a
preferred temperature of at least 89.degree. F. but not more than
about 108.degree. F. Communication with the liquid carbon dioxide
source vessel is then interrupted by disconnecting or closing of a
valve immediately prior to the immediate opening of a valve
allowing transfer of super critical vapor from storage vessel,
while carbon dioxide is allowed to escape via conduit connection
into carbon dioxide recycle vessel. In this way super critical
carbon dioxide vapor is transferred to the autoclave at a pressure
of approximately 1,500 psia and, with the suitable agitation within
autoclave, all beef particle surfaces are thereby exposed to the
aggressive solvent properties of super critical carbon dioxide.
Such exposure of pathogens (e.g., E. Coli. 0157:H7, salmonella,
Listeria Monocytogenes and others) to super-critical carbon dioxide
is lethal and will cause death within a few minutes of exposure.
After a period of time of up to 7 minutes, the flow of
supercritical carbon dioxide from vessel through autoclave and into
recycle vessel is shut off and autoclave depressurized to
atmospheric pressure prior to the pathogen deactivated beef being
transferred directly from autoclave to dicing machine prior to
transfer to and through carbon dioxide freezing tunnel.
[0312] Referring to FIG. 15, a pathogen deactivation vessel (PDV)
955 is shown in partial cross section. The vessel 955 described
herein may be used for block 4 of FIG. 1. Also as described herein,
the vessel 955 may also be used to separate carbon dioxide liquid
and/or other fluids from solid matter, such as to separate liquid
from lean matter in block 42 of FIG. 1 and to separate liquid from
fat matter in block 48 of FIG. 1.
[0313] The vessel includes a horizontally disposed tubular vessel
923 arranged with end caps 910 and 997 which are held in place by
"rings" 914 and 936, thereby providing an adequate sealing at
interfaces such as 970. The annular members 914 and 936 can be
rotated to release end caps 910 and 997 or alternatively rotate in
the opposite direction to tighten the end caps at interface such as
970.
[0314] A pair of horizontally opposing pistons 926 and 986, each
piston being sealingly mounted within the vessel to provide an
enclosed space 928. Pistons 926 and 986 are arranged with backing
plates 985 and 930, respectively, attached via piston rods 925 and
937 to hydraulic cylinders 956 and 987. Each piston assembly is
fixed at its circumferential center to a piston rod 925 or 937.
FIG. 15 shows the piston rods with pistons 986 and 926, in a fully
extended position, inwardly, toward the center of the pathogen
deactivation vessel 955 so as to provide 3 separated spaces, 928 is
the space between the pistons, space 939 is the space between the
backing plate 930 and the end cap 997 and space 917 is the space
between backing plate 985 and the end cap 910. The space 928
between pistons is connected to both spaces 939 and 917 via
conduits and valves. Space 928 connects to space 939 via valve 924,
conduit 999 and a continuation of conduit 999 which is not shown to
conduit 935 on the top side of the vessel 923 that leads into space
939. Space 928 connects to space 917 via valve 924, conduit 988 and
a continuation of conduit 988 which is not shown to conduit 915 on
the top side of the vessel 923 that leads into space 917.
[0315] An upper, centrally disposed port is attached to a manifold
984 with gate valve 924, which can seal the port closed as needed.
Gate valve 924 separates the vessel loading apparatus from manifold
984. Conduits 999 and 988 connect via suitable "open/closed" valves
1000 and 1001 (not shown) directly with ports 935 and 915
respectively (connecting pipes not shown), such that when gate
valve 942 is closed and gate valve 924 is open, a direct
communication between the centrally located space 928 with spaces
939 and 917 is provided.
