Particle separator systems and processes for improving food safety

Abstract

The disclosure provides a particle separator for removing aerosolized particles from exhaust emissions from a preconditioner or other apparatus. The separator comprises an enclosure with at least two baffles linearly spaced from one another therein. At least two baffles prevent the exhaust from linearly flowing directly from an inlet through the separator to an outlet. Each baffle is positioned at an angle relative to the linear flow of exhaust into the separator and a distance from an inner surface of the separator. This places a leading edge within the exhaust flow to redirect a portion of the flow, thereby promoting impact of particles on a portion of the inner surface of the separator, while also providing a surface that collects particles in the flow that impact the baffle surface. The separator and baffle surfaces can be cleaned through an access. The separator can be box- or tube-shaped or other configuration.

What is claimed is: 
     
         1 . A separator for removing particles from a gas flow comprising:
 an enclosure having an inner surface, an inlet and an outlet, wherein said enclosure is configured to channel a flow of gas having particles commingled therein from said inlet to said outlet; and   at least two baffles positioned within said enclosure that are linearly spaced from one another between said inlet and said outlet, wherein each of said baffles provides an upstream surface positioned at an angle that is acute to said inner surface of said enclosure, whereby a combination of each said upstream surface provides a surface area that is greater than an area of a horizontal cross-section of said enclosure.   
     
     
         2 . The separator of  claim 1  wherein said horizontal cross-section of said enclosure is round, oval, square or rectangular. 
     
     
         3 . A method for removing particles flowing in a gas stream comprising:
 channeling a flow of said gas stream through an inlet into a particle separator that obstructs linear flow of said gas stream passing through said particle separator, said particle separator comprising:
 an outlet, a first inner surface opposing at a distance a second inner surface, and a first baffle that projects at an acute angle from said first inner surface and a second baffle that projects at an acute angle from said second inner surface, whereby said first baffle and said second baffle are spaced from one another between said inlet and said outlet, 
 wherein said first baffle comprises a leading edge that is positioned at a distance from said first inner surface that is equal to or greater than one half of a distance between said first inner surface and said second inner surface, and wherein said second baffle comprises a leading edge that is positioned at a distance from said second inner surface that is equal to or greater than one half of a distance between said first inner surface and said second inner surface, 
   thereby redirecting said flow of said gas stream in a manner that promotes impact of said particles into upstream surfaces of said first baffle and said second baffle, said first inner surface, and said second inner surface before said gas stream exits said outlet with at least 80% of said particles removed therefrom.   
     
     
         4 . The method of  claim 3  wherein said first baffle and said second baffle define a first chamber upstream from said first baffle and said second baffle, and a second chamber that is downstream from said first baffle and said second baffle,
 whereby said first baffle intercepts and redirects a first portion of said gas stream flowing through said inlet into said first inner surface and said second baffle intercepts and redirects a second portion of said gas stream flowing through said inlet into said second inner surface, wherein said first portion and said second portion comprise said gas stream in its entirety flowing through said inlet, and 
 thereafter said gas stream having at least 80% of said particles removed therefrom, passes from said first chamber into said second chamber and out of said particle separator through said outlet. 
 
     
     
         5 . The method of  claim 4  wherein said leading edge of said first baffle is positioned at a distance from said first inner wall and said leading edge of said second baffle is positioned at a distance from said second inner wall that is greater than one half of a distance between said first inner surface and said second inner surface. 
     
     
         6 . The method of  claim 4  wherein said leading edge of said first baffle is positioned at a distance from said first inner wall that is greater than one half of a distance between said first inner surface and said second inner surface, and said leading edge of said second baffle is positioned at a distance from said second inner wall that is equal to one half of a distance between said first inner surface and said second inner surface. 
     
     
         7 . The method of  claim 4  wherein said leading edge of said first baffle is positioned at a distance from said first inner wall and said leading edge of said second baffle is positioned at a distance from said second inner wall whereby said distance is equal to about one half of a distance between said first inner surface and said second inner surface. 
     
     
         8 . The method of  claim 4  wherein said leading edge of said first baffle and said leading edge of said second baffle are spaced from one another at a distance that is less than a diameter or width of said inlet. 
     
     
         9 . The method of  claim 4  wherein said leading edge of said first baffle and said leading edge of said second baffle are spaced from one another at a distance that defines an opening having an average cross-sectional area that is about 65% to about 100% of a cross sectional area of said inlet. 
     
