New system for the manufacture of peeled chestnuts, with integral use (Machine-translation by Google

专利摘要:
The patent for the manufacture of peeled chestnuts will improve the systems by applying the techniques of the figures. Mucilage and tannins are recovered, obtaining spirits, animal feed and energy from hides and shells that today are waste for landfills. The technology consists of the superficial cutting of the outer skin and application of techniques for the dissolution of the adherent compounds of the inner skin or integument, through initial moistening and treatment with hot water and steam with the help of ultrasound systems, microwaves. and additives that dissolve mucilages and tannins. They will be frozen individually by absorption and contact with evaporative plates and the Cell Alive System. It will adapt to all chestnuts, making its peeling profitable. There will be no waste and there will be energy self-sufficiency due to the combustion of the skins in MAGOB burners without smoke and the use of an ORC turbine for electricity production. (Machine-translation by Google Translate, not legally binding)
公开号:ES2786449A1
申请号:ES202030557
申请日:2020-06-09
公开日:2020-10-09
发明作者:González Manuel Enrique Posada
申请人:Posada Gonzalez Manuel Enrique；
IPC主号:

专利说明:

[0002] NEW MANUFACTURING SYSTEM FOR PEELED CHESTNUTS, WITH INTEGRAL USE
[0004] TECHNICAL SECTORS
[0006] The invention belongs to the Forestry sector due to the origin of the chestnuts and to the Food sector due to the destination of its products:
[0008] BACKGROUND OF THE INVENTION
[0010] The chestnut is one of the oldest foods of Humanity. Since the Paleolithic the man took advantage of and fed on chestnuts and acorns. The chestnut tree is native to Sardis, one of the seven churches in Asia Minor mentioned in the book of Revelation. This fruit accompanies the history of European man, in his Christian-Western civilization and it is even known that it accompanied the great migrations in the glacial period. Isaiah and later Homer already cite the chestnut and in the Celtic religion, the chestnut must have been venerated by their druids, in the company of the oak, which with the laurel and yew formed the pre-Roman totemic forest.
[0012] The chestnut was the breadfruit of our Hispanic tribes. The chestnuts were used for roasting, or producing flour when they were dry and fed throughout the year. The Roman legionnaire was fed with buns made of chestnut flour, kneaded. A reference is found in the Gallic War, in which we are told that the Roman legions ascend through the French Ardeche region, under a grove of "arbus panis".
[0014] There are chestnuts in China, Korea, Japan, the United States, Chile and throughout Europe. Until a few years ago, they were the staple food of their population, in the form of fresh, dried fruit without their skins, or ground into flour. In the 16th century, potatoes and corn arrived from America and competition was established, losing prominence in the peasant diet. Later, the noble trees were attacked by the pests "canker" and "ink". In recent years, thanks to research carried out in centers such as the one in Lourizán (Pontevedra), varieties and hybrids resistant to these diseases have been achieved, hence no decrease in the number of disease production in trees.
[0016] The chestnut tree does not only produce chestnuts. It gives us magnificent shade in summer and firewood in winter. In symbiosis, it produces wonderful mushrooms, culinary companions in the most delicate dishes. It beautifies the landscape, protects and improves the human ecosystem, so preyed upon by rapid productions of a man who is in an ever-greater hurry. The chestnut provides considerable benefits both for the real value of exports and for the number of kilos traded directly or through derived products, especially candied chestnuts. The natives of the mountain areas of the provinces of Lugo (Quiroga, Caurel, for example) and Ourense (Verín, Viana do Bolo, O Barco, A Rúa, Celanova and Cartelle) know of the profitability of chestnut.
[0018] Chestnuts persist in the memory of all the traditional good dishes of the old cuisine based on chestnuts, and as a staple food, they become precious gastronomy. Even today in some remote Portuguese, Greek or Turkish villages, the plate of chestnuts is daily on the peasant tables, and in some others, the animals are kept with the smallest fruits, attacked by insects or malformed. A respectful greeting, we have to make the most exquisite of our hams, the Jabugo, raised with acorns and chestnuts in the foothills of the Sierra de Aracena in the Sierra Morena. If what is taken is raised, the raw material is as good as the finished product.
[0020] We have the obligation to dignify our Earth, plant trees and noble species and recover one of our oldest signs of identity. And with cooking and gastronomy the same thing happens, because it will not be with hamburgers that our species will be improved. Our constitution is made of chestnuts, as we have been incorporating this fruit into our body for thousands of years. Everything configures, influences, conditions, modifies and builds the human species. Not only the climate, the latitude or altitude, that is why the saying of "you are not from where you are born, but from where you peace is right."
[0022] Chestnuts are produced in autumn and at the exact time to taste the new wine, harvested in September, as well as on the days when the slaughtered pig is accompanied, as a regulation, on Saint Martin's Day, November 11, in areas such as Galician. Cities grow and traditions fade, but still In villages, towns and cities, men remember ancient traditional dishes that were eaten at their grandmothers' house, made or accompanied by chestnuts.
[0024] And it is here where the problem of the use of chestnuts for gastronomic use and the objective of this patent is observed. Humans do not have teeth or a digestive system prepared to feed on chestnuts with their skins and therefore, we must eliminate them.
[0026] In the traditional art of the system, for the preparation of the cooked chestnuts, the manual peeling of the first skin was performed, more consistent, to proceed to cook the chestnut with the second skin for its elimination as it was eaten. In a slow and manual procedure that limited consumption and intake.
[0028] For the preparation of roasted chestnuts, the chestnuts are subjected to direct contact, supported by perforated metal sheets, with firewood or incandescent charcoal at temperatures close to 400 ° C, achieving the burning of the outer skin and a roast of the inner fruit. of the chestnut and the outer skins (pericarp and episperm or integument). The outer skin was perforated to prevent its explosion by the formation of internal water vapor.
[0030] As a result of the assembly of a chestnut peeling plant in Orense, as a result of the management of engineer José Domingo Posada González with the Japanese company Marubeni, the first plant to be built in Spain, several production plants are developed in the vicinity, creating targeted investments. about the technology developed there.
[0032] Technology is also being radiated to the north and center of Portugal, with better or worse luck, without making significant advances in the technology developed at the Orense plant.
[0034] Industrial art, which arrived in Spain in the 70s of the last century, technically carried out in Spain by the owner of the patent application, there are several basic problems due to the use of imperfect methods for its treatment.
[0036] The use of a perforated steel sheet cylinder screen for size classification, mistreats the fruits and does not remove the dirt that comes from the field, but rather He distributes it over all the chestnuts. The fruits of greater diameter, of greater gastronomic value and price, pass through a rotating perforated cylinder that, due to having a treatment of longer duration than necessary, mistreat the fruits. There is no pre-sorting or cleaning on arrival from the field.
[0038] Since that time, remaining until today, two peeling systems coexist.
[0040] FIRE METHOD:
[0042] The first is the use of fire with the combustion of propane gas. The pericarp or external surface of chestnuts, formed by the two skins (the hard shell and the thin skin or integument), is subjected to contact with metal surfaces at very high temperatures, close to cherry red (815 ° C) or close to orange (940 ° C).
[0044] To achieve these temperatures and the contact of the chestnuts with the incandescent surfaces, there are isolated rotary kilns, tubular or cylindrical, through which the chestnuts are passed. Inside there are retention helixes that, when rotating on their main axis, produce a displacement in the direction of the longitudinal axis of the cylinder. The chestnuts come out of the ovens with the shell and the integument or inner skin, burned by the process. A rubbing on a surface composed of a mesh of wires, separates the shells and skins, damaged by fire, from the peeled fruits, nuts or endocarps.
[0046] STEAM METHOD:
[0048] The steam peeling method begins with the practice of randomly superficial cuts of the two skins. A special machine is used equipped with cylinders on the surface of which razor blades that protrude a few millimeters are housed. The chestnuts thus processed are passed to a steam chamber at atmospheric pressure to attack the skins and weaken the union with the seed or the endocarp. The chestnuts thus treated are passed to a roller separating machine that drags the skins by means of a rain of hot water at 60 ° C.
[0050] Both methods present a series of problems that:
[0051] 1) They damage the quality of peeled chestnuts by:
[0052] The fire burns the surface of the fruit, reducing the weight.
[0053] The surface of the chestnut loses porosity.
[0054] The lack of uniformity of the size of chestnuts
[0056] 2) Loss of raw materials occur due to:
[0057] Incomplete peeling.
[0058] The breaking of chestnuts during peeling.
[0060] 3) Inability to use types of chestnuts:
[0061] Only some varieties admit peeling.
[0063] 4) High production costs:
[0064] On fire, very high gas consumption.
[0065] In steam, very high fuel consumption to generate steam.
[0066] In steam, very high consumption of drinking water.
[0068] 5) Generation of high useless waste:
[0069] In the peeling processes, waste is generated without use.
[0070] Damp peels and skins in the steam method.
[0071] Ashes and shells and skins unburned in the fire method.
[0072] Peeling and cleaning waters.
[0074] The energy costs of fire-based peeling are not very high. Another thing is the steam peeling that uses a large boiler. As an example, in fire peeling there is a consumption of propane gas of the order of 140 g of gas per 100 kgs of peeled chestnut. In steam peeling, the order of 60 liters / hour of diesel is consumed. The quality of steam peeling is much higher than that of fire peeling.
[0076] The fire peeling method is considered obsolete and unsuitable for the food use of chestnuts due to quality and productivity problems: 1) Loss of surface quality and 2) Loss of weight. Various types are established for individualized application according to their importance.
[0078] The sales prices of the existing factories, both in Spain and Portugal are very high in relation to the cost of the raw material. With a system in which chestnuts are better used, without generating so much waste, sales prices could be reduced, increasing consumption in markets and eliminating a large part of the waste generated. The cost of the raw material represents 20% of the sale price although it could improve this relationship.
[0080] Most of the Spanish chestnuts, from Asturian, Cantabrian, Basque, Catalan, Aragonese, Valencian, Murcian, Castilian, Extremaduran, Andalusian, etc. they cannot be peeled by the procedures described. The potential for the use of these areas is very high and is wasted. The reforestation of chestnut trees with the use of chestnuts would be very important for the enhancement of forest agriculture, increasing the value of agricultural production, increasing the value of forest land and the yield of crops in general.
