Nutrient rich compositions

Abstract

This invention relates to processes and systems for converting fresh food waste into nutrient rich hydrolysates and particulate compositions. The invention also relates to the hydrolysates and compositions useful, for example, as fertilizers, feedstock or other nutrient supplements.

What is claimed is: 
     
         1 . A process for producing a nutrient rich composition from fresh food waste comprising the steps of:
 (a) providing fresh food waste using a highly efficient and effective collection system;   (b) grinding the fresh food waste using a first grinder and optionally a second grinder to produce a fresh food waste particle slurry;   (c) incubating the fresh food waste particle slurry under constant agitation by adding to said fresh food waste particle slurry a combination of enzymes comprising at least one enzyme to digest proteins, at least one enzyme to digest fats and lipids, at least one enzyme to digest cellulosic material and at least one enzyme to digest other carbohydrates and incubating the mixture at two or more temperatures ranging between about 100° F. and 130° F., to match the temperature performance curves of the enzymes wherein a third grinder is used to create shear during at least part of the incubating, whereby a hydrolysate comprising incubated fresh food waste particles is produced;   (d) pasteurizing the hydrolysate to kill pathogens; and   (e) separating the hydrolysate into a liquid hydrolysate and incubated fresh food particles using a coarse screen and a fine screen.   
     
     
         2 . The process of  claim 1 , wherein the combination of enzymes comprises at least one protease, at least one cellulase, at least one pectinase, at least one lipase, and α-amylase. 
     
     
         3 . The process of  claim 1 , wherein step (d) further comprises adding a first enzyme combination comprising at least one cellulase, and at least one lipase to the particulate fresh food waste to form an incubating mixture and increasing the temperature to a first temperature between about 100° F. and 130° F. 
     
     
         4 . The process of  claim 3 , wherein step (d) further comprises adding a second enzyme combination to the incubating mixture, comprising at least one pectinase, at least one protease, and α-amylase to the incubating particulate fresh food waste and increasing the temperature to a second temperature of about 110° F. to 130° F. to form a hydrolysate. 
     
     
         5 . The process of  claim 4 , wherein the first enzyme combination comprises endocellulase, exocellulase and lipase, the first temperature is between about 100° F. and 130° F., and the incubating mixtures is held at the first temperature for at least about 30 minutes to about 1.5 hours. 
     
     
         6 . The process of  claim 5 , wherein the incubating at the first temperature is about 30 minutes. 
     
     
         7 . The process of  claim 5 , wherein the second temperature is between about 100° F. and 130° F. and is held for at least about 1.5 to 3 hours. 
     
     
         8 . The process of  claim 5 , wherein the incubating at the second temperature is about 1.5 hours. 
     
     
         9 . The process of  claim 1 , wherein the third grinder is an in-line grinder comprising a high shear mixer. 
     
     
         10 . The process according to  claim 1 , wherein step (e) produces a liquid hydrolysate that is greater than about 85% by weight relative to the weight of the input incubating fresh food waste. 
     
     
         11 . The process according to  claim 10 , wherein the separating of step (e) produces a liquid hydrolysate that is about 85% to about 95% by weight relative to the weight of the input incubating fresh food waste. 
     
     
         12 . The process according to  claim 1 , wherein the grinding of step (c) produces particles in the particulate fresh food waste with an average size of less than about 1/16th of an inch. 
     
     
         13 . The process of  claim 1 , wherein the first grinder is a rotary knife grinder. 
     
     
         14 . The process of  claim 1 , wherein the second grinder is a low RPM/high torque grinder. 
     
     
         15 . The process according to  claim 1 , wherein the separating of step (e) produces incubated fresh food particles greater in size than can pass through the coarse screen. 
     
     
         16 . The process according to  claim 1 , wherein the fresh food particles produced in step (e) is used as an animal feedstock. 
     
     
         17 . The process according to  claim 1 , further comprising the steps of:
 (f) stabilizing and preserving the hydrolysate, using acid and/or preservatives, or using organic acids and/or organic preservatives allowed for use in the production of a certified organic hydrolysate;   (g) emulsifying the stabilized hydrolysate using an ultra-high-shear mixer to produce a stabilized, emulsified hydrolysate; and   (h) blending the emulsified hydrolysate in large storage tanks with circulation pumps, to assure the consistency of the finished product.   
     
     
         18 . The process according to  claim 17 , wherein the emulsified hydrolysate produced in step (g) has an average particle size of less than about 30 μm. 
     
     
         19 . The process according to  claim 18 , wherein the emulsified hydrolysate produced in step (g) has an average particle size of about 30 μm. 
     
     
         20 . The process according to  claim 17 , wherein the stabilizing of step (f) comprises addition and mixing of the liquid hydrolysate with an acid source consisting of one or more of hydrochloric, sulfuric, phosphoric, carbonic, acetic, stearic, propionic, tartaric, maleic, benzoic, succinic acids, lactic, or citric acid and one or more preservatives or organic preservatives. 
     
