Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
SYSTEM, PROCESS, USE AND FOOD PRODUCT OR INGREDIENT
DERIVED FROM FRUIT WINE DERIVATIVES
FIELD
[0001] This disclosure pertains to the field of fermenting fruit wine
derivatives into useful food
products and/or food ingredients.
SUMMARY
[0002] Described herein is a system, process, nutrient-rich products and uses
thereof which are
generated by the process of converting fruit winery derivatives into
nutritionally beneficial food
ingredients, products and/or supplements in an ecological manner. Integration
of this system
into a winery assists the winery to manage its previously-considered waste in
an ecological
manner, which can optionally bring the business a separate novel revenue
stream. The system,
methods, and processes are used to convert fruit winemaking derivatives into
nutrient-rich
products comprising antioxidants and other bioactive molecules, which reside
within the malt
and lees. These nutrient-rich products can be used as natural flavour,
texture, and color
enhancers, in addition to nutritional ingredients for fortifying processed
foods and consumer
recipes. They can also be used as health supplements and in the cosmetic
industry. Through use
of the proposed processing system, a winery can approach a "zero waste"
operation.
BACKGROUND
[0003] The subject matter discussed in the background section should not be
assumed to be prior
art merely because of its mention in the background section. Similarly, a
problem mentioned in
the background section or associated with the subject matter of the background
section should
not be assumed to have been previously recognized in the prior art. The
subject matter in the
background section merely represents different approaches, which in and of
themselves may also
correspond to implementations of the claimed technology.
1
Date recue/Date received 2023-05-04
100041 The winemaking industry produces millions of tons of leftovers and
residues, which
represent an ecological and economical waste management issue for the
wineries. The leftovers
and residues include organic wastes, inorganic wastes, wastewater, and
emission of greenhouse
gases (CO2, volatile organic compounds, etc.) Due to growing issues around
groundwater and
soil contamination, wineries send most of it to the landfill or compost,
costing the winery fees for
bin drop-off, removal, haulage and tipping fees in addition to winery
management costs.
Addressing these issues in an appropriate m.nner places a financial burden on
most of the
wineries, especially the smaller ones
[0005] One resource often used by winemaking industry is the intermediate bulk
container
(IBC), which are also known as an IBC tote, IBC tank, IBC, or pallet tank.
IBCs are ideal for
storing and transporting nutrient-rich products such as liquids, semi-solids,
pastes, solvents, or
granulate substances (food, chemicals, pharmaceuticals, etc.) in large
quantities. The concept of
the IBC was patented in 1993, and is described in US Patent Number 5,260,414,
of which there
are two main categories: flexible IBCs and rigid IBCs.
[0006] Rigid IBCs are stackable, reusable, versatile containers with an
integrated pallet base
mount that provides forklift and/or pallet jack maneuverability. Most IBCs are
cube-shaped and
this cube-shaped engineering contributes to the packaging, stacking, storing,
shipping, and
.. overall space efficiency of intermediate bulk containers. Almost all rigid
IBCs are designed so
they can be stacked vertically one atop the other using a forklift.
[0007] The support structure/containers can be made from metal (stainless
steel), plastic (high-
density polyethylene), or a composite construction (galvanized steel and
plastic) of the two
materials. The IBC tank can be made of plastic, stainless steel, and carbon
steel tanks The IBC
tank capacities generally used are often 1,040 and 1,250 litres (275 and 330
US gal).
[0008] The most widely utilized and known IBC is the limited re-use, caged IBC
tote container.
Caged IBC totes are composite intermediate bulk containers a
white/translucent plastic
container (typically high-density polyethylene) contained and protected by a
tubular galvanized
steel grid, common. Most have a built-in tap (valve, spigot, or faucet) at the
base of the
2
Date recue/Date received 2023-05-04
container to which hoses can be attached, or through which the contents can be
poured into
smaller containers.
100091 The winemaking process generates two major residues, which can be
harvested. The
major residues from the winemaking process after the de-stemming and crush
steps are known as
derivatives. Derivatives comprise grape marc (pomace) and lees. For every two
bottles of wine
made, typically the equivalent of one bottle of derivatives is produced.
Winery derivatives
comprise:
[0010] a) marc (pomace) consisting of grape skin, grape pulp and grape seed
derived from
varietal grapes, which have been crushed and pressed as part of the winemaking
process; and
[0011] b) lees consisting mainly of spent wine yeast, tartaric acid, malic
acid, lactic acid, grape
skin pigment, and grape pulp sediment, which has been separated from the wine
after
fermentation and again after aging.
[0012] Grape marc provides substantial nutritional potential for supplements
and to fortify food.
For example, 15 grams (-1 tbsp.) of powdered derivative may contain up to 900
mg of phenols,
150 mg of tannins (catechin), 2000 mg of protein, 180 mg of potassium, 120 mg
of magnesium,
4 mg of iron, 4% DV of riboflavin, 125% DV of vitamin E and 3% DV of vitamin
K).
100131 In general, wine lees is residue that forms at the bottom of wine
containers consisting of:
1) first and second-fermentation lees, which are formed during the alcoholic
and malolactic
fermentations, respectively (herein, lees); 2) during storage or after
treatments (herein, first-rack
lees); and 3) aging wine lees formed during wine aging in wood barrels
collected after the
filtration or centrifugation of the wine (herein, second-rack lees), The main
characteristics of
wine lees are acidic pH (between 3 and 6), a chemical oxygen demand above
30,000 mg/L,
potassium levels around 2500 mg/L, and phenolic compounds in amounts up to
1000 mg/L
Approximately 30% of red wine lees are protein that is produced from yeast
cell wall material,
which contains 30-60 % 3-b-D-glucan in dry weight.
3
Date recue/Date received 2023-05-04
[0014] Derivatives are used in livestock and poultry feed to extend the shelf-
life of milk, dairy
by-nutrient-rich products, and meat. There is extensive research on the anti-
microbial benefits as
a replacement for antibiotics for poultry and livestock. There is even
research showing that it can
cut bovine methane emissions by 30%
[0015] Although there is an identified market for these derivatives, the
current processes used to
transform it into shelf-stable nutrient-rich products creates a carbon
footprint, is prohibitively
expensive and causes significant loss in the quality in the derivatives.
[0016] The extraction of useful nutrient-rich products from wine derivatives
is known in the art.
However, most of these processes seek to isolate a specific compound, require
multiple steps,
and/or require drying the nutrient-rich product into a powder that can be
easily sold in capsule,
tablet, powder form, etc. Drying the nutrient-rich product and/or using
chemical processes to
isolate nutrient-rich products therefrom can diminish the bioavailability of
the biomolecules
desired in the final nutrient-rich products.
[0017] It is widely recognized that the nutrient value of foods has been
diminishing since at least
the 1950's, such that a need has developed for cost effective strategies to
fortifying foods in the
food supply, incorporating the resources of a winery to make adaptation easily
accessible for the
business.
100181 There is tremendous value in monetizing these derivatives. The issue
today is economics;
finding a cost-effective way to process derivatives in an ecological manner,
without losing
flavour and nutrition.
