{"title":"Framework for scaling-up extraction processes in nutraceutical beverages: A simulation, techno-economic, and environmental analysis approach","authors":"","doi":"10.1016/j.fbp.2024.08.010","DOIUrl":null,"url":null,"abstract":"<div><p>The nutraceutical beverages market has increased in recent years, motivated by the increasing trend of consumers choosing food and beverages beneficial to health, mostly after the COVID-19 pandemic. Several researchers have proposed different formulations, where the combination of plants has been tested at the laboratory and pilot scales to maximize the desirable features of the beverages, including antioxidant capacity, anticarcinogens, and anti-inflammatory properties. Developing these products requires scaling-up from these scales to the industry one and, hence, identifying the criteria and/or parameters affecting process yield due to the transport phenomena associated with the scale increment. This work proposes a framework for scaling up solid-liquid extraction in a nutraceutical beverage process using available pilot plant data, combining brute-force and empirical scaling approaches. This framework provides an alternative for industries that have acquired equipment without considering the principles of similarity between the larger scale and the laboratory stage. Operating conditions are tuned to reach the product quality at the pilot level and the maximum beverage's antioxidant capacity. A techno-economic analysis of the production process and an environmental evaluation were performed, providing the basis for an effective scaling-up to the industry level. The scaling-up proved to be feasible, as the net present value of the process is $2018,000 with a payback time of 4.83 years; the major source of solid waste is the raw materials with a carbon footprint less than 0.205 MT eCO<sub>2</sub> due this process operates with temperatures lower than 100 °C. The circular economy indicators in this project were circular material usage rate and Waste Stream Recycling Rate. The Circular Material Usage Rate ranged from 16.7 % to 66.7 % depending on the composition of the cocoa husk in the raw material, and the Waste Stream Recycling Rate (%) ranged from 4.4 % to 5 % destined for composting development. The framework is designed to be applicable to other food production processes that encounter equipment constraints. It facilitates the evaluation of process yield and enables the simulation and analysis of economic profitability and environmental impact using circular economy indicators at an industrial/commercial scale.</p></div>","PeriodicalId":12134,"journal":{"name":"Food and Bioproducts Processing","volume":null,"pages":null},"PeriodicalIF":3.5000,"publicationDate":"2024-09-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S0960308524001585/pdfft?md5=bdf0493ce1979a9a9a6dc81e25d77b10&pid=1-s2.0-S0960308524001585-main.pdf","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Food and Bioproducts Processing","FirstCategoryId":"97","ListUrlMain":"https://www.sciencedirect.com/science/article/pii/S0960308524001585","RegionNum":2,"RegionCategory":"农林科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q2","JCRName":"BIOTECHNOLOGY & APPLIED MICROBIOLOGY","Score":null,"Total":0}
引用次数: 0
Abstract
The nutraceutical beverages market has increased in recent years, motivated by the increasing trend of consumers choosing food and beverages beneficial to health, mostly after the COVID-19 pandemic. Several researchers have proposed different formulations, where the combination of plants has been tested at the laboratory and pilot scales to maximize the desirable features of the beverages, including antioxidant capacity, anticarcinogens, and anti-inflammatory properties. Developing these products requires scaling-up from these scales to the industry one and, hence, identifying the criteria and/or parameters affecting process yield due to the transport phenomena associated with the scale increment. This work proposes a framework for scaling up solid-liquid extraction in a nutraceutical beverage process using available pilot plant data, combining brute-force and empirical scaling approaches. This framework provides an alternative for industries that have acquired equipment without considering the principles of similarity between the larger scale and the laboratory stage. Operating conditions are tuned to reach the product quality at the pilot level and the maximum beverage's antioxidant capacity. A techno-economic analysis of the production process and an environmental evaluation were performed, providing the basis for an effective scaling-up to the industry level. The scaling-up proved to be feasible, as the net present value of the process is $2018,000 with a payback time of 4.83 years; the major source of solid waste is the raw materials with a carbon footprint less than 0.205 MT eCO2 due this process operates with temperatures lower than 100 °C. The circular economy indicators in this project were circular material usage rate and Waste Stream Recycling Rate. The Circular Material Usage Rate ranged from 16.7 % to 66.7 % depending on the composition of the cocoa husk in the raw material, and the Waste Stream Recycling Rate (%) ranged from 4.4 % to 5 % destined for composting development. The framework is designed to be applicable to other food production processes that encounter equipment constraints. It facilitates the evaluation of process yield and enables the simulation and analysis of economic profitability and environmental impact using circular economy indicators at an industrial/commercial scale.
期刊介绍:
Official Journal of the European Federation of Chemical Engineering:
Part C
FBP aims to be the principal international journal for publication of high quality, original papers in the branches of engineering and science dedicated to the safe processing of biological products. It is the only journal to exploit the synergy between biotechnology, bioprocessing and food engineering.
Papers showing how research results can be used in engineering design, and accounts of experimental or theoretical research work bringing new perspectives to established principles, highlighting unsolved problems or indicating directions for future research, are particularly welcome. Contributions that deal with new developments in equipment or processes and that can be given quantitative expression are encouraged. The journal is especially interested in papers that extend the boundaries of food and bioproducts processing.
The journal has a strong emphasis on the interface between engineering and food or bioproducts. Papers that are not likely to be published are those:
• Primarily concerned with food formulation
• That use experimental design techniques to obtain response surfaces but gain little insight from them
• That are empirical and ignore established mechanistic models, e.g., empirical drying curves
• That are primarily concerned about sensory evaluation and colour
• Concern the extraction, encapsulation and/or antioxidant activity of a specific biological material without providing insight that could be applied to a similar but different material,
• Containing only chemical analyses of biological materials.