     
         21 . The process according to  claim 17 , wherein the pH of the liquid hydrolysate is less than 4.0. 
     
     
         22 . The process according to  claim 17 , wherein the pH of the stabilized liquid hydrolysate is about 2.5 to about 3.5 
     
     
         23 . The process according to  claim 17 , wherein the pH of the stabilized liquid hydrolysate about 3.0. 
     
     
         24 . The process of  claim 1 , wherein pathogens are inactivated. 
     
     
         25 . The emulsified hydrolysate made by the process of  claim 17 . 
     
     
         26 . A nutrient rich emulsified hydrolysate made from fresh food waste, comprising nutrients released by grinding, shearing, homogenization and enzymatic digestion, and an acid stabilizer, wherein the emulsified hydrolysate has an average particle size of less than about 30 μm and a pH of between about 2.5 and 3.5. 
     
     
         27 . The nutrient rich emulsified hydrolysate of  claim 26  wherein multiple batches of the hydrolysate have been blended in large storage tanks with circulation pumps, to assure the consistency of the finished product. 
     
     
         28 . A method of increasing the yield of produce, the method comprising applying by drip line irrigation a composition comprising a nutrient rich emulsified hydrolysate made from fresh food waste, the nutrient rich emulsified hydrolysate comprising nutrients released by grinding, shearing, homogenization and enzymatic digestion, and an acid stabilizer, wherein the emulsified and blended hydrolysate has an average particle size of less than about 30 μm and a pH of between about 2.5 and 3.5, wherein the yield of produce is increased by up to 30%. 
     
     
         29 . A system for processing fresh food waste, the system comprising:
 a rotary blade grinder with a fresh food waste inlet port and an outlet port coupled to a first inlet port of an incubation vessel and for delivering fresh food waste particles to said incubation vessel;   said incubation vessel including an incubation unit, an agitator, a second inlet port, a mixing device for mixing components received in said first and second inlet ports and a recirculating line coupled to said incubation unit and including an in-line grinder;   a separation unit including an inlet port coupled to an outlet port of said incubation vessel, a separation device that separates fluid from particulates and having a fluid outlet port and a particulate outlet port;   a stabilization/mixing vessel having an inlet port coupled to said fluid outlet port;   an emulsification unit coupled to said stabilization/mixing vessel and including a homogenizing grinder therein; and   a blending/storage tank and pump.   
     
     
         30 . The system as in  claim 29 , wherein said separating device comprises a coarse screen and a fine screen. 
     
     
         31 . The system as in  claim 30 , wherein said coarse screen and fine screen are vibrating. 
     
     
         32 . The system as in  claim 29 , further comprising a further grinder interposed between said rotary blade grinder and said incubation vessel, said further grinder having a further grinder inlet port coupled to said rotary knife grinder and a further grinder outlet port coupled to said incubator vessel inlet port. 
     
     
         33 . The system as in  claim 32 , wherein said further grinder comprises a low RPM, high torque grinder. 
     
     
         34 . The system as in  claim 33 , wherein said low RPM, high torque grinder includes a speed of about 1200-1700 RPM and a torque of about 5000-7000 foot-lbs. 
     
     
         35 . The system as in  claim 29 , wherein said stabilization/mixing vessel includes at least a second stabilizer unit inlet port for receiving an acid. 
     
     
         36 . The system as in  claim 29 , wherein said in-line grinder is a high shear mixer with a disintegrating head. 
     
     
         37 . The system as in  claim 29 , wherein said rotary blade grinder includes blades that rotate against a screen plate or a plate that includes holes. 
     
     
         38 . The system as in  claim 29 , wherein said mixing device is a ribbon blender or a paddle mixer. 
     
     
         39 . A method of increasing soil organic matter, the method comprising applying by drip line irrigation a composition comprising a nutrient rich emulsified hydrolysate made from fresh food waste, the nutrient rich emulsified hydrolysate comprising nutrients released by grinding, shearing, homogenization and enzymatic digestion, and an acid stabilizer, wherein the emulsified and blended hydrolysate has an average particle size of less than about 26 μm and a pH of between about 2.5 and 3.5, wherein the soil organic matter may be increased by as much as 140% over a growing season. 
     
     
         40 . A method of processing fresh food waste as in  claims 1  and  14  that generates negligible amounts of emissions, effluent, solid waste, and nuisance odors, and is conducted within a warehouse in a commercial and/or industrial zoned area, so that such facility may obtain all necessary government and regulatory permits and approvals to be able to operate in an urban area. 
     
     
         41 . An efficient and effective method of collecting fresh food waste before such material becomes putrescent, to allow processing the fresh food waste as in  claim 40 , eliminating a long distance haul typical of hauling food waste to landfills. 
     
     
         42 . A method of reducing greenhouse gas emissions from food waste, and sequestering such carbon in agricultural soil, and thereby increasing soil organic matter and improving the sustainability of agriculture.