BRIEF DESCRIPTION OF TUFT FIGURES
[0019] Figure 1 provides an aerial view of one embodiment of the system,
illustrating one aspect
of the integration of the system into a winery.
4
Date recue/Date received 2023-05-04
[0020] Figure 2 illustrates one embodiment of the steps involved in separating
marc and lees
from a general winemaking process and inserting them into the system and
processes described
herein.
[0021] Figure 3 is a flow diagram showing one embodiment of the steps of
derivative conversion
presented in Figure 2, in addition to intermediates and nutrient-rich products
generated
throughout. As indicated at 226, the description of the process continues in
Figure 4.
[0022] Figure 4 is a continuation of the flow diagram of Figure 3, continuing
at 226.
[0023] Figure 5 provides one embodiment of the steps of separating marc and
lees from a
general winemaking process and inserting them into the system and processes
described herein,
wherein the process includes the addition off second-rack lees.
[0024] Figure 6 is a flow diagram showing one embodiment of the steps of
derivative-
conversion presented in Figure 5 in addition to intermediates and nutrient-
rich products
generated throughout. As indicated at 226, the description of the process
continues in Figure 7.
[0025] Figure 7 is a continuation of the flow diagram of Figure 6, continuing
at 226.
[0026] Figure 8 illustrates one embodiment of a processing container within
this system.
[0027] Figure 9 shows one example of one embodiment of the integration of a
series of
processing containers into the vineyard of a winery facility, which includes
one or more
protective covers.
[0028] Figure 10 shows one example of one embodiment of the placement of a
series of
processing containers on a winery property.
5
Date recue/Date received 2023-05-04
[0029] Figure 11 provides one example of one embodiment illustrating the
integration of the
system with the work-flow of a winery.
[0030] Figure 12 provides one embodiment of a use of the system as described
herein.
DETAILED DESCRIPTION
[0031]
[0032] The description set forth below in connection with the appended
drawings is intended as
a description of various embodiments of the described subject matter and is
not necessarily
intended to represent the only embodiment(s). In certain instances, the
description includes
specific details for the purpose of providing an understanding of the
described subject matter.
However, it will be apparent to those skilled in the art that embodiments may
be practiced
without these specific details. In some instances, structures and components
may be shown in
block diagram form in order to avoid obscuring the concepts of the described
subject matter.
Wherever possible, the same reference numbers will be used throughout the
drawings to refer to
the same or the like parts.
[0033] The words and phrases used herein should be understood and interpreted
to have a
meaning consistent with the understanding of those words and phrases by those
skilled in the
relevant art. No special definition of a term or phrase, i.e., a definition
that is different from the
ordinary and customary meaning as understood by those skilled in the art, is
intended to be
implied by consistent usage of the term or phrase herein. To the extent that a
term or phrase is
intended to have a special meaning, i.e., a meaning other than that understood
by skilled artisans,
such a special definition is expressly set forth in the specification in a
definitional manner that
directly and unequivocally provides the special definition for the term or
phrase.
[0034] The term comprising means "including but not limited to," unless
expressly specified
otherwise. When used in the appended claims, in original and amended form, the
term
"comprising" is intended to be inclusive or open-ended and does not exclude
any additional,
6
Date recue/Date received 2023-05-04
unrecited element, method, step or material. The term "consisting of' excludes
any element, step
or material other than those specified in the claim. As used herein, "up to"
includes zero,
meaning no amount is added in some embodiments.
[0035] The term "about" generally refers to a range of numerical values (e.g.,
+1-1-3% of the
recited value) that one of ordinary skill in the art would consider equivalent
to the recited value
(e.g., having the same function or result). In some instances, the term
"about" includes the values
disclosed and may include numerical values that are rounded to the nearest
significant figure.
Moreover, all numerical ranges herein should be understood to include all
integer, whole or
fractions, within the range recited.
[0036] Any reference in the specification to "one embodiment" or "an
embodiment" means that
a particular feature, structure, characteristic, operation, or function
described in connection with
an embodiment is included in at least one embodiment. Thus, any appearance of
the phrases "in
one embodiment" or "in an embodiment" in the specification is not necessarily
referring to the
same embodiment. Further, the particular features, structures,
characteristics, operations, or
functions may be combined in any suitable manner in one or more embodiments,
and it is
intended that embodiments of the described subject matter can and do cover
modifications and
variations of the described embodiments.
[0037] It must also be noted that, as used in the specification, appended
claims and abstract, the
singular forms "a," "an," and "the" include plural referents unless the
context clearly dictates
otherwise. That is, unless clearly specified otherwise, as used herein the
words "a" and "an" and
the like carry the meaning of "one or more" or "at least one." The phrases "at
least one," "one or
more," "or," and "and/or" are open-ended expressions that can be both
conjunctive and
disjunctive in operation. For example, each of the expressions "at least one
of A, B and C," "at
least one of A, B, or C," "one or more of A, B, and C," "one or more of A, B,
or C," "A, B,
and/or C," and "A, B, or C" can mean A alone, B alone, C alone, A and B
together, A and C
together, B and C together, or A, B and C together. It is also to be noted
that the terms
"comprising," "including," and "having" can be used interchangeably.
7
Date recue/Date received 2023-05-04
100381 Described herein is a system, methods, processes and nutrient-rich
products which are
generated by the process of converting winery derivatives into nutritionally
beneficial food
ingredients, products and/or supplements in an ecological manner. Integration
of this system
into a winery assists the winery to manage its previously-considered in an
ecological manner,
which can optionally provide them a novel revenue stream. The system, methods,
and processes
are used to convert winemaking derivatives into bioactive nutrient-rich
products comprising
antioxidants and other bioactive molecules that reside within the marc and
lees. These nutrient-
rich products can be used as natural flavour, texture and color enhancers, in
addition to
nutritional ingredients to fortify processed foods and consumer recipes. They
can also be used as
health supplements.