[0316] The spaces 917 and 939 are used as accumulators to receive
fluid at the same or substantially the same pressure that is within
space 929. Accordingly, when the pistons 926 and 986 are moved
distally from a proximal position, the fluid is forced from the
space 928 into one or both of spaces 917 and 939. Before admitting
fluid to either of spaces 939 and 917, preferably the spaces have
been pressurized to be in equilibrium with the pressure in space
928. Alternatively, instead of the fluid being sent to spaces 939
and 917, the fluid may be transferred to an "external" accumulator
connected to the manifold conduits 999 and 988 through a valve 924
located on the top of the vessel 923. An accumulator can be a
piston accumulator. A piston accumulator is a known device and may
include a fluid section and a gas section with a piston separating
the two sections. When the fluid section draws in the fluid from
space 928, the piston compresses the gas section, which may be
nitrogen, for example. However, other food compatible gasses may be
used. When the pressure drops in space 928, the compressed gas
forces the piston to discharge the stored fluid. In this case,
instead of transferring the fluid to the space 928, the fluid may
be transferred to the carbon dioxide recovery block 56 as seen in
FIG. 1. A suitable accumulator can be one supplied by Hydac. As
described, an accumulator can be the internal spaces 939 and 917 or
an external accumulator. However, both have the capability of an
increasing/decreasing volume space to accommodate a corresponding
change in volume as the vessel pistons 926 and 986 move together so
as to keep the carbon dioxide gas at a fairly constant pressure,
such as above the critical phase of carbon dioxide. After treating
the goods to reduce pathogen populations that may be present with
the goods, the pressure can be raised within the tubular vessel 923
to a first fluid pressure value by moving the horizontally opposed
pistons 926 and 986 together and reducing the space between them to
decrease the density of the fluid to a value lower than a density
of the goods. In some embodiments, the density of the fluid is
increased. Then, the valve 924 can be opened to connect the
pressurized space 928 to a piston accumulator and allow the
relatively lighter fluid to transfer into a liquid space of the
piston accumulator while the piston accumulator increases the
volume of the liquid space and the pistons located in the vessel
923 reduce the volume of the space 928 containing the goods until
the fluid has been transferred into the accumulator leaving a
residual quantity of fluid with the goods. Then, the valve 924 can
be closed and the pistons 926 and 986 moved apart to decrease the
fluid pressure within the vessel 923 to a lower second pressure
value and opening a second valve, such as valve 942, to allow
transfer of fluid into a second vessel at a lower pressure
value.
[0317] A lower, centrally located port 961 is connected to
extraction conduit 944 via gate valve 942. A drainage pipe 945 with
valve 997 is also provided.
[0318] Ports 981 and 879 are also connected to space 928 via pipe
945 or manifold 984. Valves (not shown) are provided at ports 981
and 879 to isolate the ports as needed.
[0319] A shaft 937 extends through the center of piston rods 987
and 925, pistons 986 and 926 and backing supports 930 and 985 to an
end 938. Impellors 992 and 993 are diametrically opposite each
other and both are attached to impellor shaft 937 and are also
profiled to fit close to the recessed surfaces of the pistons 926
and 986, respectively, as they are rotated by impellor shaft 937,
which is attached to a driving mechanism (not shown).
[0320] A spur gear (wheel) 931 is fixed to the outer circumference
of the pathogen deactivation vessel and is arranged to engage with
pinion 952 which is mounted to drive shaft 953.
[0321] A "cradle" of rollers such as 940 and 948, mounted to shafts
such as 941 and 950, are arranged to retain the entire weight of
the pathogen deactivation vessel 955 and hold the vessel captive
while allowing it to be rotated in both clockwise and counter
clockwise directions by the pinion 952, which is driven via shaft
953 so as to rotate the vessel assembly 955 190 to 180 degrees from
the perpendicular in a counterclockwise direction, and then 380 to
360 degrees in a clockwise direction, and then in a
counterclockwise direction, repeating the back and forth rotation
during each cycle of the apparatus described in association with
FIG. 15.
[0322] A rotary union 903 communicates directly between supply pipe
901 carrying carbon dioxide liquid or vapor and piston rod 902
passageway 889 and exit port 890.
[0323] Female member 922 with inner conical profile 983 is arranged
to connect with male member 919 with conical profile 982 such that
when member 919 is extended in the direction shown by arrow 921,
the outer surface 982 and inner surface 983 of member 922 contact
and provide a seal in a way that allows boneless beef to be
transferred directly from a vessel (not shown) holding a single
"charge" (for example 2,000 lbs) of predetermined quantity of
boneless beef.
[0324] Member 919 can be extended so as to sealingly mate with
member 922 so that when gate valves 942 and 924 are open and valves
1000 and 1001 closed (not shown), sealing contents of spaces 917
and 939 therein. In this way, boneless beef of a predetermined and
measured quantity (in a vessel mounted on load cells above pathogen
deactivation vessel 955) can be transferred from the vessel, via
members 919 and 922 and through manifold 984 and into space 928.