[0082] From the legislative point of view, it is worth noting the immediate transposition of the Community Directives (EU) 2018/850, 2018/851 and 2018/852 that update the legislation on the landfill of waste 1999/31 / EC, of waste 2008 / 98 / CE and packaging and packaging waste 94/62 / CE, which continues the path undertaken for the implementation of the Circular Economy.
[0084] The new Waste Directive updates its object in Article 1, with which it directly attacks the generation of waste, and not only its impacts, and expressly incorporates the obligation to make a transition towards a circular economy.
[0086] With the aim of collaborating with our society and in order to remedy the aforementioned problems, achieving the elimination of deficiencies and improving both production and investment performance and maintenance costs, there is a system widely studied by the patent applicant, called: NEW MANUFACTURING SYSTEM FOR PEELED CHESTNUTS, WITH INTEGRAL USE, which is described below.
[0088] EXPLANATION OF THE INVENTION
[0089] The method of manufacturing peeled chestnuts starts from the selection of the most appropriate varieties for industrialization and the determination of the degree of maturity and the humidity of the raw material.
[0091] That is why the purchase of chestnuts at their most appropriate time for the process determines the starting point of a rational production.
[0093] The conservation treatment must be immediate, upon the arrival of the chestnuts to the production plant
[0095] The first treatment to be carried out is the immersion of the chestnuts in a water bath to separate the floating chestnuts from the whole or normal ones. Among the floating chestnuts, the hazelnut or flabby ones will be separated as well as those that are attacked by the larvae of the chestnut weevil or Curculio elephas Gyll (Balaninus elephas) and Carpocapsa sp. (Cydia Splendana). Both rejections will be removed from the transformation process to be properly processed and prevent the spread of pests.
[0097] The chestnuts that sink in the water bath will be drained from the water and subjected to classification by diameter using a vibrating screen with mobile panels. Chestnuts with a larger diameter will remain in the upper mesh and discharge into a channel belt. The belt will immediately discharge into prismatic containers with lower discharge hopper and slide gate opening and closing valve. They will be separated into five gauges or diameters so that their processing is uniform.
[0099] The stockpiles in the containers will be moved with the gradual discharge procedure to prevent the formation of molds. The prismatic containers will be stacked in 4 heights so that, by means of a forklift, they can be easily moved. The unloading operation will be performed by substituting the filled lower container for an empty one by moving the three upper containers to the upper position of an empty container. The unloading operation is performed by opening the lower sliding gates. The upper container will discharge into the lower one, moving all the chestnuts through the containers, aerating to allow their conservation over time. The quality of chestnuts in storage will be constantly observed for their control and treatment if necessary.
[0101] CHESTNUT PEELING PROCESS
[0103] Depending on the characteristics of the chestnuts, the most suitable peeling method will be selected in application of the techniques described below, adapting the conditions of temperatures, flows, pressures and treatment times. The fire peeling method is considered inappropriate for the above reasons.
[0105] BIG SIZE, CLASSIC SHAPED CHESTNUTS
[0107] CUT: The initial operation will be to carry out a perimeter superficial cut. The cutter will be individual treatment at high speed and carried out by mechanical means. The chestnuts will be positioned so that the cuts coincide with the equatorial part of the fruit.
[0109] BATHING: The superficially cut chestnuts will be subjected to a water bath at 60 ° C, with certain additives to dissolve the mucilage from the skin, for a period of several seconds, sufficient to achieve the desired effect. For certain cases of very adherent skin, the treatment will be by water under pressure and alternative vacuum, with the use of ultrasound.
[0111] SISP: The next step is carried out in the Integral Skin Separation System with four consecutive processes:
[0113] 1) Microwave irradiation.
[0114] 2) Treatment with water / steam jets.
[0115] 3) Extraction of the skin with water and steam under pressure on the
[0116] gripping cylinders.
[0117] 4) Selection and separation of chestnuts and residues.
[0119] It is the main object of the patent system that determines the great yield and the great improvement in the quality of the peeled fruits. The sale price of this type of chestnut will be much higher than the rest due to its usefulness in the manufacture of the most exquisite sweet of history, the "Marrón Glacé", which fetch a price in France of € 1.90 / unit. The destination will be the sale to the confectionery manufacturers, or the own manufacture starting from frozen.
[0121] CHESTNUTS WITH IRREGULAR SHAPE AND VARIOUS SIZES
[0123] The process will be carried out after classifying the sizes and shapes for a uniform treatment. That is, chestnuts should be treated with the same procedure depending on the size, only then will some processes corresponding to each size be achieved.
[0125] CUT: The initial operation will be making superficial cuts randomly. The cutter will be of general treatment carried out by mechanical means.
[0127] BATHING: The superficially cut chestnuts will be subjected to a water bath at 60 ° C, with certain additives to dissolve the mucilage from the skin, for a period of several seconds, sufficient to achieve the desired effect. For certain cases of very adherent skin, the treatment will be by water / steam under pressure and alternative vacuum, with the use of ultrasound.
[0129] SISP: The next step is carried out in the Integral Skin Separation System with four continuous processes:
[0131] 1) Microwave irradiation.
[0132] 2) Treatment with water / steam jets.
[0133] 3) Extraction of the skin with water and steam under pressure on the table of prehensile cylinders.
[0134] 4) Selection and separation of chestnuts and residues.
[0136] It is the method that is the main object of the patent, which determines the great performance of the system and the great improvement in the quality of the peeled fruits for sale to national or international manufacturers at prices in line with the quality obtained.
[0138] MICROWAVE IRRADIATION:
[0139] The chestnuts are subjected to a shock irradiation to produce a separation by heating of the mucilages or polyphenols for their weakening and improvement of the following action of the vaporization. The humidity received during the previous immersion is activated to dissolve these.
[0141] VAPORIZATION:
[0143] It is the treatment by hot water or steam at high temperature (90-110 ° C), to achieve penetration into the interstitium of the seed and the second skin or episperm.
[0145] PRENSILE ROD PEELER:
[0147] By means of 14 mm diameter rods arranged in parallel, rotating in pairs with opposite directions of rotation, the fastening and dragging of the skins that have been lifted from the endocarp by the previous operations is achieved.
[0149] The upper and lower water and steam jets facilitate gripping and displacement operations, eliminating mucilages or polyphenols that can make the operation slide.
[0151] SELECTION AND SEPARATION:
[0153] It is carried out on the chestnut conveyor belt, located at the exit of the peeler of prehensile rollers. Six people will be employed on both sides of the band.
[0155] The divisions of the band allow the manual separation of the badly peeled chestnuts for their reincorporation to the most suitable stage of the process. The perforations in the bands of the belts allow the defective chestnuts to be sent to the collection and use area for crushing, fermentation, and production of brandy and animal feed pellets.
[0157] CHESTNUT FREEZING PROCESS
[0159] IQF: Individual Quick Freezing Method acronym for the English name international: "Individually Quick-Frozen". The freezing will be carried out by means of exchange with hollow metal plates where the R717, (Ammonia, NH3) evaporates, acting as a refrigerating evaporator, at a temperature of - 60 ° C. The Japanese CAS system, "Cells Alive System" or living cell system, will be used, which allows the maintenance of the original plant structure over time, with a surprising recovery of the original properties after thawing. The system allows a freezing process in a time of 4 hours with an auxiliary hopper loading system and semi-automatic unloading with the mechanical operation of a worm located in its lower part.
[0161] CALIBERS TO BE PRODUCED
[0163] For peeled chestnuts, the qualities are determined by the number of fruits that go into each kilogram:
[0165] <120 chestnuts per kilo
[0166] 120/150 chestnuts per kilo
[0167] 150/180 chestnuts per kilo
[0168] 180/210 chestnuts per kilo
[0169] > 210 chestnuts per kilo
[0170] and chopped chestnuts
[0172] INTEGRAL USE OF CHESTNUTS
[0174] Various wastes and by-products are generated in the manufacturing processes, independent of the main production, which is peeled chestnuts. Its uses are described below:
[0176] CHESTNUTS FOFAS, AGUSANADAS AND MANUFACTURING RESIDUES
[0178] The flabby chestnuts (with a reduced fruit not adjusted to the shell) and wormy or bitten by the insects, are separated by flotation in the first cleaning operation in the machine n ° 1. As the production of chestnuts, in general, is ecological and it is not treated with insecticides, there is a variable amount of this type of residue. There are chestnuts attacked by insects that are detected during the selection process and have not been separated in the flotation system. During the peeling and selection process, they will be separated and incorporated into these residual chestnuts.
[0180] This waste will be used with a treatment of:
[0182] 1 °) Crushing the chestnut waste.
[0183] 2 °) Cooking of the crushed waste.
[0184] 3 °) Inoculation of yeast in the sterilized waste.
[0185] 4 °) Fermentation of the sugars contained in the residues.
[0186] 5 °) Distillation of the brandy resulting from fermentation.
[0187] 6 °) Extrusion or pelletization of the distillation residues.
[0188] 7 °) Dehydration of the pellets for use as animal feed.
[0190] In this way, there will be a comprehensive use of waste, as part of the comprehensive use of chestnuts. A "delicatessen" or "gourmet" product such as chestnut brandy will be introduced to the national market. This will feed the pigs raised with chestnuts of extraordinary demand in the eastern markets.
[0192] The results of the operations will be:
[0194] A) Chestnut brandy
[0195] B) Chestnut pellets
[0197] CHESTNUT SKINS
[0199] The chestnut skins or peels, extracted in the peeling process, both those generated in the surface cutting process and those obtained in peeling, will be conditioned for their use as fuel in a MAGOB smokeless burner, with the production of the energy required for the various phases of the processes.
[0201] The energy to generate hot water and steam will be obtained by heating thermal oils to maximum temperatures of 300 ° C and their exchange with water to produce temperatures of 24 ° C (cleaning), 60 ° C (pasteurization and use of mucilages and polyphenols) and 90-110 ° C (steamed for peeling). The crushed mixture of flabby and wormy chestnuts will also be sterilized for fermentation and the distillate for the use of the brandy produced. The distillation residues will also be dehydrated for the production of extruded mixtures for livestock feed.