[0039] One embodiment comprises a system for integration into a wine-making
facility and its
processes comprising: one or more processing containers, designed for ease of
use by winery
staff, ease of storage during processing, efficacy, monitoring and security of
derivative-
conversion process to at least the stage of fermented puree; instructions for
the role of winery
staff to participate in the process of derivative-conversion into fermented
puree; and optionally,
microbial formulations designed to meet the fermentation objectives of a
nutrient-rich product
generated by the derivative-conversion process. One embodiment of the system
comprises the
one or more processing containers in which a version of a food-grade
intermediate bulk container
has been modified by generating a retractable lid therein. One embodiment of
the system
comprises one or more processing containers which have been modified by
incorporating
aerating means attached thereto. One embodiment of the system comprises one or
more
processing containers which have been modified by incorporating process
monitoring means
attached thereto. In one embodiment, the system can be used to conduct the
initial steps of a
.. business's process of converting winery marc into a food product and/or
ingredient at a winery
under GRAS conditions. In one embodiment, the system can be used to distribute
a business's
processing area. In one embodiment, the system can be used to expand a
business's effective
footprint to low-cost remote locations. In one embodiment, the system can be
used to conserve
industrial space by utilizing low-cost locations such as a field, empty
parking or other off-site
.. location. In one embodiment, the system can be used to provide an
additional source of revenue
to a winery by contracting with the winery to provide electrical power to the
processing
8
Date recue/Date received 2023-05-04
container location or providing access to vineyard property during off hours
and/or participating
in nutrient-rich product development field testing. In one embodiment, the
system can be used to
incorporate a winery's quality reputation into food products and/or
ingredients generated using
their marc. In one embodiment, the system can be used to facilitate
commercialization of
outdoor winery space during the winery's off-season. In one embodiment, the
system can be
used to acquire Carbon Credits by diverting waste into a food product and/or
ingredient. In one
embodiment, the system can be used to divert substances from waste management,
disposal
processes and related expenses into the bioconversion process, thereby
lowering expenses and
the impact of local health, environmental and worker safety regulations on the
winery. In one
embodiment, the system can be used to abate soil and watercourse pollution by
diverting winery
marc waste into a bioconversion process by collecting and processing it in a
sanitary manner
through fermentation and conversion it to a food product and/or ingredient. In
one embodiment,
the system can be used to convert waste marc into a food product and/or
ingredient through
fermentation. In one embodiment, the system can be used to divert winery marc
waste from
destinations such as landfill, compost and/or cattle feed by collecting and
processing it in a
sanitary manner through fermentation and conversion to a food product and/or
ingredient. In one
embodiment, the system can be used to conserve space in landfills by diverting
winery marc
waste into a food process by collecting and processing it in a sanitary manner
through
fermentation and conversion to a food product and/or ingredient. In one
embodiment, the system
can be used to reduce and/or eliminate the production greenhouse gases from
waste marc by
collecting and processing it in a sanitary manner through fermentation and
conversion to a food
product and/or ingredient. In one embodiment, the system can be used by a
winery to approach a
µ`zero waste" operation.
100401 One embodiment of the process for converting marc, first-rack lees and
optionally
second-rack lees derived from the winemaking process into refined nutrient-
rich products
comprises the steps of: a) transferring marc to a processing container; b)
hydrating marc until
berries swell; c) grinding hydrated marc to generate meal; d) optionally
inoculating meal with a
microbial formulation; e) fermenting inoculated meal to generate fermenting
meal; f) transferring
first-rack lees to the processing container; g) emulsifying the first first-
rack lees and fermenting
meal to generate a puree; h) optionally inoculating the puree; i) fermenting
said puree to generate
9
Date recue/Date received 2023-05-04
a fermented puree; j) refining fermented puree to generate a refined nutrient-
rich product; k)
optionally stabilizing refined product to generate stabilized nutrient-rich
product; and 1)
optionally packaging the stabilized nutrient-rich product. One embodiment of
the process
comprises inoculating with the microbial formulation selected from
Acetobacter, and/or
Gluconobacter and/or other known acetic acid bacteria and/or fungus
inoculants. One
embodiment of the process incorporates the use of enzymes, which may be added
the fermenting
meal. One embodiment of the process provides that methane emissions that would
otherwise be
caused by disposal of marc and lees in buried landfills is eliminated or
significantly reduced.
One embodiment of the process includes a nutrient-rich product substantially
produced thereby.
One embodiment of the process includes the nutrient-rich product comprises
varietal grape skin,
varietal grape seed, and winemaking sediment.
[0041] A process is provided for converting marc and lees derived from
winemaking into a
refined product consisting of the following steps of: a) transferring marc
containing crushed
grape berries into a processing container and hydrating until the grape
berries swelled, b)
grinding hydrated marc to generate a meal, slurry, or puree; c) fermenting the
meal to generate a
fermented meal, d) transferring lees to the processing container, e)
emulsifying the lees and
fermented meal to generate a puree, f) fermenting said puree to generate a
fermented puree and
g) refining the fermented puree to generate a refined nutrient-rich product
incorporating
substantially the entirety of the fermented marc and lees. In one embodiment,
the process step c
further includes inoculating with a microbial formulation comprising
Acetobacter, and/or
Gluconobacter and/or other known acetic acid bacteria and/or fungus
inoculants. In one
embodiment, the process step c further includes adding enzymes to the
fermenting meal. In one
embodiment the process eliminates or significantly reduced methane emissions
that would
otherwise be caused by disposal of marc and lees in buried landfills.
[0042] The present invention provides a nutrient-rich product produced by a
process for
converting marc and lees derived from winemaking into a refined product of a
process that
consisted of the following steps: a) marc containing crushed grape berries was
transferred into a
processing container and hydrated until the grape berries swelled, b) hydrated
marc was ground
to generate a meal, c) the meal was fermented to generate a fermented meal, d)
lees were
Date recue/Date received 2023-05-04
transferred to the processing container, e) the fermented meal and lees were
emulsified to
generate a puree, f) the puree was fermented to generate a fermented puree;
and g) the fermented
puree was refined to generate a refined nutrient-rich product incorporating
substantially the
entirety of the fermented marc and lees. In one embodiment, the nutrient-rich
product
comprises varietal grape skin, varietal grape seed, and winemaking sediment.
In one
embodiment, the process for making the nutrient-rich product further included
adding a
natural sweetener at step c). In one embodiment, the process for making the
nutrient-rich
product further included inoculating with a microbial formulation at step c).
In one
embodiment, the microbial formulation comprised acetic acid bacteria. In one
embodiment,
the microbial formulation comprised a fungal inoculant. In one embodiment the
lees recited
in step d consisted of first-rack lees. In one embodiment the lees recited in
process step d
comprised first-rack lees and second-rack lees. In one embodiment, the process
for
preparing the nutrient-rich product further included inoculating with a
microbial formulation
at step f). In one embodiment, the process for preparing the nutrient-rich
product further
included adding an enzyme at step b, c, d or f.
[0043] In one embodiment, the process for preparing the nutrient-rich product
further
included the step of blending with other varietals to achieve a consistent
flavour and nutrient
profile. In one embodiment, the process for preparing the nutrient-rich
product further
included a step of stabilizing the refined product of step g to generate a
stabilized nutrient-
rich product, and/or in one embodiment, this step of stabilizing included
pasteurization,
and/or correction of pH level through further fermentation. In one embodiment,
the process
for preparing the nutrient-rich product further included a step of packaging
the stabilized
nutrient-rich product, and/or wherein the stabilized nutrient-rich product was
extruded into a
container which was thereafter sealed, and/or wherein the product was extruded
into
consumer-sized sealed jars or bottles and/or was extruded into sealed
Intermediate Bulk
Containers designed for industrial food processing or pharmaceutical use. In
one
embodiment, the nutrient rich product is in the form of a paste. In one
embodiment, the
nutrient rich product is in the form of a powder
11
Date recue/Date received 2023-05-04
100441 One embodiment of the method of converting winery derivatives into
bioactive products
comprising the steps of: a) a business delivers one or more processing
containers to a winery
prior to crush; b) winery staff transfers marc to one or more processing
container(s); c) winery
staff rehydrates marc until berries swell, grinds the biomass into a meal,
inoculates with
microbials, and allows it to ferment at the winery facility; d) winery staff
transfers first-rack lees
to the one or more processing containers comprising fermenting meal; e) winery
staff emulsifies
the first-rack lees and fermenting meal to generate puree, inoculates the
puree and allows it to
ferment at winery facility; f) winery staff monitors the progress of
fermenting puree and notifies
the company when the fermentation has completed; and g) the business picks up
the one or more
processing containers and continues processing the fermented puree at the
company facility.