After transfer of a full load ("charge") of boneless beef into
space 928, gate valve 942 can be closed, and any open space
remaining within space 928 can be filled with pressurized carbon
dioxide gas to a selected pressure such as 750 psi via conduit 945
and in the direction shown by arrow 948. Following pressurizing of
space 928, valves 1000 and 1001 can be opened to provide an open
conduit between spaces 917, 928 and 939.
[0325] Hydraulic cylinders 987 and 956 hold pistons 926 and 986 in
position, as needed, and can be activated simultaneously to move
away from each other (from distal to proximal positions), thereby
increasing the volume of space 928 and decreasing the volume of
spaces 939 and 917. This action causes carbon dioxide fluid to be
displaced and transferred into space 928 from both spaces 939 and
917 via ports 915, 981, 879 and 935. Both pistons 926 and 986 can
be withdrawn as seen fit but preferably to the fullest extent
thereby transferring a major portion of the fluid carbon dioxide
into the expanded space 928. Valves 1000, 1001 and the valves
isolating ports 981 and 879 are then closed and pistons 986 and 926
activated in a direction toward each other (from proximal to distal
positions) so as to reduce the volume of space 928, increasing
pressure to about 1,500 psia.
[0326] During the movement of pistons 926 and 986 toward and away
from each other, impellors 993 and 992 are rotated and pathogen
deactivation vessel 955 is also rotated. The density drops from
around 40 lbs/cubic foot to 28.96 lbs/cubic foot The pressure in
the vessel is then increased quite rapidly to about 1,500 psia to
ensure the surface temperature of the goods is elevated to a
temperature above the critical temperature of carbon dioxide.
[0327] In one embodiment, the pressure is first elevated. Before
the pressure is elevated, the vessel 923 is charged first with
carbon dioxide gas/vapor to about 500 psia and then liquid carbon
dioxide to about 700 psia and agitated to ensure all goods
(meat/beef) surfaces are thoroughly soaked (with the liquid carbon
dioxide) at a pressure and liquid density in which boneless beef
(not frozen) will become somewhat buoyant. This spaces the pieces
apart when agitated. There also needs to be space for the sudden
expansion from below (about 990 psia) critical pressure (1,072.1
psia) to above critical pressure.
[0328] In one embodiment, pistons 926 and 986 are sequentially
activated to compress the contents of space 928 and hold a pressure
of 1,500 psia, thereby maintaining a pressure above the critical
pressure of carbon dioxide (supercritical pressure) in space 928
for a predetermined period such as 85 seconds, in one embodiment,
followed by a movement of pistons 926 and 986 away from each other,
reducing the pressure in space 928 to a subcritical pressure of 900
psia for 85 seconds.
[0329] A treatment of boneless beef can be arranged such that each
alternated 85 second period at 900 psi and 85 seconds at 1,500 psi
can be sequentially repeated in a series of alternating sub
critical and super critical carbon dioxide phase conditions and in
such a way that any bacteria present on the boneless beef will be
rendered none viable or killed.
[0330] At the conclusion of the treatment (cycle), the two pistons
926 and 986 move toward each other and in so doing, reduce the
volume of space 928 to a minimum and expand the volume in spaces
917 and 939, while still rotating the vessel (back and forth) until
the boneless beef is compressed in the center so as to expel all
carbon dioxide fluid which is extracted via the upper manifold and
into the spaces 917 or 939. In this way, carbon dioxide loss is
substantially reduced. A further advantage is to avoid the freezing
of boneless beef during the removal of the fluid carbon
dioxide.
[0331] The following TABLE 3 provides one embodiment of a sequence
of steps that may be executed by the pathogen deactivation vessel
955.
