Framework for scaling-up extraction processes in nutraceutical beverages: A simulation, techno-economic, and environmental analysis approach

IF 3.5 2区 农林科学 Q2 BIOTECHNOLOGY & APPLIED MICROBIOLOGY
Yris Gonzalez , Fernando Zea , Alexander Espinoza , Daniela Galatro , Glenda Pilozo , Wilfredo Angulo , Manuel Rodríguez Hernández , Jesus Urrucsaca , Marcela Muzzio , Michael Rendón-Morán , Patricia Manzano
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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.

扩大营养保健饮品提取工艺的框架:模拟、技术经济和环境分析方法
近年来,消费者越来越倾向于选择有益于健康的食品和饮料,主要是在 COVID-19 大流行之后,营养保健饮料市场也随之增长。一些研究人员提出了不同的配方,并在实验室和试验规模上对植物组合进行了测试,以最大限度地提高饮料的理想特性,包括抗氧化能力、抗癌和抗炎特性。开发这些产品需要从这些规模扩大到工业规模,因此需要确定影响工艺产量的标准和/或参数,这些标准和/或参数是与规模扩大相关的传输现象造成的。这项工作提出了一个框架,利用现有的中试工厂数据,结合蛮力和经验缩放方法,对营养保健饮料工艺中的固液萃取进行缩放。该框架为那些已购置设备但未考虑大规模和实验室阶段相似性原则的行业提供了一种替代方案。对操作条件进行了调整,以达到中试水平的产品质量和饮料的最大抗氧化能力。对生产过程进行了技术经济分析和环境评估,为有效地将规模扩大到工业水平奠定了基础。事实证明,扩大规模是可行的,因为该工艺的净现值为 2018,000 美元,投资回收期为 4.83 年;固体废物的主要来源是原材料,由于该工艺的操作温度低于 100 °C,其碳足迹小于 0.205 MT eCO2。该项目的循环经济指标是循环材料使用率和废物流回收率。根据原材料中可可壳的成分,循环材料使用率从 16.7% 到 66.7% 不等;废物流回收率(%)从 4.4% 到 5% 不等,主要用于堆肥发展。该框架适用于遇到设备限制的其他食品生产过程。它有助于评估工艺产量,并能在工业/商业规模上使用循环经济指标模拟和分析经济盈利能力和环境影响。
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来源期刊
Food and Bioproducts Processing
Food and Bioproducts Processing 工程技术-工程:化工
CiteScore
9.70
自引率
4.30%
发文量
115
审稿时长
24 days
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.
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