[0203] Electric energy will be generated based on an ORC turbine, Organic Rankine Cycle, with low pressures and temperatures, which will achieve energy self-sufficiency in the processes of:
[0205] 1 Cleaning Bath 1.50 kW
[0206] 1 fresh chestnut sieve 3.00 kW
[0207] 1 Large chestnut slicer 0.50 kW
[0208] 1 General cutter 3.00 kW
[0209] 1 Anti-mucus bath 60 ° C 1.00 kW
[0210] 1 Microwave tunnel 1.00 kW
[0211] 1 Vaporization 1.50 kW
[0212] 1 Skinning 1.75 kW
[0213] 1 Inspection band 1.31 kW
[0214] 1 Freezing-Absorption Cabinet 2.5 kW 55.00 kW 1 Frozen chestnut sieve 3.00 kW
[0215] 1 Waste shredder 1.30 kW
[0216] 3 Cooker, fermenter mixer and still 6.00 kW
[0217] 1 Manufacture of extruded chestnut pellets 2.00 kW
[0219] The energy necessary for freezing can be obtained from the combustion of chestnut shells and skins in the application of refrigeration absorption technology, instead of compression of refrigerant or refrigerant fluids, through the use of mechanical compressors.
[0221] DESCRIPTION OF THE PARTS
[0223] 1 - Initial classification water bath.
[0224] 2 - Green chestnut classification sieve.
[0225] 3 - Prismatic storage containers.
[0226] 4 - Large chestnut superficial slicer.
[0227] 5 - Normal chestnut random surface slicer.
[0228] 6 - Anti-mucus bath.
[0229] 7 - Microwave irradiation.
[0230] 8 - Chestnut steamer.
[0231] 9 - Skin-fruit separation, on a prehensile roller table.
[0232] 10 - Selection tape.
[0233] 11 - Plate freezing.
[0234] 12 - CAS Freezing System, Cell Alive System
[0235] 13 - Peeled chestnut classification sieve.
[0236] 14 - Waste shredder
[0237] 15 - Reactor for cooking, fermentation, distillation process.
[0238] 16 - Manufacture of dehydrated pellets
[0239] 17 - Energies demanded, energies consumed
[0241] INITIAL CLASSIFICATION WATER BATH
[0243] As can be seen in figures (1), (2) and (3), a container is formed in the shape of an inclined tub and a horizontal water bath surface. It will be made of 316 AISI stainless steel sheets and profiles. It will be equipped with a tank with a substantially triangular plant and an inverted pyramidal shape, with a top load on both sides. An endless screw in the bottom, with an upward position, will allow the extraction of chestnuts that have been submerged.
[0245] Chopped and flabby chestnuts and other residues will be separated by floating in the water. A surface water spillway will separate the chestnuts and various floaters towards a reversible conveyor separator mesh, for the loading of suitable receiving containers located at both ends. The containers will be charged and replaced alternately. The water from the spill will be introduced into a filtering system, which will extract the solids that have not been retained by the selective mesh. The filtered water will be injected with a pump through the lower part of the container, stirring the bottom and facilitating the cleaning of the chestnuts stored there, at the same time that it drags them towards the lifting screw. The filtered water will be renewed permanently, with a flow dependent on the quantities of chestnuts treated. The residues retained in the filtration will be incorporated into the fuels for their energy use
[0247] In the bath water, a product may be included that prevents the formation of molds, in safe quantities for later treatment.
[0249] DRAINAGE SCREEN AND SIZE CLASSIFICATION
[0251] As can be seen in figures (4), (5) and (6), there will be a sorting sieve for sizes or diameters of the fruits. It will be equipped with 5 vibrating panels, made of steel mesh with different spacings between the wires, flat, slightly inclined to promote the movement of the chestnuts along the length and width of the panels. In the lower part, there will be panel 6 without sieving mesh, to collect the chestnuts that have passed through the mesh of the sieve panel 5
[0253] To achieve a faster surface drying, it will be equipped with ventilation fans.
[0255] The five vibrant panels will separate the chestnuts of the different calibers in units per kilo:
[0257] Panel 1 - They do not go through the mesh, class <50 units / kilo
[0258] Panel 2 - They do not pass through the mesh, class 50 - 60 units / kilo
[0259] Panel 3 - They do not go through the mesh, class 60 - 70 units / kilo
[0260] Panel 4 - They do not go through the mesh, class 70 - 80 units / kilo
[0261] Panel 5 - Do not pass through the mesh, class 80 - 90 units / kilo
[0262] Panel 6 - collection of the output of panel 5, class> 90 units / kilo
[0264] PRISMATIC STORAGE CONTAINERS
[0266] To achieve adequate storage for the peeling process, with the chestnuts being preserved for the required time, some prismatic, stackable containers will be built, shaped like cages, as can be seen in figures (7), (8) and (9). The volume of the container will be 1,022 liters. The approximate weight of the content depends on the caliber and the average is 850 kgs.
[0268] The structure will be made of painted steel angles, with adequate perforations for fastening wooden sheets screwed to the vertical angles. The chestnuts will only be in contact with the wood and not with any other material. To perform the falling movement that prevents the formation of molds and fermentations, at the base of the prismatic container, a truncated pyramidal hopper with a sliding closing gate will be arranged. To move the chestnuts, the stacked containers will be arranged so that, by opening and closing the gates, periodic movements can be carried out. By this procedure, the chestnut storage capacity of the warehouse's surface multiplies dramatically, with reference to the existing situation of 0.4 m3 / m2, going to 4.0 m3 / m2, that is, ten times more and its conservation is guaranteed. Entry into the process is controlled by the movement of the containers, with their individual weight and controlled quality.
[0270] LARGE CHESTNUT SURFACE CUTTER
[0272] The machine necessary to generate the perimeter cut to large chestnuts can be seen in figure (10). These must be processed independently, due to the differential value they have in the international market. The manufacture of the famous sweet of French origin "Marron Glacé" requires the use of large chestnuts with a very high price.
[0274] The machine makes a superficial and perimeter cut in the outer shell that opens the access for the separation of the skins from the endocarp. To do this, an immersion will be carried out for the necessary time in the antimucilage bath. Subsequently, microwave radiation will be applied and treated with steam and hot water under pressure to displace the skin and drag with prehensile rollers for total extraction.
[0276] NORMAL CHESTNUT RANDOM SURFACE CUTTER
[0278] As can be seen in figures (11), (12) and (13), the surface cutting machine in a global and random way, is composed of cutter rollers of cylindrical pieces that hold cutting blades that protrude superficially, about 5 mm from the surface of the main roller. Each roller is attached to another in the shape of a cylindrical brush that cleans the cutting blades. They are joined in a group with a circular anchor, which forms a cylinder closed by brushes and cutting rollers, through which the chestnuts circulate, displaced by an endless screw. The rotation speed will be variable to give more or less cuts to the skins. The rotation of the displacement worm screw can also be regulated so that the treatment is more or less prolonged.
[0279] During the passage of chestnuts through the interior of the device, multiple cuts will occur on the superficial or pericarp and internal or episperm skins. This will be followed by an immersion for the necessary time in the antimucilage bath. Subsequently, the microwave radiation will be applied and treated with steam and hot water under pressure to move the pieces of hides and the following clamping and dragging with the prehensile rollers, for total separation.
[0281] ANTIMUCILAGE BATH
[0283] As can be seen in Figures (14), (15) and (16), it is an endless screw located inside a closed pipe, 400 mm in diameter, to receive the chestnuts and house them during the time of desired treatment. The machine will be built with AISI 316 stainless steel and the rotation speed will be controlled by a reduction motor equipped with a speed variator. The outer pipe will be insulated with rock wool panels covered with bandage. The placement will be inclined with an angle of 15 ° sexagesimal.
[0285] The duration of the treatment will be between 30 "and 60", although, depending on the variety of chestnut, it could be modified. The speed will be controlled by a reducer coupled to a speed variator that will regulate the number of revolutions of the gearmotor output, which will be coupled to the worm shaft and will be from 20 to 40 rpm. The water temperature will be 60 ° C which, in addition to weakening the adherence of mucilages or polyphenols and tannins, will pasteurize the fruits. The treatment water will have its appropriate composition according to the investigations carried out and to be carried out. The process will be improved by the incorporation of ultrasound generators (10).
[0287] The water, with the dissolved mucilage content, will be passed through a separator filter with initial cooling (recovering the heat) to reach the solidification point of the mucilage. In the filtration panels, the mucilage will be periodically recovered or separated automatically with a self-cleaning filter. Subsequent heating before being returned to the main vessel is produced by a heat exchanger that raises the temperature to 60 ° C. The cooling-heating circuit will be a refrigeration cycle with the evaporator serving as a cooler for the solidification of the mucilage and the condenser. serving as a heater for the filtered fluid.
[0289] The recycling of the water by means of the pump and the filter, as well as the heat exchanger allows to partially eliminate the consumption of water, as well as the use of soluble materials, such as tannins and mucilages, starting from the dissolution with greater or lower concentration.
[0291] MICROWAVE IRRADIATION
[0293] In Figures (17) and (18) the microwave irradiation tunnel can be seen. The radiation will be emitted by a low-power commercial magnetron. In order to produce a uniform temperature rise in all the fruits, including the skins, external and internal, the chestnuts are subjected to a microwave radiation of a frequency of 2,450 MHz. The flow of the microwaves on the external, moistened shell By the cleaning water treatment as well as the mucilage removal bath, you will receive the radiation will produce a strengthening of the skin structure. This treatment will also generate an opening and weakening of the union between the episperm or inner skin and the fruit to allow the improvement of the subsequent separation.
[0295] VAPORIZATION AND TREATMENT WITH HOT WATER AND STEAM
[0297] The humid steam treatment chamber is based on a 400 mm diameter stainless steel cylinder figures (19), (20), (21), (22) and (23) with the outer surface insulated to prevent the losses of hot. An endless screw located inside the cylinder with a perforated tubular shaft that injects hot water and steam onto the chestnuts, at the same time that they rotate and move. Through its treatment in this chamber with low pressure humid steam, the water in the liquid and vapor states will be introduced into the interstices of the interior skin or episperm to eliminate the remains of mucilage that act as adherent. Its constant movement will produce the detachment of the remains of the inner skin.
[0299] The water and steam will condense due to the transfer of heat to the chestnuts and the corresponding loss of energy.
[0301] The condensed water vapor output will be recycled by filtering the cold condensate for the recovery of mucilage and tannins and heating prior to the reincorporation of the fluid to the tubular shaft that distributes the water vapor spray over the chestnuts located inside the endless treatment. The mucilages and tannins retained in the filter are periodically removed from the system. The water losses are compensated by the incorporation of water from the losses of the antimucilage bath.