One embodiment of the method comprises using Acetobacter, and/or Gluconobacter
and/or other
known acetic acid bacteria and/or fungus inoculants in the microbial
formulation. One
embodiment of the method comprises the use of enzymes, which may be added the
fermenting
meal. One embodiment of the method comprises eliminating or significantly
reducing methane
emissions that would otherwise be caused by disposal of marc and lees in
buried landfills. One
embodiment of the method comprises a nutrient-rich product substantially
produced by the
method. One embodiment of the method comprises a nutrient-rich product
comprising varietal
grape skin, varietal grape seed, and winemaking sediment made thereby.
100451 According to one embodiment, a nutrient-rich product produced by the
following process
for converting marc comprising crushed or milled fruit derived from a
winemaking process into a
refined bioactive product, the process comprised the steps of: a) transferring
marc containing
crushed or milled fruit into a processing container; b) hydrating marc until
the crushed or milled
fruit swelled; c) optionally grinding hydrated marc to generate a meal; d)
fermenting the meal to
generate a fermented meal; e) optionally transferring lees to the processing
container; f)
emulsifying the fermented meal to generate a puree; g) fermenting said puree
to generate a
fermented puree; and h) refining fermented puree to generate a refined
nutrient-rich product
incorporating substantially the entirety of the fermented marc. In one
embodiment, the nutrient-
rich product comprises a cultivar of fruit skin, optionally seed, and
winemaking sediment.
In one embodiment, process step d included adding a natural sweetener in an
amount to
ensure an appropriate level of ethanol production. In one embodiment, process
step d,
12
Date recue/Date received 2023-05-04
included inoculating with a microbial formulation. In one embodiment, said
microbial
formulation comprised acetic acid bacteria. In one embodiment, said microbial
formulation
comprised a fungal inoculant. In one embodiment, said lees recited in process
step e
comprised first rack lees. In one embodiment, said lees recited in process
step e comprised
second rack lees. In one embodiment, process step d, included adding one or
more
enzymes. In one embodiment, process step g, included inoculating with a
microbial
formulation. In one embodiment, said process further included the step of
blending with
other types of fruit to achieve a consistent flavour and nutrient profile. In
one embodiment
the process further included a step of stabilizing the refined product of step
g to generate a
stabilized nutrient-rich product. In one embodiment, the step of stabilizing
the refined
product of step h included pasteurization. In one embodiment, the step of
stabilizing the
refined product of step h included correction of pH level through further
fermentation. In
one embodiment, the process further included a step of packaging the
stabilized nutrient-rich
product. In one embodiment, the stabilized nutrient-rich product was extruded
into a
container which was thereafter sealed and in one embodiment, the stabilized
nutrient-rich
product was extruded into consumer-sized sealed jars or bottles. In one
embodiment, the
stabilized nutrient-rich product was extruded into sealed Intermediate Bulk
Containers
designed for industrial food processing or pharmaceutical use. In one
embodiment, the
product is in the form of a paste. In one embodiment, the product is in the
form of a powder.
100461 A process is provided for converting marc comprising crushed or milled
fruit and
optionally lees derived from a winemaking process into refined products
comprising the steps of:
a) transferring marc comprising crushed for milled fruit to a processing
container; b) hydrating
marc until the crushed or milled fruit swells; c) optionally grinding hydrated
marc to generate a
meal; d) inoculating the meal with a microbial formulation; e) fermenting the
meal to generate a
fermented meal; 0 grind and emulsifying the fermented meal to generate a
puree; g) optionally
inoculating the puree; h) optionally fermenting said puree to generate a
fermented puree; i)
refining the puree or fermented puree to generate a refined nutrient-rich
product; j) optionally
stabilizing refined product to generate stabilized nutrient-rich product; and
k) optionally
packaging the stabilized nutrient-rich product. In one embodiment, the process
comprises a
cultivar of fruit skin, optionally seed, and winemaking sediment. In one
embodiment, the
13
Date recue/Date received 2023-05-04
step d of the process includes adding a natural sweetener in an amount to
ensure an
appropriate level of ethanol production In one embodiment, step d of the
process includes
inoculating with a microbial formulation and in one embodiment the microbial
formulation
comprises acetic acid bacteria. In one embodiment said microbial formulation
comprises a
fungal inoculant. In one embodiment the lees recited in step e of the process
comprises first
rack lees. In one embodiment, the lees recited in step e comprises second rack
lees. In one
embodiment, step g of the process includes inoculating with a microbial
formulation. In one
embodiment, step d includes adding one or more enzymes. In one embodiment, the
process
further includes the step of blending with other types of fruit to achieve a
consistent flavour
and nutrient profile. In one embodiment, said process further includes a step
of stabilizing
the refined product of step g to generate a stabilized nutrient-rich product.
In one
embodiment, the step of stabilizing the refined product of step h includes
pasteurization. In
one embodiment, the step of stabilizing the refined product of step h includes
correcting pH
level through further fermentation. In one embodiment, the process further
includes a step
of packaging the stabilized nutrient-rich product. In one embodiment, the
stabilized
nutrient-rich product is extruded into a container which is thereafter sealed.
In one
embodiment, the stabilized nutrient-rich product is extruded into consumer-
sized sealed jars
or bottles. In one embodiment, the stabilized nutrient-rich product is
extruded into sealed
Intermediate Bulk Containers designed for industrial food processing or
pharmaceutical use.
In one embodiment, the product is in the form of a paste. In one embodiment,
the product is
in the form of a powder.
[0047] A nutrient-rich product is provided, produced by a process for
converting marc derived
from winemaking into a refined product incorporating substantially the
entirety of the marc of a
process comprising the following steps: a) marc containing crushed or milled
fruit was
transferred into a processing container and hydrated until the crushed or
milled fruit swelled; b)
hydrated marc was ground to generate a meal; c) the meal was fermented to
generate a fermented
meal; d) lees were transferred to the processing container; e) the fermented
meal and lees were
emulsified to generate a puree; f) the puree was fermented to generate a
fermented puree; g) the
fermented puree was blended with ground/emulsified marc from other varietals;
and h)
14
Date recue/Date received 2023-05-04
refining the fermented puree to generate a refined nutrient-rich product
incorporating
substantially the entirety of the fermented marc.
