Modular mechanical system for high-precision cocoa fraction separation
High-throughput modular system for precise cocoa nibs, shells, and fines separation using mechanical and fluidized air techniques, offering compact, energy-efficient integration into existing lines.
Overview
The modular mechanical system for high-precision cocoa fraction separation is designed to enhance the efficiency and accuracy of cocoa processing. This innovative solution combines staged mechanical cracking, air-jet fluidized sifting, and adaptive classification zones to precisely isolate cocoa nibs, shells, and fines. By integrating controlled mechanical agitation with fluidized air streams, the system mitigates caking due to cocoa fat, achieving a misclassification performance of less than 0.5% w/w while maintaining a throughput of over 20 MT/hr. This compact and energy-efficient system can seamlessly integrate into existing processing lines, reducing maintenance and operational costs.
Technical specifications
- High-throughput capacity: Operates continuously at 20+ MT/hr.
- Precision separation: Achieves less than 0.5% w/w misclassification.
- Components: Includes staged mechanical cracking, air-jet fluidized sifting, and adaptive classification zones.
- Adjustable parameters: Air velocity, vibration frequency, and geometry can be tuned at each stage.
- Inline sensors: Monitor flow behavior and adjust operating parameters in real time.
- Scalability: Designed for easy integration into existing cocoa processing lines.
- Energy efficiency: Optimized for minimal energy consumption.
Technology readiness level
The technology has reached a readiness level of 6, indicating that a prototype has been demonstrated in a relevant environment. Future validation phases include benchtop testing using cocoa bean fractions to test separation accuracy and throughput, followed by the development of a pilot-scale unit for integration with existing systems.
About Re-Du Company
RE-DU is a recycling technology company that has developed a patented process for the chemical deconstruction of mixed plastic waste. By breaking down diverse plastic types—such as PET, PC, PU, and PA—into monomers, the company enables the transformation of previously difficult-to-recycle materials into commercially valuable chemical products. This technology eliminates the need for costly sorting of mixed waste streams and offers an efficient, cost-effective alternative to traditional plastic management systems, which often rely on outdated processes that fail to address the majority of global plastic waste.
By providing a scalable solution for chemical recycling, RE-DU aims to reduce reliance on fossil fuels and minimize the environmental impact of plastic pollution in landfills. The company serves as a partner for industries seeking sustainable chemical feedstocks and is contributing to the development of a circular economy. Supported by initiatives like the Innovation Crossroads Award and research collaboration with Oak Ridge National Laboratory, RE-DU is positioned to help transition toward a net-zero carbon society by proving that mixed plastic waste can be successfully converted into high-quality, reusable resources.
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