[0303] SKIN-FRUIT SEPARATION ON GRIP ROLLER TABLE
[0305] As can be seen in the machine shown in Figures (24) and (25), a relatively flat area is created based on pairs of surface-marked metal rods that rotate in the opposite direction. This arrangement produces the grip of the chestnut skins and their separation from the fruit, at the same time that it moves them towards the lower part of the equipment. In order to improve trapping, the mucilage residues that may remain in the chestnut will be eliminated by means of jets of hot water / steam under pressure on the fruits located on the area formed by the prehensile rollers that will eliminate the peeled skins or in process detachment. Towards the bottom of the roller table, pressurized hot water / steam jets will also be applied to clean the rollers to improve their grip qualities.
[0307] The chestnuts, once peeled, will be unloaded on the selection conveyor belt.
[0309] The extracted hides separated by the rollers will be discharged towards a reception and separation area and pressed to recover the separation water. The hides will be transported to a conditioning tunnel for subsequent combustion.
[0311] The process water will be recycled for the recovery of mucilage and tannins by filtering it, as well as its subsequent use with a rise in temperature necessary for its reuse.
[0313] FINAL CLASSIFICATION OF FRUITS
[0315] The peeled chestnuts will be selected in a classifying band of qualities (26), (27), (28) and (29) by means of a conveyor belt and specialized operators.
[0316] Chestnuts that meet the quality criteria will be separated from those that do not meet them. Of the latter, those that are recoverable will be separated from those that are residual or irrecoverable.
[0318] The chestnuts of acceptable quality, as well as the pieces of chestnuts will be taken to the previous stabilization storage system in a bath to prevent oxidation or rancidity of the surface, with a prior cooling to temperatures close to 5 ° C. Later they will be incorporated into the IQF plate freezing system.
[0320] Chestnuts that do not meet the quality due to the presence of chestnut skins will be incorporated back into the process in the most suitable place for reprocessing.
[0322] The fruits that present irreparable defects due to the presence of externally imperceptible inner wormy, fungal attack, etc., will be eliminated towards the recycling area for their incorporation into the integral use area, together with the flabby chestnuts, chopped etc. for your consequent process.
[0324] FREEZING CHESTNUTS
[0326] The freezing of the peeled chestnuts will be produced by means of a static system of contact plates that can be seen in figure (30). The contact of the chestnuts directly with the plates, in 16 holes of 60 mm wide, and a unit volume of 271 liters, will allow the reduction of temperature by conduction between the plates and the chestnuts. It can be stated that the freezing will be done individually at high speed with an IQF result, "Individually Quick Frozen".
[0328] The system will be closed with accessible cupboard-type panels and doors, with an upper loading opening and a lower discharge hopper.
[0330] The upper loading will be carried out by means of an auxiliary hopper (31) with outlet openings that will coincide with the upper entrances of the holes between plates. The hopper will be located in the upper part of the set of plates, with a volume equivalent to that of the capacity of the freezing zones between plates, that is, about 4.34 m3. This will allow for uniform loading and distribution in a short time. The hopper will be equipped of a vibrator that will create a fluid state in the chestnuts of the hopper for their entry movement into the holes. In the lower part of the gaps between plates, hinged closing sheets will be arranged, which will prevent the chestnuts from leaving during loading and freezing.
[0332] Freezing of the chestnuts will be achieved, with a stabilization in the temperature of the product that will reach the temperature of - 20 ° C in the heart of each chestnut, which will be achieved in a time of 3.5 hours of operation of the refrigeration system. The daily freezing capacity will be 21 t / day in 6 periods of 4 hours, including loading and unloading.
[0334] Once the freezing cycle is finished, the aforementioned lower closures, made up of rotating hinged blades, will open, unloading the chestnuts into the hopper located at the bottom. There will be a discharge worm screw in the hopper of the screening system to allow separation by commercial calibers
[0335] CELL ALIVE SYSTEM, CAS
[0337] The system of Japanese origin CAS, "Cell Alive System" or Living Cell System, will be incorporated to achieve a product quality similar to natural, after thawing, regardless of the duration of the frozen conservation of the product.
[0339] CLASSIFICATION SCREEN OF PEELED CHESTNUTS
[0341] There will be a sorting screen for sizes or diameters of the frozen fruits. It will be equipped with 5 vibrating panels, made of stainless steel mesh with different spacings between the wires, flat, slightly inclined to promote the movement of the chestnuts along the length and width of the panels.
[0343] In the lower part there will be a panel without sieving mesh, to collect the chestnuts that have passed through the mesh of the screening panel 5.
[0345] The differences of this screen with the classification of chestnuts in fresh or with skin, will be the characteristics of the panels and the mesh opening as well as the material used, which will be ANSI 316 stainless steel.
[0346] The five vibrant panels will separate the chestnuts of the different calibers in units per kilo:
[0348] Panel 1 - They do not go through the mesh, class <120 units / kilo
[0349] Panel 2 - They do not pass through the mesh, class 120 - 150 units / kilo
[0350] Panel 3 - Do not pass through the mesh, class 150 - 180 units / kilo
[0351] Panel 4 - Do not pass through the mesh, class 180 - 210 units / kilo
[0352] Panel 5 - They do not pass through the mesh, class> 210 units / kilo
[0353] Panel 6 - collection of the output of panel 5, pieces of chestnuts
[0355] The outputs of the classification belts will discharge into the hoppers of the packaging machinery, to allow their packaging in Big-Bags or machinery for filling sacks or bags.
[0357] RESIDUAL CHESTNUT CRUSHER
[0359] Chestnuts rejected from the flotation system due to being countersunk, bitten by insects or attacked by pests, as well as those eliminated by the manual classification system, due to having undetected internal worms, will be subjected to fresh crushing to obtain a granular mass relatively homogeneous.
[0361] The crushing will be carried out fresh as they are extracted from the production areas. The discharge will be carried out in the main reactor by vertical loading in the container.
[0363] COOKER, MIXER, FERMENTER AND DISTILLER
[0365] This is the reactor vessel that can be seen in Figures (32), (33) and (34), for carrying out the shredded waste processing operations. As the destination is animal feed, the mixture will be pasteurized and sterilized, as well as the inactivation of all enzymes and microorganisms that may harm the activity of yeasts and bacteria present in the final product.
[0367] COOKING THE CRUSHED DOUGH:
[0368] The crushed waste mass is introduced into the reactor from its upper part, generating homogenization with the helix, rotating in both directions.
[0370] Once loaded into the 2,160-liter volume of the reactor, the 1,850 kg of shredded waste produced daily in the system, thermal oil is injected into the lower jacket of the reactor, with about 75 liters at a temperature of 110 ° C, recirculating the oil to give the heat to the dough and keep the temperature constant. When closing the lid of the reactor and making the movement of the helicoid, there is an increase in temperature up to 105-110 ° C and a pressure of 1.2 to 1.4 bars (120 to 140 kPa). The container is kept closed and the pressure is maintained for 1 hour to achieve the sterilization of the dough.
[0372] MIXING THE DOUGH:
[0374] The movement of the dough, induced by the helix, will serve to homogenize it and achieve a suitable result for your process. The crushed shells and skins will produce the effect of providing fiber to the food, so necessary for the digestion of the animals for which the final product will be destined.
[0376] INOCULATION OF THE MASS FOR FERMENTATION:
[0378] When the temperature is reduced to 30 ° C, an inoculation of Saccharomyces cerevisiae type yeasts and lactic acid bacteria is produced so that the fermentation of the chestnut's own sugars begins, mainly sucrose. The production of alcohols and other aromatic compounds begins.
[0380] The fermentation process is controlled by the movement of the dough and its conditioning by injecting fluids into the jacket that surrounds the lower part of the reactor, at different controlled temperatures. The duration of the process can be two to three days, depending on the composition of the dough and its sugar content.
[0382] When the generation of CO2 begins, the amount emitted is controlled and it is expelled to the outside by means of an "Airlock" type valve that prevents the entry of air into the interior of the reactor. The temperature is kept at that studied for the reaction from 17 ° C to 30 ° C. The formation of compounds derived from the action of yeasts and bacteria, stops when the formation of CO2 ends.
[0384] DISTILLATION OF THE FERMENTED DOUGH:
[0386] The same reactor vessel that has been used to carry out the fermentation will be used for the distillation. For this, in the jacket of the lower zone of the reactor, thermal oil will be introduced so that the temperature of the mass reaches the boiling and vaporization temperatures of the alcohols. The vapors generated will be conducted to a condensation system for the compounds, obtaining a mixture of distilled alcohols.
[0388] The most important alcohols and compounds obtained by experimental analysis are: Ethanol (387.3 g / l), Methanol (0.561 g / l), 1 Propanol (0.445 g / l), Isobutanol (0.171 g / l), 2 methyl 1 Butanol, 3 Methyl 1 Butanol, Acetaldehyde (0.197 g / l), Methyl Acetate (0.030 g / l) and Ethyl Acetate (0.163 g / l).
[0390] CONTINUOUS DISTILLATION PROCESS
[0392] In order to carry out a constant process, there will be 3 reactors with a volume of 2.2 m3 each. This will allow to process, the amount of waste produced daily, independently, achieving the use of all waste, during the 90 days a year of the production campaign. The production of chestnut brandy will be constant, staggering the processes in the three planned reactors, with a permanent one in the distillation process, with figures close to 185 liters per day and a total of 16,625 liters per year in each campaign.
[0394] MANUFACTURE OF FOOD PELLETS
[0396] The fermentation residues, which have been used for the extraction of the liquor, will be discharged from the reactor through the hole in the lower area of the container by means of the helical screw, introduced into an extruder to manufacture pellets.
[0398] The extruded pellets will be introduced into a dryer to reduce the humidity of the mass from 50% to 15% that would allow its packaging and marketing. In a first approximation, the distillation residues would represent about 150 tons / year that would produce 88 tons / year of dehydrated food with 15% humidity.
[0400] ENERGIES DEMANDED - ENERGIES CONSUMED
[0402] The energy generation system is based on the use of burners of shells, skins and combustible residues to take advantage of the combustion energy, through the use of MAGOB burners and ORC turbine, with an adequate structure for the generation of electrical and thermal energy as follows :
[0404] MAGOB BURNERS:
[0406] Each burner has a fuel consumption of 63 kg / hour and an approximate power of 189,000 kcal / h (219.81 kW) and an energy generation of 408,240,000 kcal (474,783 kWh) during the 90 days / year of the campaign. chestnut processing.