[0048] Various embodiments for the use of the product described herein are
provided. In one
embodiment the product is used as a natural flavour, texture, and/or color
enhancer in food. In
one embodiment the product is used as a nutritional ingredient for fortifying
processed foods
and/or consumer recipes. In one embodiment the product is used to reduce the
amount of sodium
in a food formula. In one embodiment the product is used to preserve dairy,
meat, condiment
and or cereal nutrient-rich products. In one embodiment the product is used to
enhance the
flavour of fruits, vegetables, and spices within a food formula. In one
embodiment the product is
used to provide significant nutrient value to a food formula. In one
embodiment the product is
used to provide a source of yeast and other bacteria to cause the leavening of
bread. In one
embodiment the product is used to provide a source of bacteria to cause the
fermentation of dairy
nutrient-rich products. In one embodiment the product is used to provide a
source of bacteria to
cause the fermentation of plant-based proteins. In one embodiment the product
is used to provide
a medium for extraction of nutrients for pharmaceutical use. In one embodiment
the product is
used to provide a medium for topical applications in cosmetics or skin therapy
[0049] A process is provided for converting marc derived from winemaking into
a refined
product incorporating substantially the entirety of the marc comprising the
following steps: a)
transferring marc containing crushed or milled fruit into a processing
container and hydrating
until the crushed or milled fruit swells; b) grinding hydrated marc to
generate a meal; c)
fermenting the meal to generate a fermented meal; d) transferring lees to the
processing
container; e) emulsifying the lees and fermented meal to generate a puree; f)
fermenting said
puree to generate a fermented puree; g) blending the fermented puree with marc
from other
varietals; h) refining the fermented puree to generate a refined nutrient-rich
product
incorporating substantially the entirety of the fermented marc.
[0050] A process is provided for converting marc and lees derived from
winemaking into a
refined product of a process comprising the following steps: a) transferring
marc containing
crushed or milled fruit into a processing container and hydrating until the
crushed or milled fruit
Date recue/Date received 2023-05-04
swells; b) grinding hydrated marc to generate a meal; c) inoculating the meal
with a microbial
formulation and fermenting to generate a fermented meal; d) emulsifying lees
and fermented
meal to generate a puree; e) fermenting said puree to generate a fermented
puree; 0 inoculating
the fermented puree with a microbial formulation and fermenting it to generate
a fermented
puree; and g) refining the fermented puree to generate a refined nutrient-rich
product
incorporating substantially the entirety of the fermented marc and lees.
[0051] In one embodiment, a system provided by a business for integration into
a wine-making
facility and its processes enabling winery staff to collect marc generated
during crush and
enabling the business to conduct a primary fermentation in a location that is
off premises
comprising: a) one or more processing containers configured for: i) ease of
use to collect fruit
marc at a winery, ii) the ability to conduct primary (aerobic) fermentation
(optionally anaerobic
and aerobic) of fruit mare in an autonomous and/or semi-autonomous manner
requiring minimal
oversight, and iii) conforming to the minimal requirements for the food safety
and quality
regulations of the jurisdictions in which the ultimate products will be
directly and/or indirectly
sold; b) instructions for the role of winery staff to use the processing
container; and c) optionally,
microbial formulations designed to meet the fermentation objectives. In one
embodiment, the
system can be used to conduct the initial steps of a business's process of
converting winery marc
into a food product and/or ingredient at a winery under GRAS conditions. In
one embodiment,
the system can be used to distribute a business's processing area. In one
embodiment, the system
can be used to expand a business's effective footprint to low-cost remote
locations. In one
embodiment, the system can be used to conserve industrial space by utilizing
low-cost locations
such as a field, empty parking or other off-site location. In one embodiment,
the system can be
used to provide an additional source of revenue to a winery by contracting
with the winery to
provide electrical power to the processing container location or providing
access to vineyard
property during off hours and/or participating in nutrient-rich product
development field testing.
In one embodiment, the system can be used to incorporate a winery's quality
reputation into food
products and/or ingredients generated using their marc. In one embodiment, the
system can be
used to facilitate commercialization of outdoor winery space during the
winery's off-season. In
one embodiment, the system can be used to acquire Carbon Credits by diverting
waste into a
food product and/or ingredient. In one embodiment, the system can be used to
divert substances
16
Date recue/Date received 2023-05-04
from waste management, disposal processes and related expenses into the
bioconversion process,
thereby lowering expenses and the impact of local health, environmental and
worker safety
regulations on the winery. In one embodiment, the system can be used to abate
soil and
watercourse pollution by diverting winery marc waste into a bioconversion
process by collecting
and processing it in a sanitary manner through fermentation and conversion it
to a food product
and/or ingredient. In one embodiment, the system can be used to convert waste
marc into a food
product and/or ingredient through fermentation. In one embodiment, the system
can be used to
divert winery marc waste from destinations such as landfill, compost and/or
cattle feed by
collecting and processing it in a sanitary manner through fermentation and
conversion to a food
product and/or ingredient. In one embodiment, the system can be used to
conserve space in
landfills by diverting winery marc waste into a food process by collecting and
processing it in a
sanitary manner through fermentation and conversion to a food product and/or
ingredient. In one
embodiment, the system can be used to reduce and/or eliminate the production
greenhouse gases
from waste marc by collecting and processing it in a sanitary manner through
fermentation and
conversion to a food product and/or ingredient. In one embodiment, the system
can be used by a
winery to approach a "zero waste" operation.
[0052] An Overview of the Derivative-Conversion Process Integrated with
Winemalcing
Processes
[0053] Primary and Optional Secondary Fermentation
[0054] The process describes a primary fermentation and an optional secondary
fermentation,
which may be used to stabilize or further refine the product.
[0055] Herein, "primary fermentation" refers mainly to an acetic acid
fermentation. Prior to the
acetic acid fermentation, it may be desirable to conduct an ethanolic
fermentation in order to
elevate the level of ethanol present in the processing container. Prior to the
acetic acid
fermentation, it may be desirable to conduct a lactic-acid fermentation in
order to convert malic
acid to lactic acid. These three types of fermentation may be conducted in
separate phases using
different microorganisms, or they may be conducted using a mixed culture in a
more
17
Date recue/Date received 2023-05-04
simultaneous fashion. Thus, "primary fermentation" may refer to: only an
acetic acid
fermentation; or an acetic acid fermentation preceded by either/or an
ethanolic fermentation or a
lactic acid fermentation; or all three types of fermentation conducted in an
effective manner.
[0056] Herein, "secondary fermentation" refers mainly to optional
fermentations that may be
performed downstream from the primary fermentation, for example, to further
refine and/or
stabilize the product. It may be desirable to add lees, pomace from another
source, or other
additive and then conduct another fermentation to further refine and/or
stabilize the product,
[0057] With reference to FIGS. 2 and 5, this section of the description will
introduce an
overview for two embodiments the derivative-conversion process alongside and
integrated with a
general description for fruit wine making processes (including grape). The
subsequent section,
with reference to FIGS. 3, 4, 6 and 7, will describe further details of these
steps, without
reference to the general fruit winemaking processes. One skilled in the art
would appreciate and
know that this system, methods, processes and nutrient-rich products made
thereby 200 could be
adapted for wineries producing specific types of fruit wine, other than grape.
In one
embodiment, the system 200 is integrated with a winery that produces fruit
wine other than
grape-based wine. One embodiment, the system 200 is integrated with a winery
that produces
both grape wine and other specific-type of fruit wine. In one embodiment, the
system, processes,
nutrient-rich products made thereby 200 and use thereof include the
derivatives produced by
both the grape winemaking process and the non-grape fruit winemaking process.
If a distinction
is not made, descriptions pertaining to fruit winemaking are intended intend
to include grape
winemaking.
[0058] With reference to FIGS. 2 and 5, embodiments of the process for making
these bioactive
nutrient-rich products are described below. The steps of a traditional general
fruit winemaking
(especially grape) process are labeled with alpha characters (A, B, C, etc.).
