MANUFACTURING METHOD OF ORGANIC FERTILIZER WITH PROTEINS AND HYDROLYSED AMINO ACIDS AND RESULTING ORGANIC FERTILIZER

Abstract

It is a manufacturing method (10) of organic fertilizer (FG) obtained from the disposal of fish such as carcasses and viscera; said manufacturing method (10) of organic fertilizer (FG) consists of two sequential operational stations, namely the feeding station (FT), which is connected to the controlled hydrolysis station (ETH) using a set of equipment (CP) fed by steam, compressed air, fuel gas, water-soluble lewis acid, drinking water stored in tanks, reservoirs, chiller, among other equipment used to obtain the organic fertilizer (FG).

Claims

1. “MANUFACTURING METHOD OF ORGANIC FERTILIZER WITH PROTEINS AND HYDROLYSED AMINO ACIDS AND RESULTING ORGANIC FERTILIZER”, more precisely it is a manufacturing method (10) organic fertilizer (IG) obtained from the discarding of fish as carcasses and viscera; characterized by being the manufacturing method (10) of organic fertilizer (FG) formed by two sequential operational stations, which are the feeding station (ET), which is connected to the controlled hydrolysis station (ETH) using a set of equipment (CP) fed by steam, compressed air, fuel gas, water-soluble lewis acids, drinking water stored in tanks, reservoirs, chiller, among other equipment used to obtain the organic fertilizer (FG) where: the feeding station (ET) of this method (10) of organic fertilizer manufacturing (FG) presents the stages of: a) Storage and conveying of raw material, i.e., discards (20) of carcasses (21) of fish—In this stage the carcasses (21) are received in the unit in plastic boxes (11) with a volume of about 300 kg per unit. The boxes (11) are stored in cooled warehouse, with the necessary observations in relation to the state of conservation and guarantee of quality coming from them. These discarded boxes (20) are carried by forklift trucks to the tumbler assembly (30) of boxes (11), in an air-conditioned environment, where it unloads the fish carcasses into the material intake hopper, installed over the crusher (40). Said tumbler assembly (30) comprises tumbler (31) and conveyor belt (32); b) Crushing of the carcass (21)—At this stage the crusher (40) standardizes the size of the particle (21a) to be hydrolyzed for efficiency of the enzymatic action and significant reduction of the process time. Said crushed material (21a) is then pumped directly to the hydrolysis reactor (43) through a helical pump (42) of crushed carcasses (21a), which is connected to a storage silo (41). Said hydrolysis reactor (43) is equipped with a load cell weighing system, preferably in the 50-90% carcass ratio. Then the water is added, proportionally in the order of 10-50% of the carcasses (21a) already transferred; the transformation/hydrolysis station (ETH) (FIG. 2), after complete loading of the crushed carcasses (21a) of fish and water, follows the order below: a1) steam controlled temperature rise, considering as instantaneous parameter the temperature of the direct core, mass of the product. This stage raises the temperature starting from the ambient state from 10° C. to 20° C. until reaching the required parameter of 60° C., with the reactor (43) under constant stirring; the relation for mass balance and time of this phase with scenario from 10° C. to 60° C., is necessary about 1400 kgv/h, and the rise time is about 30 minutes; when the ideal temperature of the product core is reached at 60° C., with the reactor (43) in constant stirring, after 5 minutes of operation, the condition of the PH is analyzed, indicated directly in a panel with human-machine interface of the reactor (43) located on the operating floor; the PH value must be in the range of 6.0 to 9.0, and if it is in different parameters it is required to adjust it until it reaches ideal conditions, chemically executed through a lewis base to raise the range and or lewis acid to reduce the range; b1) The proteolytic enzyme, previously weighed and diluted in non-chlorinated water, is added in the order of direct addition by the reactor receiving hopper (43), being 0.1-2.0% of the total weight of the raw material composed of viscera (22) and carcasses (21) counted in the reactor (43); c1) After 10 minutes of process, sampling for process and control recording is initiated, with samples being taken every 30 minutes, totaling 7 samples, in the 3:30 h of estimated process of hydrolysis, being also able to make extra samples if necessary; the analyses that must be registered reveal if the parameters of PH and Brix—% dissolved solids until reaching the ideal parameter of PH range 6.0 to 7.0 and Brix of 10-18; when reached starts a new cycle of increase of temperature, starting from 60° C. of the process to 80° C., this necessary for inactivation of the acting enzymes; Starting from the scenario of 60° C. to 80° C., 1400 kgv/h are required, and the rise time is about 20 minutes, waiting 20 minutes for the end of the inactivation cycle to make the transfer to the soluble and insoluble separation process by sieving; separation transfer/sieving time of about 60 minutes; d1) After the transference by the vibratory classifier (44) and the total hydrolyzed solution is reached, keeping it homogenized by recycling process, the solution is kept in storage process for minutes, for homogenization of the oily phases; the transference to the final formulation reactor is initiated (50); the transfer time of the solution from the hydrolyzed reservoir (43) to the final formulation reactor (50) is 45 minutes, and the solution tends to reach the final formulation reactor (50) at a temperature of about 65° C., which should be reduced to 40° C., under constant stirring; e1) Assessing the pH, the reactor (50) starts the adjustment process and should reach the ideal range of pH 3.0 to 5.0, in this case the automated addition of lewis acid; after 10 minutes of stirring the antioxidant and preservative are added; for the conclusion of the method (10), the rheology modifying suspending agent is added, preferably xanthan gum in the order of 0.35%, and the solution coming from the acid hydrolysis, obtained in the process so that it remains in suspension, besides other additives, such as minerals, carboxylic acids and other raw materials for preparation of the final product to be developed; for the reduction of temperature and final formulation considering already fractioned raw material the time is about 2:20 h.