[0408] The availability of energy depends on the amount of waste produced in the plant during the work period of 90 days / year and a total of 1,440 hours of production (16 h / day) and 2,160 total hours (24 h / day): Shells and chestnut skins 356,000 kgs / year and other combustible residues 8,750 kgs / year, totaling 364,750 kgs / year. The PCI for these wastes is 3,000 kcal / kg, so the energy availability will be 1,094,250,000 kcal or 1,272,613 kWh.
[0410] Taking into account that each burner can produce 408,240,000 kcal (474,783 kWh), with three burners, we would have the possibility of generating 1,224,720,000 kcal (1,424,350 kWh) that is 10.65% higher, which could be achieved with the contribution of additional waste.
[0412] ORC BOILERS AND TURBINE:
[0414] The planned system, of an ORC turbine, Organic Rankine Cycle, requires a thermal energy input that is capable of generating an electrical energy production of 15% of the energy supplied, 75% of thermal energy of recovery and losses of 10% of the total thermal energy provided.
[0416] POWER AND ENERGY DEMAND:
[0418] Of the chestnut shells and other residues, which reach a quantity of 1,094,250,000 kcal, 75%, that is, 820,687,500 kcal in the form of heat (928,632.60 kWh) and 15% in the form of energy are obtained electricity, that is 185,726.52 kWh.
[0420] The annual demand for electrical energy in the various processes is as follows:
[0422] 1 Cleaning Bath 1.50 kW 2,160 kWh 1 Fresh chestnut sieve 3.00 kW 4,320 kWh 1 Large chestnut slicer 0.50 kW 720 kWh 1 General slicer 3.00 kW 4,320 kWh 1 Anti-mucus bath 60 ° C 1.00 kW 1,440 kWh 1 Microwave tunnel 1.00 kW 1,440 kWh 1 Vaporization 1.50 kW 2,160 kWh 1 Skin separation 1.75 kW 2,520 kWh 1 Inspection band 1.31 kW 1,886 kWh 1 Freezing-Absorption Cabinet 56.42 kW 121,867 kWh 1 Frozen chestnut sieve 3.00 kW 6,480 kWh 1 Waste crusher 1.30 kW 1,872 kWh 3 Cooker, fermenter mixer and still 6.00 kW 8,640 kWh 1 Manufacture of extruded chestnut pellets 2.00 kW 2,880 kWh
[0424] Total power and annual consumption 85.78 kW 168,105 kWh
[0426] The annual demand for thermal energy in the various processes is as follows:
[0428] 1 Cleaning Bath 20,000 kcal / h 28,800 Mcal 1 Antimucilage bath 60 ° C 16,000 kcal / h 23,040 Mcal 1 Vaporization 40,000 kcal / h 57,600 Mcal 1 Skinning 60,000 kcal / h 86,400 Mcal 3 Cooker, fermenter mixer and still 11,545 kcal / h 24,937 Mcal
[0430] 1 Manufacture of extruded chestnuts 19,966 kcal / h 43,127 Mcal Total power and annual consumption 147,511 kcal / h 235,105 Mcal
[0432] Electric power Thermal power 85.78 kW 147,511 kcal / h = 253.34 kW Electric energy Thermal energy 168,105 kWh 235,104 Mcal = 441,531 kWh
[0434] If the absorption method were chosen for the freezing system, the power and energy demand would have the following distribution:
[0436] Electric energy: annual power and consumption 29.36 kW 46,238 kWh Thermal energy: annual power and consumption 193,872 kcal / h 364,044 Mcal
[0438] Electric power Thermal power 29.36 kW 193,872 kcal / h = 254.83 kW Electric energy Thermal energy 46,238 kWh 364,045 Mcal = 469,622 kWh
[0440] The exposed figures, together with the investments and maintenance expenses and others of each type of technology (compression / absorption) can help us make investment decisions.
[0442] In both cases, the energy produced by the combustion of the processed chestnut waste, being a theoretical total of 1,151,250,000 kcal or 1,338,904 kWh, far exceeds the demand in the maximum contemplated case of 403,802,128 kcal or 469,622 kWh. As the calculated energy has a considered period of 90 days of manufacture, during the rest of the year the remaining energy available can be used.
[0444] DESCRIPTION OF THE PRODUCTS PROCESS
[0446] In the description of the parts, for descriptive and interpretive purposes, details of the product processes have already been included, therefore, in this description, a more concise and clear summary of the products to be manufactured and sold is carried out.
[0448] PEELED CHESTNUTS:
[0450] The manufacturing process begins with the selection of chestnuts to be processed with the elimination of unsuitable or useless ones. As these are live products, the quality tends to decline over time. That is why it is necessary to continue with a conservation treatment to have more processing time.
[0452] Classification by size seeks an improvement in the processes, which is why it is carried out by means of a suitable sieve to the fruit that separates the different sizes. This uniformity improves chestnut peeling performance.
[0454] The vertical storage method with the prismatic, stackable containers with a wooden interior lining, allows for the preservation of chestnuts with suitable characteristics for peeling.
[0456] The objective is summarized in the elimination of the skin with several stepped systems that tend to weaken the union between the inner skin and the fruit or seed and produce the separation in a simple way. Initially, superficial cuts are generated that make the outer shell accessible and detachable, as well as the beginning of the attack on the integrity of the mucilages or polyphenols that adhere the inner skin to the fruit.
[0458] Access to the interior of the outer shell, through the cuts made, begins with the moistening generated by the treatment by immersion in the antimucilage bath. The temperature of 60 ° C initiates the process of weakening the union of the inner skins to the nut or fruit with the first dissolution of the mucilages or polyphenols in addition to the soluble tannins.
[0460] The presence of an ultrasound emission will improve the access of water to the interstitial areas of the inner skin of chestnuts, weakening their union.
[0462] The water used for this first bath is recycled in a closed circuit for the separation by filtration of the mucilages and tannins as well as the recovery of the temperature by a heat exchanger.
[0464] Following this treatment, the chestnuts are passed through a microwave tunnel so that the radiation acts on the water and the moistened skin to enhance the weakening effects of the mucilages without weakening the skin. The intensity of radiation will be controlled by a speed variator as well as a regulator of the emitting power.
[0465] Following microwave treatment, the chestnuts are immersed in a rotating cylinder fitted with a fixed endless screw with a perforated hollow tubular shaft. During the rotation of the cylinder, the chestnuts will be displaced towards the upper part while they are attacked by jets of water and steam conducted inside the tube that forms the axis of the endless screw. The inclination of the cylinder produces a movement of the condensates towards the lower part where they are recovered for recycling with the recovery of mucilage and tannins as well as the heating of the water-steam injection in the cylinder by the tubular axis of the auger .
[0467] The chestnuts that come out of the upper part of the cylinder, fall into the hide separator, equipped with cylindrical rods that rotate in a substantially flat and inclined area, forming prehensile pairs due to their rotation in the reverse direction, which trap the now softened hides, moving them toward the bottom of the rod assembly. The jets of water and steam that are projected on the upper part of the assembly improve adherence by eliminating mucilage and tannins. On the lower part of the assembly, jets of cleaning water are also projected from the rotating rods, improving the grip of the system. The water used is recovered for recycling through mucilage and tannin filters as well as reheating through a heat exchanger.
[0469] The peeled chestnuts are output on a manual inspection and selection conveyor belt by specialized operators. Chestnuts that have not completed the peeling process satisfactorily are selected on the belt. These are sent to the corresponding area of the system for reprocessing. Chestnuts that present sanitary defects due to being attacked by insects or pests, as well as those that are not recoverable, will be sent to the integral use area for their use.
[0471] The chestnuts are removed from the selection area to intermediate storage in 850 kg containers, in water baths at a temperature of 5 ° C. As the peeling is produced during 16 hours and the freezing during 24 hours, this storage in containers will serve as intermediate storage to be able to carry out the freezing process continuously, in batches of 3,400 kilos per 4-hour freezing cycle. The freezing shifts will be 6 and the number of containers for storage will be 24, totaling 20.4 tons of production per day during the 16 hours of daily work.
[0473] The freezing will be carried out by means of a set of 17 vertically located plates, by introducing the chestnuts in the gap between them. The evaporation of the refrigerant (R717 or NH3, Ammonia) at a reduced pressure, allows to reach very low temperatures on the plates. The possibility of using cold absorption systems with the use of thermal energy from the combustion of chestnut skins could be a great advantage.
[0475] Once the freezing process has been carried out, the chestnuts will be classified by means of a stainless steel grader for packaging and refrigerated storage.
[0477] CHESTNUT AGUARDIENTE:
[0479] To take advantage of the chestnut waste, a reactor vessel has been designed that will serve for the integral processing of the waste. It comprises a container with a cylindrical base with a jacket or heating chamber lining located at the bottom of the reactor. It will be equipped with a rotating helicoid for the movement of the dough. It will have a tight lid that will withstand working pressures of 1.2 to 1.4 bar (120 to 140 kPa) or 105 ° C to 110 ° C.
[0481] The waste separated in the initial cleaning area, consisting of flabby chestnuts, insect worms, attacked by pests, etc. as well as those separated in the selection processes, they will be suitably crushed for the reactor load. The mixture will be heated at the same time as it moves to ensure uniformity of temperature.
[0483] When the temperature reaches 105-110 ° C, it is maintained for about 20 minutes to inactivate the existing microorganisms and others present and wait until the temperature is reduced to 30 ° C. An inoculation of "Saccharomyces cerevisiae" yeasts and milk bacteria will be carried out to initiate the alcoholic fermentation of the sugars. With the heating chamber, the corresponding energy will be added to keep the fermentation temperature constant.
[0485] Once the fermentation is finished, in the closed chamber, the temperature of the dough will be raised to proceed to the formation of vapors from the Alcohols present, derived from the decomposition of sugars.
[0487] The vapors will be condensed in a distilling heat exchanger and collected in a container for analysis and bottling.
[0489] FEED FOR SWINE CATTLE FEED:
[0491] There is a very well-known brand in the cattle market known as "Chestnut-fed pork." The residue resulting from the extraction of the alcohols will be extruded into pellets and dehydrated from the initial 50% water content to the resulting 15%. The properties of pork raised with this feed are highly demanded by the Asian market, due to its great organoleptic quality.