The steps within
embodiments of the general derivative-conversion process for generating
bioactive nutrient-rich
products are labelled with numeric characters (1, 2, 3, etc.).
18
Date recue/Date received 2023-05-04
[0059] In Step A 102, the winery either picks or buys varietal wine gapes that
are optimized for
winemaking and they are transported to the winery "crush pad" to be processed.
The grapes may
be destemmed or not destemmed prior to Step B 104, depending upon the
preferred method of
wine production, and loaded into the grape crusher. During Step B 104, the
grapes are
masticated so that the juice (must) can be separated from the skins, pulp and
seeds. If the
crushed grapes and must are to be used in a white or rose style wine, they are
immediately
treated according to the process of Step C 108.
[0060] In Step A 102, if the winery is making a specific (non-grape) fruit
wine, the winery either
picks or buys fruit that is optimized for winemaking and they are transported
to the winery
"crush pad" or fruit mill (for milling) to be processed. Depending upon the
type of fruit to be
made into a wine and the preferred method of wine production, the fruit may be
first processed in
a finishing mill such as a brush finisher to remove skins and seeds (or pits)
prior to crushing or
milling. The fruit is crushed or milled so that the juice (must) can be
separated from the marc. if
the crushed/milled fruit is to be used in a white or rose style wine, they are
immediately treated
according to the process of Step C 108.
[0061] If the crushed or milled fruit (e.g., grapes) and must are to be used
in a red or "orange"
style wine, they are processed in Step B1 106, which entails loading the
crushed or milled fruit
(e.g., grapes) and must into the fermentation tank where yeast is added to
initiate alcoholic
fermentation. When the alcoholic fermentation process has terminated, the wine
("free run
wine") and the crushed or milled fruit (e.g., grapes) are further processed in
Step C 109.
Typically, the free run wine is pumped off into tanks and the skins subjected
to step C 108,
where they are pressed to extract the remaining juice and wine. The press wine
may optionally
be blended with the free run wine at the winemaker's discretion.
[0062] Thus, Step C 108 is applied to either the must derived from Step B 104
(e.g, in the
production of white wine) or to the alcoholic fermented wine (free run wine)
derived from Step
B1 106 (e.g., in the production of red wine). During Step C 108, the crushed
for milled fruit (e.g.
grapes) and either, the unfermented must derived from Step B 104 or the free
run wine derived
from Step B1 106, are loaded into the press so that the must or free run wine
can be squeezed
from the marc 109 (solid matter). The must, destined to become a grape-based
white wine, is
19
Date recue/Date received 2023-05-04
loaded into a fermentation tank where yeast may be added to initiate alcoholic
fermentation of
the must. The press wine produced from Step C 108, which has now been
separated from the
marc109, in step D 110 is inoculated with specific strains of bacteria
(lactobacter) to initiate
malo-lactic fermentation to convert "crisp, green apple" malic acid to "soft,
creamy" lactic acid
to soften the taste of the wine. The marc 109, which is traditionally treated
as food waste, is
immediately removed from the "food preparation" area (crush pad).
[0063] As illustrated by FIG. 2 and 5, the process of derivative-conversion,
begins by
transferring marc 109 to one or more processing containers 300 (illustrated in
FIG. 8) of this
system to be processed during Step 1 204, 206, 208, 210 (illustrated in FIGS.
3 and 6). The marc
109 is rehydrated with enough water to saturate the marc 109. After the
crushed fruit (e.g.
grapes) has swollen, the saturated marc is optionally ground into fine
particulates and is then
inoculated with microbials to cause fermentation and dissolution of solid
particles. This process
can generally last for approximately 2 to 6 weeks before proceeding to Step 2
218, 224.
[0064] During Step D 110 of the general winemaking process for grape-based
white wine, the
must is fermented until it turns into wine. As part of this step the spent
yeast, tartaric acid, skin
and pulp particulates settles to the bottom of the fermentation tank. As
mentioned above, the
press wine is usually subjected to malo-lactic fermentation during Step D,
during traditional red
wine making practices.
[0065] During Step E 112 of the winemaking process, the settled particulates
are separated from
the wine by drawing the wine off of the top in a process known as racking and
placed into oak,
steel or ceramic vessels for aging. This particulate matter, suspended in a
residual amount of
.. wine is referred to herein as first-rack lees 113. During traditional
winemaking, the first-rack
lees 113 is typically treated as food waste and is immediately removed from
"food preparation"
area.
[0066] In one embodiment, wherein the optional step of incorporating the first-
rack lees during
the process of derivative-conversion, Step 2 214, 218, 224, incorporates the
first-rack lees 113
into the processing container 300 where it is emulsified with the biomass,
which is then further
Date recue/Date received 2023-05-04
fermented. In one embodiment, the lees may be obtained from a different
source, such as
different winery that produces a large amount of lees of a consistent quality,
for example. Lees
from a different source winery, may include first rack lees and/or second rack
lees.
[0067] During Step F 114 of winemaking, the wine is aged for 2 to 60 months,
depending on the
crushed fruit (e.g. grape) varietal and winemaking technique. The wine is then
filtered to remove
any residual lees, herein referred to as second-rack lees 115, and placed into
bottles, kegs or
waterproof boxes. During traditional winemaking, the second-rack lees 115
typically is treated
as food waste and is immediately removed from the "food preparation" area. In
one
embodiment, wherein the optional step of incorporating the second-rack lees
during the process
of derivative-conversion, however, as illustrated in FIG. 5 the second-rack
lees 115 can be
transferred to the processing container 300 during Step 2A 214, 218 224, 228.
230, the biomass
is then further-fermented to generate a further-fermented purée 232.
[0068] Thus, FIG. 2 illustrates that the first rack-lees 113 from Step E 112
is added to the
emulsion created during Step 1 204, 206, 208, 210 mixed and then further
fermented during Step
2 218, 224 until the fermented nutrient-rich product 226 achieves the desired
flavour profile,
nutrient value, and PH level. FIG. 5 illustrates that the first rack-lees 113
from Step E 112 is
added to the emulsion created during Step 1 204, 206, 208, 210. mixed and then
further
fermented during Step 2 218, 224 until the second-rack lees 115 are ready, at
which time they are
transferred to the processing container and fermentation is continued until
the further-fermented
nutrient-rich product 232 achieves the desired flavour profile, nutrient
value, and PH level.
[0069] FIGS. 2 and 5 describe that at Step 3 234, the fermented purée 225 or
further-fermented
purée 232 are refined using filtration, homogenization, other techniques, or a
combination of
techniques. At this step, excess water is removed along with any undesirable
particulates or
substances such as sulfur, bentonite, etc.
[0070] FIGS. 2 and 5 teach at Step 4 238 that refined a nutrient-rich product
236 is rendered
shelf-stable through pasteurization or correction of PH level through further
fermentation and
thereby converted to a stabilized nutrient-rich product 240.
21
Date recue/Date received 2023-05-04
[0071] FIGS. 2 and 5 illustrate that during Step 5 242, the stabilized
nutrient-rich product 240 is
packaged into consumer, culinary and/or industrial vessels. It is then stored
for shipment. The
stabilized nutrient-rich product 240 could be in liquid, paste or powder
format based on the needs
of the end-user.