TABLE-US-00004 TABLE 3 Sequ. Sequence/Action per single system
cycle and then repeat # in a continuous succession of cycles
Seconds 1 PDV Evacuation [50%] by retracting pistons--aided by 16
external blower (if needed) 2 Load 2,000 lbs boneless beef = to
<50% PDV volume 75 [exclude any atmospheric oxygen] 3 Pressurize
PDV with vapor/gas 500 pisa to 900 psia 15 4 Close gas valves; open
liquid valves, pressure to 700 psia 10 to 900 psia 5 Fill with
liquid carbon dioxide @ <900 psi PDV pressure 30 (from reverse
side of piston) by retracting piston (additional from remote source
via piston rod) 6 Rotate PDV Thru' 1900 from perpendicular in both
85 directions [additional agitation by activating pistons stroke--2
ways .times. 24''] and rotating impellor 7 Increase PDV pressure to
1,500 psi and <120 F. 5 8 Continue rotation of PDV Thru'
190.degree. from perpendicular 85 in both directions [agitation by
activating pistons stroke--2 ways .times. 24''] plus impellor 9
Decrease PDV pressure to 900 psi and <85 F. 5 10 Continue
rotation of PDV thru' 190.degree. from perpendicular 85 in both
directions [agitation by activating pistons stroke--2 ways .times.
24''] plus impellor 11 Increase PDV pressure to 1,500 psi and
<120 F. 5 12 Continue rotation of PDV Thru' 190.degree. from
perpendicular 85 in both directions [agitation by activating
pistons stroke--2 ways .times. 24''] plus impellor 13 Decrease PDV
pressure to 900 psi and <85 F. 5 14 Continue rotation of PDV
thru 190.degree. from perpendicular 85 in both directions
[agitation by activating pistons stroke--2 ways .times. 24''] plus
impellor 15 Compress beef between pistons to remove a pre- 70
determined quantity of carbon dioxide vapor and/or fluid from beef
and transfer via an upper port (open valves to LP storage PDVs) 16
Chill beef by sudden internal PDV pressure drop of a 75 measured
quantity of liquid carbon dioxide (by retracting pistons to lower
pressure) and then open valve to external accumulation vessels--may
be strapped to PDV) 17 Close//open valves as required 15 18 Reduce
PDV Pressure to ambient (T = 32 F. to 36 F.] 45 [could be combined
with 21] 19 Unload beef from PDV (via lower 14'' D port) 75 20
Open/close valves 10 21 Return pistons to 45% PDV volume between
pistons 15 [L-carbon dioxide behind pistons] CPH 4.02 3600
896.00
[0332] TABLE 4 below shows the deactivation levels using the
pathogen deactivation vessel for various pressures and times.
TABLE-US-00005 Exposure Time After 4 Days Initial Hi Pressure
Storage at Treatment - cpSC-carbon Exposure Ambient dioxide Initial
Total Hi Reduc. Reduction - Pressure Log.sub.10CFU/ Log.sub.10CFU/
Rep # Organism PSIG Min Gm. Gm. 1 Generic E. Coli 2,400 3 1.2 4.0 2
E. Coli 0157:H7 2,100 3 1.8 3.5 3 Generic E. Coli 1,800 7 1.1 3.0 4
E. Coli 0157:H7 1,600 7 1.9 4.1 5 E. Coli 0157:H7 1,500 1 1.6 3.8 6
Generic E. Coli 1,300 5 0.9 2.9 7 E. Coli 0157:H7 1,100 5 0.8
2.9
[0333] TABLE 5 below shows the deactivation levels using the
pathogen deactivation vessel for various pressures and times.
TABLE-US-00006 Hi Organisms Pressure Exposure Reduction Rep #
(Cocktail) PSIG Minutes Log.sub.10CFU/Gm. Treatment - controlled
phase Super Critical carbon dioxide 1 Generic E. Coli 1,100 3 5.8
E. Coli 0157:H7 to 5.7 Listeria 1,300 4.0 monocytogenes Salmonella
- spp. 5.8 2 Generic E. Coli 1,600 3 5.8 E. Coli 0157:H7 to 6.4
Listeria 1,800 4.7 Monocytogenes Salmonella - spp. 6.0 3 Generic E.
Coli 2,000 3 1.9 E. Coli 0157:H7 to 4.4 Listeria 2,200
Monocytogenes 5.2 Salmonella - spp. 6.0 Treatment - Sub-Critical
(Liquid) carbon dioxide 4 E. Coli 0157:H7 3 5.5 Listeria 700-800
2.7 Monocytogenes Salmonella - spp. 5.4
[0334] As can be appreciated from the description of FIG. 15, the
device may be used in a method for deactivating pathogens in meat.