[0493] BRIEF DESCRIPTION OF THE DRAWINGS
[0495] To better complement the description that is being made and in order to help a better understanding of the characteristics of the invention, some drawings are attached as an integral part of said description, in which, with an illustrative and non-limiting nature, it has been represented the next:
[0497] Figure 1.- Cleaning System - Wired Side View
[0499] You can see the view of the chestnut cleaning container (1) with its endless screw (2) for extraction of the chestnuts that, due to their density, greater than water, move to the bottom of the container. The water recirculation system with the pump (6) that injects the water in the lower part of the container, produces the displacement of the floating chestnuts or supernatants towards the chute (3) which, when discharging the water with the chestnuts in the top of a separation system with a mesh (4), sends the water to a filter of the recirculated water (5) that feeds the recirculation pump (6). You can see the geared motor (7) of the rotational movement of the worm screw (2).
[0501] Figure 2 .- Cleaning system - Right side view
[0503] You can see the view of the chestnut cleaning container (1) with its screw screw (2) for extraction of chestnuts which, due to their density, higher than water, move to the bottom of the container. The water recirculation system with the pump (6) that injects the water in the lower part of the container, produces the displacement of the floating chestnuts or supernatants towards the chute (3) which, when discharging the water with the chestnuts in the top of a separation system with a mesh (4), sends the water to a filter of the recirculated water (5) that feeds the recirculation pump (6). You can see the geared motor (7) of the rotational movement of the worm screw (2).
[0505] Figure 3.- Cleaning system - Left side view
[0507] You can see the view of the chestnut cleaning container (1) with its endless screw (2) for extraction of the chestnuts that, due to their density, greater than water, move to the bottom of the container. The water recirculation system with the pump (6) that injects the water in the lower part of the container, produces the displacement of the floating chestnuts or supernatants towards the chute (3) which, when discharging the water with the chestnuts in the top of a separation system with a mesh (4), sends the water to a filter of the recirculated water (5) that feeds the recirculation pump (6). You can see the geared motor (7) of the rotational movement of the worm screw (2).
[0509] Figure 4.- Green chestnut sieve - Schematic lateral view
[0511] It is used to classify chestnuts by size. It is made up of several panels (1), (2), (3), (4) and (5) made up of a frame and a perforated mesh formed by steel wires. The top panels have larger wire gaps than the bottom panels. This staggering produces a retention of the chestnuts of greater diameter in the upper panels, reducing the size to the lower panel (5), with less separation. The last panel (6) is used to receive the chestnuts that fall from the last panel (5). Each panel is inclined towards the discharge on its collection and transport belt (7), (8), (9), (10), (11) and (12) that receives the chestnuts that pass through the holes in the panel. Each of them is equipped with vibrators to move the chestnuts on the panels. The sizes are identified with the sizes or the number of fruits that each kilo has.
[0512] Figure 5 Green chestnut sieve - Right side view
[0514] You can see the view of the right side front of the set of the components of the machine in three dimensions, of the screen panels (1), (2), (3), (4) and (5), the lower panel ( 6) and the reception and transport conveyor belts for each panel (7), (8), (9), (10), (11) and (12).
[0516] Figure 6.- Green chestnut sieve - Left side view
[0518] You can see the view of the left side front of the set of the components of the machine in three dimensions, of the screen panels (1), (2), (3), (4) and (5), the lower panel ( 6) and the reception and transport conveyor belts for each panel (7), (8), (9), (10), (11) and (12).
[0520] Figure 7 .- Chestnut storage container- Top views with closing device
[0522] You can see the wireframe views of the prismatic container, without hiding the lines with the details of the closing device of the lower discharge opening of the container. The gate (1) and the gate movement lever (2) are shown. In the image on the right, the gate is open and in the image on the left, the gate is closed.
[0524] Figure 8 .- Chestnut storage container - Side views with closure device
[0526] You can see the wireframe views of the prismatic container, without hiding the lines with the details of the closing device of the lower discharge opening of the container. The gate (1) and the gate movement lever (2) are shown. In the image on the right, the gate is open and in the image on the left, the gate is closed.
[0528] Figure 9 .- Chestnut storage container- Three-dimensional wireframe views with closing device
[0530] You can see the views of the prismatic container, without hiding the lines with the details of the closing device of the lower discharge opening of the container. The gate (1) and the gate movement lever (2) are shown. In the image on the right, the gate is open and in the image on the left, the gate is closed.
[0532] Figure 10.- Sawing system for large chestnuts
[0534] In the image you can see the three views, right side, front and left side with the chestnut (1) arranged in a horizontal position and the toothed disk saw (3) mounted on the motor shaft (2) that prints the sawing movement superficial on chestnut. By means of this opening, the fruit is superficially reached with the start, motivated by the special design of the tooth, which barely reaches to touch the fruit or seed.
[0536] Figure 11.- Superficial cutting system of normal chestnuts - Three-dimensional view
[0538] In the three-dimensional image you can see the cylinders equipped with cutting blades (1), attached to the cylindrical brushes for cleaning the blades (2), arranged with their axes of rotation (4) to make superficial cuts to the chestnuts that are driven by the worm screw (3) driven by its shaft (5).
[0540] Figure 12.- Superficial cutting system for normal chestnuts - Front view
[0542] In the front view image you can see the cylinders equipped with cutting blades (1), attached to the cylindrical brushes for cleaning the blades (2), arranged with their axes of rotation (4) to make superficial cuts to chestnuts that are driven by the worm screw (3) driven by its shaft (5).
[0544] Figure 13.- Superficial cutting system for normal chestnuts - Side view
[0546] In the side view image you can see the cylinders equipped with cutting blades (1), attached to the cylindrical brushes for cleaning the blades (2), arranged with their axes of rotation (4) to perform surface cuts to chestnuts that are driven by the worm screw (3) driven by its shaft (5).
[0548] Figure 14.- Mucilage removal system - Three-dimensional wireframe view In order to weaken mucilages or polyphenols and soluble tannins, chestnuts, coming from the superficial cutting area, will be introduced through the loading port (1) with hot water at 60 ° C in adequate quantity to maintain the level of water in the worm screw cylinder (2) so that they remain immersed, moving from a slight initial pressure, up to the outlet to the immersion water draining and recycling ramp (3). The ultrasound emitters (10) will enhance the dissolving action of the mucilage.
[0550] In the image you can see the system for recovering excess water from the humidification that occurs in the drilled ramp with a collector (4) that collects the drained water in the ramp to lead them to the pump (5). The system produces the sending to the cooling heat exchanger (6) that will generate a loss of solubility in water and retention in the separator filter (7). The water, once the mucilage has been retained, will pass through the heat exchanger (8) where the temperature will rise again to 60 ° C of the process to proceed to the introduction in the lower part of the endless screw. Both exchangers will be combined as a heat pump, for maximum use of energy.
[0552] In the lower part of the worm screw, the geared motor for driving the rotation movement of the worm (9) will be located
[0554] Figure 15 .- Mucilage removal system - Three-dimensional left side view
[0556] In the image you can see the parts: (1) inlet of superficially cut chestnuts (2), draining ramp (3), recovered water collector (4), water recycling pump (5), cooling exchanger (6 ), mucilage and tannin retention filter (7), heating exchanger (8) and auger rotation drive gear motor (9). The ultrasound emitters (10) will enhance the dissolution of the mucilage.
[0558] Figure 16.- Mucilage removal system - Three-dimensional right side view
[0560] In the image you can see the parts: (1) entrance of cut chestnuts surface (2), draining chute (3), recovered water collector (4), water recycling pump (5), Cooling exchanger (6), mucilage and tannin retention filter (7), Heating exchanger (8) and geared motor for driving the rotation of the worm (9). The ultrasound emitters (10) will enhance the dissolution of the mucilage.
[0562] Figure 17.- Microwave irradiation tunnel - Right view
[0564] The irradiation system consists of a conveyor belt (1), driven by a gearmotor (4), which is the duration-controlled movement method, inside a chamber (3) that is equipped with a microwave generator to irradiate chestnuts transported. Once subjected to the treatment, the chestnuts have their outlet (2) that discharges into the feed of the steaming system.
[0566] Figure 18.- Microwave irradiation tunnel - Left view
[0568] The irradiation system consists of a conveyor belt (1), driven by a gear motor (4), which is the method of movement controlled in duration, inside a chamber (3) equipped with a microwave generator to irradiate the chestnuts transported. Once subjected to the treatment, the chestnuts have their outlet (2) that discharges into the feed of the steaming system.
[0570] Figure 19.- Water-Steam Treatment of chestnuts - Wireframe View
[0572] The chestnuts are entered with a loading hopper (1) that feeds a hollow and integral worm screw (4) with a double-layer cylinder (2) to isolate the process. The rotation of the cylinder with the endless screw, causes a displacement of the chestnuts towards the outlet of the cylinder where the discharge hopper (3) is located. The cylinder rotates by means of an electric motor (11) that drives the drive and support wheels (5). Inside the cylinder (2) there is a perforated tubular conduit (6) that generates a spray of the chestnuts along the screw with hot water and steam. The condensed water is collected in a collector (7) to proceed to its recycling by means of the pump (8) that sends it to a filter for the recovery of mucilage and tannins (9) and to a heat exchanger (10) that raises the temperature for its contribution to the spray shaft (6).
[0573] Figure 20 Water-Steam Treatment of chestnuts - Right Side View
[0575] The entry of the chestnuts is seen is carried out with a loading hopper (1) that feeds a hollow endless screw and attached to a double layer cylinder (2) to isolate the process. The rotation of the cylinder with the endless screw, causes a displacement of the chestnuts towards the outlet of the cylinder where the discharge hopper (3) is located. The cylinder rotates by means of an electric motor (11) that drives the drive and support wheels (5). Inside the cylinder (2) there is a perforated tubular conduit (6) that generates a spray of the chestnuts along the screw with hot water and steam. The condensed water is collected in a collector (7) to proceed to its recycling by means of the pump (8) that sends it to a filter for the recovery of mucilage and tannins (9) and to a heat exchanger (10) that raises the temperature for its contribution to the spray shaft (6).
[0577] Figure 21.- Water-Steam Treatment of chestnuts - Left Side View
[0579] The entry of the chestnuts is seen is carried out with a loading hopper (1) that feeds a hollow endless screw and attached to a double layer cylinder (2) to isolate the process. The rotation of the cylinder with the endless screw, causes a displacement of the chestnuts towards the outlet of the cylinder where the discharge hopper (3) is located. The cylinder rotates by means of an electric motor (11) that drives the drive and support wheels (5). Inside the cylinder (2) there is a perforated tubular conduit (6) that generates a spray of the chestnuts along the screw with hot water and steam. The condensed water is collected in a collector (7) to proceed to its recycling by means of the pump (8) that sends it to a filter for the recovery of mucilage and tannins (9) and to a heat exchanger (10) that raises the temperature for its contribution to the spray shaft (6).