     
         10 . The method of  claim 3  wherein said particle separator comprises a third baffle, along with said first baffle and said second baffle, that define:
 a first chamber upstream from said first baffle and said second baffle, a second chamber that is downstream from said first baffle and upstream from said third baffle, and a third chamber that is downstream from said second baffle and said third baffle, 
 whereby said first baffle intercepts and redirects at first portion of said gas stream flowing through said inlet into said first inner surface of said particle separator in said first chamber, said second baffle intercepts and redirects a second portion of said gas stream flowing through said inlet into said second inner surface of said particle separator in said first chamber, and said third baffle intercepts and redirects said gas stream entering said second chamber into said first inner surface of said particle separator in said second chamber, and 
 thereafter said gas stream having a substantial amount of particles removed therefrom, passes from said second chamber into said third chamber and then through said outlet. 
 
     
     
         11 . The method of  claim 10  wherein said leading edge of said first baffle is positioned at a distance from said first inner wall and said leading edge of said second baffle is positioned at a distance from said second inner wall whereby said distance is greater than one half of a distance between said first inner surface and said second inner surface. 
     
     
         12 . The method of  claim 9  wherein said leading edge of said first baffle is positioned at a distance from said first inner wall that is greater than one half of a distance between said first inner surface and said second inner surface, and said leading edge of said second baffle is positioned at a distance from said second inner wall at a distance is equal to one half of a distance between said first inner surface and said second inner surface. 
     
     
         13 . The method of  claim 9  wherein said leading edge of said first baffle is positioned at a distance from said first inner wall and said leading edge of said second baffle is positioned at a distance from said second inner wall whereby said distance is equal to about one half of a distance between said first inner surface and said second inner surface. 
     
     
         14 . A method for extruding a food product comprising:
 combining ingredients for said food product in a preconditioner of an extruder;   injecting steam into said preconditioner to hydrate said ingredients to form a preconditioned dough in said preconditioner;   removing particulate matter from steam exhaust emissions from said preconditioner by:
 channeling flow of said steam exhaust emissions through an inlet into a particle separator having an outlet; and 
 obstructing said flow of said steam exhaust emissions through said particle separator comprising a first baffle extending away from a first inner surface at an acute angle and a second baffle extending away from a second inner surface at an acute angle, wherein said first baffle and said second baffle are linearly spaced at a distance from one another between said inlet and said outlet so that leading edges of said first baffle and said second baffle define an opening having an average cross-sectional area that is about 65 to about 100% of a cross-sectional area of said inlet,
 wherein said first baffle comprises a leading edge positioned at a distance that is equal to or greater than one half of a distance between said first inner surface and said second inner surface, and wherein said second baffle comprises a leading edge positioned at a distance that is equal to or greater than one half of a distance between said first inner surface and said second inner surface; 
 
 thereby redirecting said flow of said steam exhaust emissions in a manner that promotes said particulate matter into contact with said upstream surfaces of said first baffle and said second baffle and said first inner surface and said second inner surface of said particle separator before said steam exhaust emissions exits said outlet having at least about 80% of said particles removed therefrom; and 
   extruding said preconditioned dough using said extruder.   
     
     
         15 . The method of  claim 14  wherein said food product comprises pet food, pet treats, animal feed, fish meal, or human food. 
     
     
         16 . An extruder apparatus comprising:
 a preconditioner having steam or water injection ports and an exhaust opening;   a particle separator in communication with said exhaust opening of said preconditioner, said particle separator comprising:
 an enclosure having a first inner surface spaced at a distance from an opposing second inner surface, an inlet, and an outlet, 
 wherein said enclosure is configured to channel a flow of exhaust emissions from said preconditioner through said inlet to said outlet; and 
 said first baffle extending away from said first inner surface at an acute angle and said second baffle extending away from said second inner surface, wherein said first baffle and said second baffle are spaced from one another between said inlet and said outlet and each provides an impact surface on which particles can deposit, and wherein said first baffle positions a leading edge at distance from said first inner surface that is equal to or greater than one half of a distance measured between said first inner surface and said second inner surface and said second baffle positions a leading edge at a distance from said second inner wall that is equal to or greater than one half of a distance measured between said first inner surface and said second inner surface; and 
   an extruder.   
     
     
         17 . The extruder apparatus of  claim 16  wherein said leading edge of each of said first baffle and said second baffle are spaced from one another at a distance that is less than a diameter or width of said inlet. 
     
     
         18 . The extruder apparatus of  claim 16  wherein said leading edge of each of said first baffle and said second baffle are spaced from one another at a distance that defines an opening having an average cross sectional area that is about 65 to about 100% of a cross sectional area of said inlet. 
     