2. “RESULTING ORGANIC FERTILIZER”, according to claim 1, characterized by resulting organic fertilizer (FG) using discards (20) of fish as, carcasses (21) and viscera (22) employed technique of enzymatic hydrolysis in association with acid hydrolysis to benefit 100% of the waste material turning it into organic fertilizer (FG).

3. “RESULTING ORGANIC FERTILIZER”, according to claim 1, characterized by resulting organic fertilizer (FG), obtained from fish discards used in the method (10), includes proteins and hydrolyzed amino acids and physical characteristics that do not cause fouling.

Description

DESCRIPTION OF THE FIGURES

[0023] To complement this description in order to obtain a better understanding of the features of this invention and in accordance with a preference for its practical implementation, a set of drawings is attached to this description, in which, in an exemplary but not limitative manner, its operation was represented:

[0024] FIG. 1 represents a schematic view of the feeding station of the fertilizer manufacturing method with proteins and hydrolyzed amino acids obtained from fish discards such as carcasses and viscera; and

[0025] FIG. 2 shows a schematic view of the controlled hydrolysis station for the completion of the innovative method.

DESCRIPTION OF THE INVENTION

[0026] As regards the illustrated drawings, the present invention patent refers to the “MANUFACTURING METHOD OF ORGANIC FERTILIZER WITH PROTEINS AND HYDROLYSED AMINO ACIDS AND RESULTING ORGANIC FERTILIZER”, more precisely it is a manufacturing method (10) of organic fertilizer (FG) obtained from fish discards, such as carcasses and viscera.

[0027] According to the present invention, the manufacturing method (10) of organic fertilizer (FG) is formed by two sequential operational stations, which are the feeding station (ET) (FIG. 1), which is connected to the controlled hydrolysis station (ETH) (FIG. 2) using a set of equipment (CP) fed by steam, compressed air, fuel gas, water-soluble lewis acids, drinking water stored in tanks, reservoirs, chiller, among other equipment used to obtain the organic fertilizer (FG).

[0028] The feeding station (ET) of this manufacturing method (10) of organic fertilizer (FG) has the following stages: [0029] a) Storage and conveying of raw material, i.e., discards (20) of carcasses (21) of fish—In this stage the carcasses (21) are received in the unit in plastic boxes (11) with a volume of approximately 300 kg per unit. The boxes (11) are stored in cooled warehouse, with the necessary observations in relation to the state of conservation and guarantee of quality coming from them. These discarded boxes (20) are carried by forklift trucks to the tumbler assembly (30) of boxes (11), in an air-conditioned environment, where it unloads the fish carcasses into the material intake hopper, installed over the crusher (40). Said tumbler assembly (30) comprises tumbler (31) and conveyor belt (32); [0030] b) Crushing of the carcass (21)—At this stage the crusher (40) standardizes the size of the particle (21a) to be hydrolyzed for efficiency of the enzymatic action and significant reduction of the process time. Said crushed material (21a) is then pumped directly to the hydrolysis reactor (43) through a helical pump (42) of crushed carcasses (21a), which is connected to a storage silo (41). Said hydrolysis reactor (43) is equipped with a load cell weighing system, preferably in the 50-90% carcass ratio. Then the water is added, proportionally in the order of 10-50% of the carcasses (21a) already transferred.