The method includes transferring meat to a vessel, wherein the
vessel includes an enclosed elongated space fitted with a first and
a second piston within the interior of the space at each of two
opposing ends, and the pistons include a front and back side;
charging the vessel with carbon dioxide; moving the first and
second piston in a direction toward each other so as to reduce the
volume of the space and increase the pressure within the space to
create a super critical carbon dioxide phase in the space
containing the meat; holding the super critical pressure of carbon
dioxide for a predetermined period of time; after holding the super
critical pressure for the predetermined period of time, moving the
first and the second pistons away from each other to reduce the
pressure in the space to a subcritical pressure of carbon dioxide;
holding the subcritical pressure of carbon dioxide for a
predetermined period of time; and after holding the subcritical
pressure of carbon dioxide, moving the first and second pistons in
a direction toward each other so as to reduce the volume of the
space while expelling the carbon dioxide from the space in front of
the pistons to spaces created at the back of the pistons.
[0335] In one embodiment, the front side of the first and the
second piston is fitted with an impeller that rotates as the first
and second pistons move toward each other.
[0336] In one embodiment, the vessel includes a central
longitudinal axis, and the vessel is rotated back and forth on the
axis while the first and second pistons move toward each other.
[0337] In one embodiment, the method may comprise performing a
plurality of super critical carbon dioxide phases alternating with
subcritical carbon dioxide phases before expelling the carbon
dioxide.
[0338] In one embodiment, the super critical pressure produced is
1,500 psi or greater.
[0339] In one embodiment, the subcritical pressure produced is 900
psi or less.
[0340] A different embodiment related to a method for inactivating
pathogens present on goods, includes: (a) introducing into an
apparatus, pieces of beef, and a fluid comprising water and carbon
dioxide; (b) raising a pressure within the apparatus above a
critical pressure of carbon dioxide without elevating a temperature
within the apparatus above a temperature to damage the beef; and
holding the pressure and temperature for a selected period of time;
(c) reducing the pressure within the apparatus, and increasing a
density of the fluid to suspend and separate the pieces of beef in
a suspension to enable surfaces of the beef to be in contact with
low pH fluid to result in death of pathogenic microorganisms on the
surfaces of the beef.
[0341] In one embodiment, the method may further comprise adjusting
the density of the fluid where the beef becomes buoyant to allow
spacing apart of beef.
[0342] In one embodiment, the method may further include: (d)
raising the pressure within the apparatus to increase the
temperature at the surface of the goods to above freezing point of
water. This method may further include repeating steps (c) and (d)
in rapid succession for more than one cycle.
[0343] In one embodiment, the method may further include adjusting
the pressure of the carbon dioxide and water to form carbonic acid,
having a selected temperature and pH, wherein the pH value is
lethal to at least one microorganism present with the goods.
[0344] In one embodiment, the method may further include adjusting
the pressure of the carbon dioxide to form Carbonic Acid having a
pH less than 5, wherein due to the low pH the carbonic acid is
lethal to at least one microorganism on the goods.
[0345] In one embodiment, the method may further include applying
ultrasonic energy to separate microorganisms from the goods and
mixing the goods within the chamber.
[0346] In one embodiment, the method may further include, after
reducing the pressure, holding while agitating, raising the
pressure and temperature of the carbon dioxide to reach
supercritical conditions, and holding the supercritical conditions
for a period of time sufficient for the supercritical carbon
dioxide to be lethal to pathogens.
[0347] In one embodiment, the method may further include, wherein
liquid carbon dioxide is in contact with the surfaces of the goods
in sufficient quantities to cause freezing of the free water in
contact with microorganisms.
[0348] In one embodiment, the method may further include further
charging the apparatus with carbon dioxide gas/vapor to about 500
psia and then liquid carbon dioxide to about 700 psia and agitating
the apparatus to soak goods' surfaces with liquid carbon dioxide at
a pressure and liquid density in which beef (not frozen) will
become buoyant to allow spacing apart of beef pieces when
agitated.
[0349] As can be appreciated from the description of FIG. 15, the
device may also be used in a method of separating a high vapor
pressure fluid from beef, including: (a) in an apparatus comprising
a vessel, and a piston disposed within the vessel, wherein a space
is provided adjacent to the piston, adding a high vapor pressure
fluid with beef in the space; and (b) moving the piston to compress
the space to separate the fluid from the beef, wherein the fluid is
compressed at a pressure to prevent evaporation and freezing of the
beef.