     
         19 . A method for extrusion comprising:
 combining grain-based and/or animal protein-based ingredients for a food product in a preconditioner of an extruder;   injecting steam into said preconditioner to hydrate said grain and/or animal protein-based ingredients to form a preconditioned dough;   scrubbing exhaust emissions created by injecting steam into said grain and/or animal protein-based ingredients in said preconditioner, wherein said exhaust emissions include particulate matter comprising aerosolized grain-based and/or animal protein-based ingredients, by:
 directing a linear flow of said exhaust emissions through an inlet into a separator having an outlet; and 
 redirecting said linear flow of said steam exhaust emissions with a first baffle and a second baffle that are linearly spaced from one another between said inlet and said outlet of said separator,
 wherein said first baffle has an upstream surface at an acute angle relative to a first inner side surface of said particle separator and said second baffle has an upstream surface at an acute angle relative to a second inner side surface of said particle separator, and 
 wherein said first baffle provides a leading edge that is positioned at a distance from said first inner side surface that is equal to or greater than one half of a distance between said first inner side surface and said second inner side surface, and said second baffle provides a leading edge that is positioned at a distance from said second inner side surface that is equal to or greater than one half of a distance between said first inner side surface and said second inner side surface, 
 
 whereby said flow of said steam exhaust emissions is redirected by said first baffle and said second baffle in a manner that promotes said particulate matter to impact on said upstream surfaces of said first baffle and said second baffle, said first inner surface and said second inner surface before said steam exhaust emissions exits said outlet having at least 80% of said particulate matter removed therefrom; and 
   extruding said preconditioned dough using said extruder.   
     
     
         21 . A device for removing particles from exhaust emissions of an extrusion system comprising:
 an enclosure comprising an inlet and an outlet on opposing ends of said enclosure and a first inner surface provided at a distance from an opposing second inner surface, wherein said enclosure is configured to channel a flow of exhaust emissions commingled with particles from said inlet through said enclosure to said outlet;   a first baffle comprising an upstream surface at an acute angle to said first inner surface of said enclosure and a leading edge positioned at a distance equal to or greater than one half of said distance measured between said first inner surface and said second inner surface; and   a second baffle having an upstream surface position at an acute angle to said second inner surface and a leading edge positioned at a distance equal to or greater than one half of said distance measured between said first inner surface and said second inner surface;   wherein said leading edge of said first baffle is spaced from said leading edge of said second baffle at a distance that is less than a diameter or width of said inlet thereby defining an opening having an average cross sectional area that is about 65 to about 100% of a cross sectional area of said inlet.   
     
     
         21 . The device of claim  20  wherein said first baffle and said second baffle are sealed along exterior edges to said particle separator to restrict said flow of exhaust emissions between said exterior edges and said particle separator. 
     
     
         22 . The device of claim  20  wherein said acute angle is in a range of about 35-75 degrees. 
     
     
         23 . The device of claim  20  wherein said upstream surfaces of said first baffle and said second baffle is flat, convex, or concave, or have a cross section that can be L-shaped. 
     
     
         24 . The device of claim  20  wherein said leading edge has a surface that is flat, rounded or beveled. 
     
     
         25 . The device of claim  20  wherein said leading edge is linear, curvilinear, notched, or any combination thereof. 
     
     
         26 . The device of claim  20  wherein downstream surfaces of said first baffle and said second baffle are coated with a rough coating or a slick coating. 
     
     
         27 . The device of claim  20  comprising a third baffle spaced downstream from said first baffle and said second baffle. 
     
     
         28 . The device of claim  20  wherein a combination of each of said upstream surfaces provides a surface area that is greater than an area of a horizontal cross-section of said enclosure. 
     
     
         29 . A device for separating particles from exhaust emissions of an extrusion system comprising:
 a tube having an inner surface configured to channel a flow of exhaust emissions commingled with particles therein from an inlet to an outlet of said tube;   a first baffle attached at an acute angle to said inner surface, said first baffle comprising an upstream surface and a leading edge that is positioned perpendicular to said inner surface and said leading edge having a center portion positioned at a distance equal to or greater that one half of a diameter of said tube;   a second baffle attached at an acute angle to said inner surface, said second baffle comprising an upstream surface and a leading edge that is positioned perpendicular to said inner surface and said leading edge having a center portion positioned at a distance equal to or greater that one half of a diameter of said tube;   wherein said leading edge of said first baffle is positioned at a distance from said leading edge of said second baffle that is less than a diameter of said inlet, thereby defining an opening having an average cross sectional area that is about 65 to about 100% of a cross sectional area of said inlet.