[0031] The processing/hydrolysis station (ETH) (FIG. 2), after complete loading of the crushed carcasses (21a) of fish and water, follows the order below: al) steam controlled temperature rise, considering as instantaneous parameter the temperature of the direct core, mass of the product. This stage raises the temperature starting from the ambient state from 10° C. to 20° C. until reaching the required parameter of 60° C., with the reactor (43) under constant stirring. The ratio for mass balance and time of this phase with scenario from 10° C. up to 60° C. is required approximately 1400 kgv/h, and the rise time is approximately 30 minutes. When the optimum product core temperature of 60° C. is reached with the reactor (43) constantly stirring after 5 minutes of operation, the condition of the PH is analyzed and displayed directly in a panel with the reactor's HMI (43) located on the operating floor. The PH value must be in the range of 6.0 to 9.0, and if it is in different parameters it is necessary to adjust it until it reaches ideal conditions, chemically executed through a lewis base to raise the range and or lewis acid to reduce the range;

[0032] b1) The proteolytic enzyme, previously weighed and diluted in non-chlorinated water, is added in the order of direct addition by the reactor receiving hopper (43), being 0.1-2.0% of the total weight of the raw material composed of viscera (22) and carcasses (21) counted in the reactor (43);

[0033] c1) After 10 minutes of process, sampling for process and control recording is initiated, with samples being taken every 30 minutes, totaling 7 samples, at 3:30 h of estimated hydrolysis process, and extra samples can be taken if necessary. The analyses that must be recorded reveal the parameters PH and Brix—% dissolved solids until reaching the ideal parameter of PH in range 6.0 to 7.0 and Brix of 10-18. When reached, a new cycle of temperature increase begins, starting from 60° C. of the process to 80° C., which is required for inactivation of the active enzymes. Starting from the scenario of 60° C. to 80° C., 1400kgv/h are required, and the rise time is about 20 minutes, waiting 20 minutes for the end of the inactivation cycle to make the transfer to the soluble and insoluble separation process by screening. Separation transfer/screening time of about 60 minutes;

[0034] d1) After the transfer through the vibratory classifier (44) and reaching the total hydrolyzed solution, keeping it homogenized by recycling process, keeps the solution in storage process for 20 minutes, for homogenization of the oily phases. The transfer to the final formulation reactor begins (50). The transfer time of the solution from the hydrolyzed reservoir (43) to the final formulation reactor (50) is 45 minutes, and the solution tends to reach the final formulation reactor (50) at a temperature of about 65° C., which should be reduced to 40° C., under constant stirring;

[0035] e1) Assessing the pH, the reactor (50) starts the adjustment process and should reach the ideal range of pH 3.0 to 5.0, in this case the automated addition of lewis acid. After 10 minutes of stirring the antioxidant and preservative are added. For the conclusion of the method (10), the rheology modifying suspending agent is added, preferably xanthan gum in the order of 0.35%, and the solution coming from the acid hydrolysis, obtained in the process so that it remains in suspension, besides other additives, such as minerals, carboxylic acids and other raw materials for preparation of the final product to be developed. For the reduction of temperature and final formulation considering already fractioned raw material the time is about 2 hours and 20 twenty minutes.

[0036] The resulting organic fertilizer (FG) using fish discards (20) such as carcasses (21) and viscera (22) employs a technique of enzymatic hydrolysis in association with acid hydrolysis benefiting 100% of the discarded material, converting it into 80% of amino acid solution and 20% of organic insolubles which, after micronized, incorporate organic fertilizer (FG).

[0037] The resulting organic fertilizer (FG), obtained from fish discards used in the method (10), includes proteins and hydrolyzed amino acids and physical characteristics that do not cause fouling.

[0038] It is certain that when the present invention is put into practice, modifications may be introduced with regard to certain details of construction and shape, without this implying a departure from the basic principles that are clearly substantiated in the claiming framework, it being understood that the terminology used did not have the purpose of limitation.