[0350] In one embodiment, the method may further include, wherein
the apparatus comprises a second piston, wherein the piston are
disposed opposite to each other, and the pistons are moved together
to compress the space to separate the fluid from the beef.
[0351] In one embodiment, the method may further include, wherein
the high vapor pressure fluid does not exist as a liquid at 1
atmosphere and 20.degree. C.
[0352] In one embodiment, the method may further include, wherein
the fluid is carbon dioxide.
[0353] In one embodiment, the method may further include, wherein
the apparatus further comprises a space behind the piston, wherein
the space in front of and behind the piston are in communication,
and the fluid is transferred to the space behind the piston during
compression.
[0354] Another embodiment related to a method for separating human
edible goods from a pressurized fluid includes: (a) providing a
horizontally disposed tubular vessel having a pair of horizontally
opposed pistons, each piston being sealingly mounted within an end
of the tubular vessel to provide an enclosed space into which the
goods and a pressurized fluid are transferred; (b) after treating
the goods to reduce pathogen populations that may be present with
the goods, raising the pressure within the tubular vessel to a
first fluid pressure value by moving the horizontally opposed
pistons together and reducing the space between them to decrease
the density of the fluid to a value lower than a density of the
goods; (c) opening a first valve in a conduit connecting a
pressurized space within an end of a piston accumulator to a port
centrally located on the upper side of the first vessel and
allowing the relatively lighter fluid to transfer into a second
space of the piston accumulator from the first vessel while the
piston accumulator increases the volume of the second space and the
pistons located in the first tubular vessel reduce the volume of
the space containing the goods until the fluid has been transferred
into the accumulator leaving a residual quantity of fluid with the
goods; and (d) closing the first valve and moving the pistons apart
to decrease the fluid pressure within the first vessel to a lower
second pressure value and opening a second valve to allow transfer
of the fluid into a second vessel at a lower pressure value.
[0355] The apparatus of FIG. 15, includes: (a) a housing defining a
cylindrical chamber with a first end and an opposite, second end;
(b) a first piston and a second piston disposed in a sealing manner
at the opposite ends of the chamber so as to provide an enclosed
and sealed space between the first and second pistons, wherein the
first piston and the second piston are driven towards one another
to pressurize contents in said space between the pistons to a
first, high pressure and away from one another to depressurize
contents within the space to a second, lower pressure; and (c) a
mixer disposed within the housing to mix any contents between the
pistons.
[0356] In one embodiment, the apparatus may further include,
wherein the mixer has a piston-like member disposed in the housing,
wherein the piston-like member is in a sealing disposition with the
inner surface of the chamber.
[0357] In one embodiment, the apparatus may further include,
wherein the mixer has a piston-like member disposed in the housing,
and the piston-like member has an opening for the passage of goods
from one end of the chamber towards the other.
[0358] In one embodiment, the apparatus may further include an
ultrasonic generator that transmits ultrasonic energy to the mixer
to separate microorganisms from goods being processed within the
chamber.
[0359] In one embodiment, the apparatus may further include,
wherein the first and the second pistons are driven by the
introduction and withdrawal of a liquid compatible with goods
edible for human consumption.
[0360] In one embodiment, the apparatus may further include,
wherein the mixer is configured to rotate and reciprocate in
relation to the chamber length.
[0361] In one embodiment, the apparatus may further include a first
and a second piston disposed at opposite ends of the housing to
form a first chamber and a second chamber, wherein the chambers
receive a fluid to drive the first piston and the second
piston.
[0362] In one embodiment, the apparatus may further include a
direct communication between a second chamber containing goods to
be treated after transfer into the space via a port located on the
upper side of, and centered on a perpendicular center-line of the
chamber, such that when the first and second pistons are driven
away from one another, a vacuum is created and the goods are thusly
transferred into the space.
[0363] In one embodiment, the apparatus may further include a
direct communication between said space and a third chamber into
which said treated goods are to be transferred via a port located
on the lower side of, and centered on a perpendicular center-line
of the first chamber, such that when a vacuum is created within the
third chamber and first and second pistons are driven toward one
another, the goods are transferred into the space.