[0072] The Steps of the Derivative-Conversion Process Described in Greater
Detail
[0073] FIGS. 4, 5, 7 and 8 outline the steps described above, including the
sub-steps constituting
the steps, intermediaries and nutrient-rich products involved in embodiments
of the system,
methods processes, and nutrient-rich products made thereby. For example, Step
1204, 206, 208,
210 comprises four sub-steps and various intermediates. The details for each
of the steps and
sub-steps are described herein.
[0074] Step 1 Initial Acetic Acid Fermentation
[0075] As described in FIGS. 4 and 7, the man 109 derived from the press is
transferred to a
processing container 300 of the system. In one embodiment, sub-step 202 is
conducted by
transferring the marc 109 from a collection vessel typically used in a winery
to collect marc 109
from the press and pouring the contents into a processing container 300. The
marc 109 is then
rehydrated with an amount of water for a sufficient period of time to allow
the crushed fruit (e.g.,
berries) to swell. In one embodiment, a processing container 300 is filled to
50-80% of its
capacity, depending on the amount of marc available from the press. The
addition space is
reserved for lees and to provide sufficient air above the cap of the mixture
to accelerate aerobic
fermentation.
[0076] Once the crushed or milled fruit (e.g., berries) have swollen, the
biomass is optionally
ground into a meal 205. In one embodiment, the rehydrated fruit (e.g, berries)
are fermented
without grinding. In one embodiment, the rehydrated fruit (e.g., berries) are
ground prior to
fermentation. In one embodiment, the rehydrated fruit (e.g., berries) are
coarsely ground in order
22
Date recue/Date received 2023-05-04
to facilitate the homogeneity of the primary fermentation process. The
fermented material may
be ground to a finer level downstream in the process (e.g. emulsification).
[0077] In one embodiment described for winemaking from grapes, the grinding
process involves
the use of a portable pureeing device that is inserted into the tank, which
shreds the skins and
pulp, and cuts up the seed, allowing the microbial "cocktail" to attack the
grape skin particles,
pulp, seed pulp and bruised husk. In one embodiment, a macerating pump, may be
reversibly
attached to the spigot that draws out the material, passing it though a
grinder, and then pumping
it back into the top of the container. In one embodiment, the grinding process
is conducted after
the primary fermentation.
[0078] The meal 205 is then inoculated with a microbial culture that may
comprise bacteria (e.g.,
acetic acid bacteria), enzymes and/or yeast to cause fermentation and
dissolution of solid
particles. Optionally, sugar or other natural sweetener may be added to
accelerate the
fermentation. In one embodiment, enzymes such as pectinase, cellulase,
amylase, protease,
etc., may be added. The inoculated meal then is aeriated at a level that
introduces enough
oxygen to allow aerobic fermentation to dominate all bioactivity. The
inoculated meal 205 is
then allowed to rest and begin fermentation and thereby becomes fermenting
meal 212. The
processing containers are checked periodically to monitor the progression of
fermentation as
assessed by the pH, the Brix level, optionally the temperature. One skilled in
the art of
fermentation would know which factors would be most relevant to the type of
nutrient-rich
product they are seeking to generate. The design for fermentation and process
instruction can be
found in one or more books/reference manuals, such as, for example, "Wine
Microbiology". By
Fugelsang and Gump, "Food Microbiology," "Food Fermentations," "Indigenous
Fermented
Foods," or "Food Microbiology: Fundamentals and Frontiers", edited by Michael
P. Doyle,
Larry R. Beuchat, and Thomas J. Montville.
[0079] This process can generally last for 2 to 6 weeks. As this system is
integrated with the
general winemaking process, as depicted in FIGS. 2 and 5, the time-period for
this process can
depend upon the availability of the lees generated by the winemaking process.
23
Date recue/Date received 2023-05-04
[0080] Step 2: Lee-Addition and continued Fermentation
[0081] As described above, within the General Overview section, Step E 112 of
the process of
conventional winemaking, wherein either the must or pressed wine (red) is
racked, generates
first-rack lees 113. The first-rack lees 113 is typically considered food
waste and immediately
removed from the "food preparation" area. Wineries will either syphon the wine
from the top of
the fermentation tank until the wine becomes cloudy, or will drain the wine
the wine from the
bottom of the tank using a filtration system to remove lees particles.
[0082] First-rack 113 lees can be collected in food safe containers and then
optionally poured
over the fermenting meal 212 in a processing container 300 during sub-step
214. In one
embodiment, the lees may be obtained from a different source, such as
different winery that
produces a large amount of lees of a consistent quality, for example. Lees
from a different
source winery, may include first rack lees and/or second rack lees. During sub-
step 218, the
first-rack lees 113 and the fermenting meal 212 are optionally emulsified to
generate a purée
220. The purée is then fermented in sub-step 224, during which the pH of the
purée will be
expected to drop to below 3.5 pH.
[0083] Optional Inoculation of the Purée
[0084] One objective for this fermentation process is to establish how "sour"
the ultimate
fermented purée 225 should be allowed to become. Care must be provided
regarding the levels
of acetic acid present during the fermenting process. Ideally the optimal pH
can be attained with
the lactic acid remaining in the first-rack lees 113.
[0085] As described in the General Overview section, step D 110 of the general
red winemaking
process, involves inoculating the press wine produced from Step C 108, with
specific strains of
bacteria (lactobacter) to initiate malo-lactic fermentation to convert malic
acid to lactic acid to
soften the taste of the wine. If there is not sufficient lactic acid remaining
in the first-rack lees
113 after the mato-lactic fermentation, the purée 220 in processing container
300 is inoculated
24
Date recue/Date received 2023-05-04
with a microbial solution comprising acetic acid bacteria during sub-step 224
and allowed to
ferment for approximately 60 ¨ 90 days.
[0086] The fermentation process is monitored by periodically checking the
pH/Brix ratio to
maintain the pH of the purée 220 below 4.5. This stage of the process is
considered finished
when the pH drops to an appropriate level, likely around 3.5 or possibly less.
and the purée 220
is considered completely converted to fermented purée 225. The processing
containers are
checked periodically to monitor the progression of fermentation as assessed by
the pH, the Brix
level, optionally the temperature. One skilled in the art of fermentation
would know which
factors would be most relevant to the type of nutrient-rich product they are
seeking to generate.
[0087] Optional Storage-Lee-Addition Process
[0088] In one embodiment, illustrated in FIG. 5, an additional lee transfer
step is included in the
derivative-conversion process. During Step F 114 of the conventional
winemaking process, the
wine is stored for aging, which generates second-rack lees 115. This
embodiment entails
collecting and transferring the second-rack lees 115 to processing container
300 during sub-step
228. In one embodiment, the lees may be obtained from a different source, such
as different
winery that produces a large amount of lees of a consistent quality, for
example. Lees from a
different source winery, may include first rack lees and/or second rack lees.
In one embodiment
lees from a different source winery may optionally be added to the processing
container at this
point in the process.