[0581] Figure 22.- Water-Steam Treatment of chestnuts - Back View
[0583] The entry of the chestnuts is seen is carried out with a loading hopper (1) that feeds a hollow and integral worm (4) with a double layer cylinder (2) to isolate the process. The rotation of the cylinder (2) with the endless screw (4), causes a displacement of the chestnuts towards the outlet of the cylinder where the discharge hopper (3) is located. The cylinder rotates by means of an electric motor (11) that drives the
[0584] drive and support wheels (5). Inside the cylinder (2) there is a perforated tubular conduit that generates a spray of the chestnuts along the screw (4) with hot water and steam. The condensed water is collected in a collector (7) to proceed to its recycling by means of the pump (8) that sends it to a filter for the recovery of mucilage and tannins (9) and to a heat exchanger that raises the temperature for its contribution to the spray shaft.
[0586] Figure 23.- Water-Steam Treatment of chestnuts - Front View
[0588] The chestnuts exit towards the discharge hopper (3) fed by a hollow and integral worm (4) with a double-layer cylinder (2) to isolate the process. The rotation of the cylinder (2) with the endless screw (4), causes a displacement of the chestnuts towards the outlet of the cylinder where the discharge hopper (3) is located. The cylinder rotates by means of an electric motor that drives the drive and support wheels. Inside the cylinder (2) there is a perforated tubular conduit (6) that generates a spray of the chestnuts along the endless screw (4) with hot water and steam. The condensed water is collected in a collector to proceed to its recycling by means of the pump (8) that sends it to a filter for the recovery of mucilage and tannins and to a heat exchanger (10) that raises the temperature for its contribution to the shaft of sprayed (6).
[0590] Figure 24.- Skin separator - General View
[0592] The set of 60 rods grouped in pairs of rods to separate the skins can be seen. The area covered is 0.9 m2. The movement of the rods is combined in opposition to generate the gripping phenomenon with the skins that protrude from the surface of the chestnuts.
[0594] On the lower and upper part of the set of rods that perform the functions of separating the skins, hot water jets will be applied to eliminate the traces of polyphenols and tannins that induce a sliding effect reducing grip. These waters will be recovered with a filter to recover the dissolved products and raise the temperature.
[0596] Figure 25.- Skin separator - Drive detail
[0597] The drive of the rods 1 and 2 with gears that perform the opposite rotation can be seen to generate the trapping effect of the skins that protrude from the surface of the chestnuts.
[0599] Figure 26.- Peeled chestnut selection system - SE view
[0601] You can see the main conveyor belt (1) marked in the loading area of chestnuts derived from peeling and the secondary ones (2) corresponding to chestnuts that meet the appropriate conditions, (3) of poorly peeled chestnuts that must be processed again and (4) of the residual skins and defective chestnuts that the operators will introduce in the perforations of the channels (5) to take them to the separation mesh (4). The flow used for transport will be pumped by the pump (6) and introduced into the water pipes and manufacturing waste that will be properly recovered.
[0603] The selection operations will be carried out manually and must be suitably illuminated by LED tubes (7) of adequate intensity for the identification of the products to be classified.
[0605] The motorization of the main conveyor belt (1) is achieved by including the drive motor inside the tractor roller (8). The reduction motors (9) for the movement of the rest of the belts will be applied to their traction rollers.
[0607] The tank (10) will serve as storage of the recycling waters for the transport of the waste from the selection and cleaning of the bands. The waste will be properly treated for processing as raw material for the manufacture of spirits and animal feed and the unsuitable ones will be subjected to combustion for their energy use.
[0609] Figure 27.- Peeled chestnut selection system - NE view
[0611] The image corresponds to that of Figure 26, changing the point of view to 135 °. The most notable elements are numbered.
[0613] Figure 28.- Peeled chestnut selection system - NO view
[0614] The image corresponds to that of Figure 26, changing the point of view to 225 °. The most notable elements are numbered.
[0616] Figure 29.- Peeled chestnut selection system - SW view
[0618] The image corresponds to that of Figure 26, changing the point of view to 315 °. The most notable elements are numbered.
[0620] Figure 30.- Peeled chestnut freezing system - 3D Wireframe View
[0622] The image corresponds to a freezer with cold plates (1) located vertically, leaving gaps (2) between them, which will serve to introduce the chestnuts for their freezing process. In the front and rear parts, welded closing sheets (3) will be arranged which, closing the gaps, will prevent the chestnuts from coming out. In the lower part, in order to facilitate the retention and exit of the chestnuts from the hole, hinged plates (4) will be placed which, during the freezing process, will prevent them from falling. In the opening position (4 ') the exit of the holes will be free and the chestnuts will fall on the lower hopper (5) equipped with an emptying screw (6).
[0624] The interior of the refrigerating plates is filled with refrigerant (Ammonia, NH3) in a liquid state, subjecting it to a depression that causes the evaporation of the fluid and the absorption of heat from the medium, generating the freezing of the chestnuts.
[0626] For the application of the CAS system, "Cell Alive System", suitable radiation emitters will be placed to achieve the very high quality freezing that this technology entails.
[0628] Figure 31.- Loading hopper of the peeled chestnut freezing system - 3D Wireframe View
[0630] You can see the walls (1) inclined 60 ° of the hopper, with a height of 0.7 m, enough to total a volume of 4.9 m3, for a load of 3,375 kg each cycle of 4 hours, assuming a production total of 20,250 kgs / day, equivalent to 1,266 kg / h during 16 hours of manufacture. The lateral edges of the hopper will be reinforced with steel profiles (2).
[0632] To carry out the loading, the hopper is arranged on the set of plates, making the openings (3) of its base coincide with the upper entrance of the gaps between the freezing plates. The reinforcement angle profiles (4) will be supported on the upper part of the freezing plates. The loading is done in a reduced time with the help of vibratory systems of the hopper and the fluidization of the chestnuts.
[0634] Figure 32.- Process of liquor and cattle feed - NE Wire View
[0636] Once the shredded waste has been loaded into the container (1), it is closed with the lid (2) and thermal oil injected into the heating jacket (3) to proceed with cooking under pressure (120 to 140 kPa). The helicoid (4), attached to the drive shaft (5) moved by the gearmotor (6), will serve to homogenize and standardize the dough.
[0638] Once the cooking is finished, we will proceed to wait for the dough to cool down to reach a temperature of 30 ° C. At this temperature, the yeasts "Saccharomyces cerevisiae" and milk bacteria will be added to start the alcoholic anaerobic fermentation. The duration of the process will be 2 to 3 days or until the CO2 production ends, which will go out through an "Airlock" valve that allows the exit, preventing the entry of air.
[0640] At the end of the fermentation reaction, by means of the contribution of heat with the heating jacket (3), the temperature of the dough will be raised to generate alcohol vapors and their extraction through the upper opening of the lid and its introduction into a distillation column for the condensation of alcohols.
[0642] Once the alcohols have been extracted, the process will be stopped and the dough will be extracted through the opening (7) through which it will be driven by the part (4 ') of the helicoid pressing against it.
[0644] Figure 33.- Process of liquor and livestock feed - SE Wire View
[0646] The image corresponds to that of Figure 32, changing the point of view. The most notable elements are numbered.
[0647] Figure 34 Liquor and livestock feed process reactor - Interior View
[0649] The image corresponds to a view of the machine (1) with the cover (2) raised to be able to see the worm screw (4) mounted on the shaft (5) driven by the gear motor (6). You can see the heating jacket (3) for raising and maintaining the temperature of the dough.
[0651] PREFERRED EMBODIMENT OF THE INVENTION
[0653] The device described has a preferred embodiment for the manufacture of marketable products. The utility of the system has two main aspects:
[0655] 1) Manufacture of peeled chestnuts
[0656] 2) Manufacture of Mucilages and Tannins
[0657] 3) Distillation of chestnut brandy
[0658] 4) Manufacture of feed based on chestnuts
[0660] The manufacture will be carried out while there is availability of fresh chestnuts in the market, that is, during 90 days / year of campaign, at a rate of 16 hours / day for manufacturing and 24 hours / day for freezing and fermentation processing, distillation and dehydration with 2,160 annual hours.
[0662] The chestnuts for production are of origin close to the installation of each of the 4 manufacturing plants of 2,500 tons / year, totaling 10,000 tons / year. The cost of the development of the technology, to be carried out on the investigations object of the industrial property of this patent, will be distributed among the four plants to be installed. The cost of chestnuts is variable and depends on the size or number of units per kilo, with an average of 1,500 Euros / ton.
[0664] The objective pursued is the production of peeled chestnuts that can be quantified for the different sizes in units per kilo, with the following quantities and sales prices:
[0666] Sales of caliber 100/120 257,250 kg 9 € / kg 2,315,250 € / year Sales of caliber 120/150 459,375 kg 6.5 € / kg 2,985,938 € / year Sales of size 150/180 477,750 kg 5.5 € / kg 2,627,625 € / year Sales of size 180/210 496,125 kg 4 € / kg 1,984,500 € / year Sales of pieces of peeled chestnuts 140,000 kg 3 € / kg € 441,000 / year
[0668] Totals 1,837,500 kg € 5.64 / kg € 10,354,313 / year
[0670] The estimate for obtaining chestnut derivatives such as tannin mucilages is:
[0671] Mucilages 25,000 kg € 4 / kg € 100,000 / year Tannins 12,500 kg € 2 / kg € 25,000 / year
[0673] Totals € 125,000 / year
[0675] In the case of residues derived from the selection and processing of chestnuts, the integral use is pursued, as indicated in the title of the patent. Defective chestnuts separated in the initial float and those separated by the selection system
[0677] The estimate for obtaining distilled liquor from the fermentation of chestnut sugars is:
[0679] Brandy 16,625 l 5 € / l 83,125 € / year
[0681] The estimate for obtaining animal feed, derived from the sterilization and fermentation of chestnut residues is:
[0683] Chestnut feed 88,014 kg € 0.87 / kg € 76,572 / year
[0685] Sales revenue:
[0686] Peeled chestnuts € 10,354,313 / year Mucilages and Tannins € 125,000 / year Brandy € 83,125 / year Chestnut feed 76,572 € / year
[0688] Total Income € 10,639,010 / year
[0689] In the case of chestnut peeling waste, the hides that are estimated at 15% of the weight of the inputs stand out, that is, 375 t / year in addition to 8.75 t / year of fuel waste that total 383.75 t / year available.