[0364] The following properties are provided for reference.
[0365] The temperature of liquid carbon dioxide at 900 psia is
about 74.degree. F.
[0366] The density of liquid carbon dioxide at 900 psia is about 45
lbs/cubic foot.
[0367] The temperature of fluid carbon dioxide at or equal to or
greater than 1072.1 psia is about 87.8.degree. F. (the Critical
Temperature).
[0368] The density of fluid carbon dioxide at or equal to or
greater than 1072.1 psia is about 28.96 lbs/cubic foot; (the
Critical Temperature).
[0369] The density just below the Critical Point, at say about
84.degree. F. is about 41 lbs/cubic foot; so it can be seen there
is a substantial reduction in density at just above The Critical
Temperature, when compared to just below The Critical Point.
[0370] The density of the food (boneless beef), which comprises
lean beef of about 66 lbs/cubic foot and tallow/beef-fat of about
55 lbs/cubic foot and, therefore, an equal quantity of each (50's)
averages about 60 lbs/cubic foot to 61 lbs/cubic foot.
[0371] When boneless beef, at about 60.5 lbs/cubic foot, is
immersed in fluid supercritical carbon dioxide at about 1,100 psia,
the buoyancy effect of the supercritical carbon dioxide, at 28.96
lbs/cubic foot (say less than 30 lbs/cubic foot) is minimal when
compared to liquid carbon dioxide at say 18.degree. F. and 400
psia, which is about equal to the average density of 50's (i.e.,
60.5 lbs/cubic foot).
[0372] However, the temperature of liquid carbon dioxide at 60.5
lbs/cubic foot and 400 psia is about 18.degree. F. and beef will
freeze at this temperature. It is therefore useful to provide
suitable temperature conditions at the surface of the boneless beef
as is pressure. A temperature of 18.degree. F. will freeze boneless
beef with any bacteria that may be present which could provide
conditions in which at least some bacteria would be preserved.
These conditions must be avoided and therefore a compromise is
required.
[0373] It is useful that all pieces of any quantity of boneless
beef being treated to remove or kill bacteria, or pathogens that
may be present on the beef, are thoroughly soaked and "wetted" with
carbon dioxide and to such an extent that the entire surface of
each piece including within and under any and all slits, cracks,
cuts, flaps or folds, is sufficiently saturated. Most preferably,
the treated surface will have absorbed carbon dioxide during the
sub-critical treatment.
[0374] When the boneless beef is immersed in higher density, fluid
carbon dioxide, such that the buoyancy effect of the carbon dioxide
is sufficient to cause separation or the improved capacity of the
beef pieces to separate, each piece of boneless beef will be more
readily exposed to the carbon dioxide in which it is immersed. When
the density of the carbon dioxide is greater, thorough soaking of
all boneless beef surfaces in the carbon dioxide is more readily
provided and carbon dioxide is more readily in contact with the
surfaces. Under these conditions, agitation of the combined
boneless beef and fluid carbon dioxide can enhance the exposure,
hence the process provides for such agitation.
[0375] More particularly, in order for the entire surfaces of the
boneless beef pieces to be thoroughly soaked in fluid carbon
dioxide when immersed in the fluid carbon dioxide, greater buoyancy
will more readily and thoroughly facilitate the desired exposure of
all surfaces to carbon dioxide and, more particularly, enable the
beef surfaces to absorb relatively greater proportions of carbon
dioxide (which occurs more readily at lower temperature). By
alternating between a lower and higher pressure, carbon dioxide is
absorbed at the beef surfaces at the lower temperature, which then
becomes a "source" of carbon dioxide, at the surfaces (which is
where any bacteria will be present) and provide for the lethal
conditions desired when a sudden pressure increase can provide the
desired super-critical conditions at the surfaces of the boneless
beef.
[0376] In consideration of the above, a method is disclosed that
provides alternating conditions of exposure to super-critical
carbon dioxide conditions (which is lethal to bacteria) with
sub-critical conditions, wherein pressure within the autoclave or
pathogen deactivation vessel 955 is sequentially and rapidly
increased and decreased between about 1,500 psia and about 900
psia, is disclosed.
[0377] While illustrative embodiments have been illustrated and
described, it will be appreciated that various changes can be made
therein without departing from the spirit and scope of the
invention.
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