[0691] The PCI or Lower Calorific Power, by widely studied and cited research in the bibliography, is set at:
[0693] Chestnut residues PCI 12,560.0 kJ / kg 3,000 kcal / kg
[0695] The fuel consumption of a MAGOB burner, Model 04, amounts to 63 kg / hour, so the amount of thermal energy generated is:
[0697] Chestnut waste PCI 791,305.2 kJ / h 189,000 kcal / h 219.81 kWh
[0699] From which it follows that the burner power can range between 200 kW and 240 kW with normal fuels and reach 315 kW with commercial pellets.
[0701] The amount of 383.75 t / year available, at a rate of 3,000 kcal / kg or 12,560 kJ / kg, implies an available energy capacity of 1,151,250,000 kcal / year (4,820,053,500 kJ / year and 1,338,904 kWh / year ) with the process capacity of each burner is 408,240,000 kcal / year, the theoretical number of burners is 2.82 units. In other words, with 3 burners, it will be possible to take advantage of the energy available from the combustion of manufacturing waste.
[0703] The investments for the construction of the chestnut peeling factory are:
[0705] - Control of entrances and exits.
[0706] Truck scale
[0707] Pallet scale
[0708] - Storage and transportation of raw materials.
[0709] Chestnut storage containers
[0710] Transport and stacking truck
[0711] - Cleaning system.
[0712] Cleaning machinery
[0713] - Chestnut processing system.
[0714] Calibration system
[0715] Surface cutting systems
[0716] Antimucilage system
[0717] Skin separation system
[0718] - Chestnut freezing system.
[0719] Plate freezing cabinet Absorption refrigeration system CAS system, "Cell Alive System"
[0720] - Calibration of frozen chestnuts.
[0721] Stainless steel calibration screen
[0722] - Cooker, Fermenter, Distiller and Feed.
[0723] Cooked and sterilized
[0724] Fermented
[0725] Distilled brandy
[0726] Feed extrusion
[0727] Dehydrated feed
[0728] - Thermal oil burners and boilers.
[0729] MAGOB waste burners Thermal oil boilers
[0730] - ORC turbine generating electricity ORC turbine
[0731] Electricity generator
[0732] - Packaging machines.
[0733] "Big Bags" packaging machine
[0734] 35 kg sack packaging
[0735] 10 kg bag packaging
[0736] 5 kg bag packaging
[0737] - Industrial facilities.
[0738] Treated drinking water
[0739] Residual water
[0740] Electricity
[0741] Compressed air
[0742] Fire protection
[0743] Security
[0744] - Assembly and testing labor.
[0745] Investment budget excluding land or buildings € 2,118,350
[0748] SALES REVENUE
[0749] Sale of mucilage 100,000 € Sale of tannins 25,000 € Sale of chestnut brandy 83,125 € Sale of chestnut feed 76,572 € Sale of frozen chestnuts 10,354,313 €
[0751] Total sales revenue € 10,639,010
[0753] EXPENSES
[0754] Procurement 3,785,109 € 52.93% Consumption and impairment of inventories 35,109 €
[0755] Raw materials (chestnuts) € 3,750,000
[0757] Personnel expenses: 68 jobs 1,120,000 € 15.66% a) Fixed Expenses 758,000 €
[0758] b) Variable Expenses € 362,000
[0760] Other operating expenses: € 2,034,200 28.45% a) External services € 1,927,810
[0761] b) Taxes € 63,830
[0762] c) Other current management expenses € 42,560
[0764] Annual expenses € 6,939,309
[0766] Amortization of fixed assets € 211,835 2.96%
[0768] Operating income € 3,699,701
[0770] Financial expenses € 74,142 1.04%
[0772] Profit before tax € 3,413,724 Income tax 20% € 682,745 20.00% Net Profit 2,730,979 € 25.67%
[0774] It should be noted the total absence of external energy consumption, both electrical and the use of fuels, since the system is self-sufficient with the combustion of chestnut shells and skins with the MAGOB burners and the ORC (Organic Rankine Cycle turbine ), which transforms thermal energy into electrical energy with a ratio of 15%, subtracting 75% useful for use in manufacturing processes and energy consumption the rest of the year.
[0776] The substitution of imported energy for that generated by the waste produced and processed in a natural way, will mean an improvement in the financial situation of our balance of payments abroad. The energy consumed in electric motors and other uses such as microwave radiation, is calculated at 46,238 kWh in the 90 days of production and the availability of electricity is 15% of 1,338,904 kWh, which is the thermal energy available per the combustion of waste.
[0778] Taking into account the cost structure, the profitability of the activity is fully demonstrated. Taking into account the absence of smoke in the MAGOB burner emissions and its renewable origin from plant biomass, the carbon footprint is ZERO.
[0780] Therefore, it is considered proven that the burner is of industrial application, both in terms of manufacturing and in the multiple applications mentioned, from the elimination of waste to the use of fuels of renewable origin.
[0782] The manufacturing will be carried out with professionals of industrial engineering of various specialties (electrical, mechanical, chemical, energy, electronics, etc.) as well as agricultural and forestry engineers, etc. For the control of emissions, environmental engineers, from the company and in auxiliary companies, as well as scientists and maintenance professionals will participate.
[0784] The creation of 68 jobs stands out. Of these, 18 jobs will be permanent with annual dedication and 50 temporary in the three months of manufacture of peeled chestnuts.

权利要求:
Claims (8)
[1]
1. The new peeled chestnut manufacturing system, with integral use, for the use of the inner fruit, the mucilage and tannins, as well as the spirits from the fermentation of sugars and the use of fermentation residues as animal feed, using as a source of thermal and electrical energy, the combustion of waste in general and the skins product of the process, with the use of MAGOB smokeless burners, characterized in that it comprises:
• a chestnut cleaning system and selection of usable waste for the process of obtaining spirits and animal feed (1), (2) and (3).
• a sieve system for size classification using vibrating panels (4), (5) and (6).
• some containers for the storage of chestnuts (7), (8) and (9) formed by welded steel profiles with screwed inner wooden slat, constituting adequate storage volumes for contact with chestnuts. The container opening and closing system is remarkable.
• a surface sawing system for large chestnuts (10) with starter saws.
• a random surface cutting system (11), (12) and (13) for the treatment of chestnuts of normal dimensions.
• a system of moistening and beginning of the dissolution with the help of ultrasound and use of the mucilages and tannins of union between the inner skin and the fruit (14), (15) and (16).
• a treatment system based on an irradiation tunnel with a magnetron as a microwave source (17) and (18).
• a chestnut steaming system with a transport screw and axial tubular shaft for launching steam-water jets (19), (20), (21), (22) and (23).
• a peeling system with 30 pairs of gripping rods to remove the skins (24) and (25).
• a classification system using visual inspection belt and conveyor belts (26), (27), (28) and (29).
• a freezing system by vertical evaporative plates forming holes in contact with the chestnuts, with opening and closing of holes at the bottom (30) and loading hopper (31).
• a system for processing crushed chestnut waste for its cooking, sterilization, fermentation and formation of brandy vapors for its condensation (32), (33) and (34).
[2]
2. System according to claim 1, characterized by the use of the chestnut cleaning and separation system (1), (2) and (3) described for antifungal cleaning of the chestnut surface, separating the flabby, wormy and other floating ones of the healthy ones and the filtering of the cleaning water for recycling.
3. System according to claim 1 characterized by the use of the chestnut storage container (7), (8) and (9) described for, taking advantage of the possibility of stacking, to achieve a vertical use of space and aeration with movement newspaper that maintains the quality of the chestnuts by preventing the formation of fungal molds.
[3]
3. System according to claim 1 characterized by the use of the system of immersion in water (14), (15) and (16) of the superficially cut chestnuts to, aided by ultrasound emitters, begin the dissolution in the water at 60 ° C from mucilages and tannins from the union of the integument with the fruit at the same time that they are recovered in the corresponding filter.
[4]
4. System according to claim 1 characterized by the use of the microwave irradiation system (17) and (18), generating the temperature rise of the skins and their prior consolidation for the dissolution of the mucilage and tannins of the integument union with the fruit.
[5]
System according to claim 1 characterized by the use of the attack system with jets of steam and pressurized water on chestnuts inside a rotating insulated cylinder equipped with an endless screw (19), (20) and (21) , to generate the dissolution of mucilages and tannins from the union of the integument with the fruit and their recovery in a closed water-steam circuit.
[6]
6. System according to claim 1 characterized by the use of the skin separator system (24) and (25) with pairs of gripping rods that move them towards the bottom, using jets of steam and pressurized water on the top and bottom of the rods to carry out the cleaning and its grip effect at the same time that drags the mucilages and tannins from the union of the integument with the fruit for their recovery in the closed water-steam circuit equipped with a suitable filter.
[7]
7. System according to claim 1 characterized by the use of the evaporative plates freezing system and loading hopper (30) and (31) arranged with gaps between them, laterally closed for direct contact of the chestnuts with the plates and their reduction Of temperature. The holes will be closed at the bottom with hinged plates that, by opening them, allow the chestnuts to exit once the process is finished. Loading and unloading takes place in a short time using the lower hopper screw for emptying.
[8]
8. System according to claim 1 characterized by the use of the process reactor (32), (33) and (34) for the execution of multiple concatenated functions: a) Filling with crushed chestnut residues, b) Cooking-Sterilization, c) Inoculation of yeasts and bacteria for fermentation, d) Alcoholic fermentation, e) Emission of alcohol vapors towards the distillation system, f) Emptying towards the extrusion system.

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同族专利:

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公开号 | 公开日

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ES2786449B2|2021-04-26|

引用文献:

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公开号 | 申请日 | 公开日 | 申请人 | 专利标题

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JPH04112779A|1990-08-30|1992-04-14|Toyo Bussan Kk|Peeling treatment of japanese chestnut and peeling treatment device therefor|

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KR20140107842A|2013-02-28|2014-09-05|김용태|Method for peeling chestnut using microwace|

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CN103622141A|2013-11-14|2014-03-12|浙江大学|Method for synchronously removing shell and peel of Chinese chestnut through microwaves|

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ES202030557A|ES2786449B2|2020-06-09|2020-06-09|New peeled chestnut manufacturing system, with integral use|ES202030557A| ES2786449B2|2020-06-09|2020-06-09|New peeled chestnut manufacturing system, with integral use|