[0089] This optional step is performed in a manner similar to the collection
and transfer of the
first-rack lees 113, described above. In this collection and transfer step,
however, care must be
taken to ensure that the winery did not employ any filtration catalysts, such
as bentonite (clay),
egg whites (non-vegan), that would contaminate the final nutrient-rich
product. If these other
substances are present, one skilled in the art would know what appropriate
applications would
work for the final nutrient-rich product that will eventually be produced and
what should be
avoided.
Date recue/Date received 2023-05-04
[0090] During sub-step 230, the processing containers are checked periodically
to monitor the
progression of fermentation as assessed by the pH, the Brix level, optionally
the temperature, etc.
One skilled in the art of fermentation would know which factors would be most
relevant to the
type of nutrient-rich product they are seeking to generate. Once the desired
factors are present
within the biomass, the further fermented purée 232 will be refined according
to Step 3 324
[0091] Step 3: Raw Nutrient-rich product Refinement Process
[0092] During Step 3 234, the fermented purée 225 or optionally, the further-
fermented purée
232 is refined using filtration, homogenization, other techniques, or a
combination of techniques
in order to convert the fermented purée 225 or the further-fermented purée 232
into a refined
nutrient-rich product 236. At this step, excess water is removed along with
any undesirable
particulates or bi-nutrient-rich products, such as sulfur, bentonite, etc. One
skilled in the art will
appreciate the qualities and characteristics for the end nutrient-rich
product, will know what
criteria to look for at this stage of the process and will make the
appropriate adjustments to
generate an appropriate refined nutrient-rich product 236.
[0093] Some examples of steps that one skilled in the art may choose to employ
include the
following.
[0094] During Step 3 234 the fermented purée 225 or the further-fermented
purée 232 will first
be tested for bentonite, sulphur and other food contaminants (likely before
removal from the
winery)
[0095] In general, at this stage as described in more detail below during the
work flow section,
the processing container(s) 300 will be collected by the business to continue
processing within
the business facility.
[0096] If contaminants are present, the fermented purée 225 or the further-
fermented purée 232
will likely be processed in a different manner that will be used only for
livestock feed or nutrient
extraction.
26
Date recue/Date received 2023-05-04
[0097] If sulphur is present, the fermented purée 225 or the further-fermented
purée 232 is
treated with a sulphur extractant (eg hydrogen peroxide) to remove the sulfur.
It then would be
homogenized, dewatered to a specific water %, and stored, usually by varietal.
[0098] The stored material could optionally be blended with other varietals
(if necessary) to
achieve a consistent flavour and nutrient profile. There may be an optional
homogenization step
after blending to stabilize to purée (keep the water from separating). This
step also may involve
dewatering. Once the objectives for the chemical characterization of the
nutrient-rich product
have been met, the material is considered to be final nutrient-rich product
236.
[0099] Step 4 Refined Nutrient-Rich Product Stabilization Process
[0100] During Step 4 238, the refined nutrient-rich product 236 is rendered
shelf-stable through
a heat treatment such as pasteurization or correction of pH level through
further fermentation in
order to convert the refined nutrient-rich product 236 into a stabilized
nutrient-rich product 240.
One skilled in the art will appreciate the qualities and characteristics of
the target final nutrient-
rich product, will know what criteria to look for at this stage of the process
and will make the
appropriate adjustments to generate an appropriate stabilized nutrient-rich
product 240.
[0101] There are applications for both a pasteurized purée (with no bioactive
materials) and a
probiotic purée. High-pressure pasteurization technology may optionally be
used to create a
pasteurized nutrient-rich product, although other current or future heat-
treatment/pasteurization
techniques may be employed. The bioactive purée will have been fermented to an
approved pH
level for sealed storage at room temperature, refrigerated temperature, and/or
frozen.
[0102] Step 5: Nutrient-Rich Product Packaging Process
[0103] During Step 5 242 the stabilized nutrient-rich product 240 is packaged
into consumer,
culinary and/or industrial vessels in order to convert the stabilized nutrient-
rich product 240 into
a packaged nutrient-rich product 244. It is then stored for shipment. The
stabilized nutrient-rich
27
Date recue/Date received 2023-05-04
product 240 could be in liquid, puree, paste or powder format based on the
needs of the end-user.
One skilled in the art will appreciate the qualities and characteristics for
the packaged nutrient-
rich product 244, will know what criteria to look for at this stage of the
process and will make
the appropriate adjustments to generate an appropriate.
[0104] The stabilized nutrient-rich product 240 may optionally be optimized
for extrusion into
sealed containers, which are specific to the industry and application using
it. For example, the
stabilized nutrient-rich product 240 may be extruded into consumer-sized
sealed jars or bottles to
generate packaged nutrient-rich product 244 designed for home use.
Alternatively, stabilized
nutrient-rich product 240 may be extruded into 4 liter /1 gallon sealed
containers to generate
packaged nutrient-rich product 244 designed for culinary use. Alternatively,
stabilized nutrient-
rich product 240 may be extruded into sealed 20 liter /5-gallon pails, or 1000-
liter Intermediate
Bulk Containers to generate packaged nutrient-rich product 244 designed for
industrial food
processing or pharmaceutical use.
[0105] The Nutrient-Rich Product
[0106] The nutrient-rich product can be used in food preparation, to: a)
reduce the amount of
sodium in a food formula; b) preserve dairy, meat, condiment and cereal
nutrient-rich products c)
enhance the flavour of fruits, vegetables, and spices within a food formula;
provide significant
nutrient value to a food formula; d) provide a source of yeast and other
bacteria to cause the
leavening of bread; e) provide a source of bacteria to cause the fermentation
of dairy nutrient-
rich products; and/or f) provide a source of bacteria to cause the
fermentation of plant-based
proteins.
[0107] The nutrient-rich product may also be used to provide a medium for
extraction of
nutrients for pharmaceutical use in addition to provide a medium for topical
applications in
cosmetics or skin therapy.
[0108] Acetic Acid Bacteria
28
Date recue/Date received 2023-05-04
[0109] The steps of the derivative-conversion require inoculation of microbial
formulation,
comprising acetic acid bacteria. One skilled in the art of fermentation would
know which one(s)
to select from the family of family Acetobacteraceae.
[0110] Acetic acid bacteria (AAB) are a group of rod-shaped, Gram-negative
bacteria which
aerobically oxidize sugars, sugar alcohols, or ethanol with the production of
acetic acid as the
major end nutrient-rich product. This special type of metabolism
differentiates them from all
other bacteria. The acetic acid bacteria consist of 10 genera in the family
Acetobacteraceae,
including Acetobacter. Species of Acetobacter include: A. ace!!; A.
cerevisiae; A. cibinongensis;
A. estunensis; A. fabarum; A. farinalis; A. indonesiensis; A. iambic!; A.
liquefaciens; A.
lovaniensis; A. malorum; A. must!; A. nitrogenifigens; A. oeni; A. okinawensis
; A. orientalis; A.
orleanensis; A. papaya; A. pasteurianus; A. peroxydans; A. persici; A.
pomorum; A.
senegalensis; A. sicerae; A. suratthaniensis; A. syzygii;A. thailandicus; A.
tropicalis; and A.
xylinus. Several species of acetic acid bacteria are used in industry for
production of certain
foods and chemicals.
[0111] The strains, which have been identified include: Acidibrevibacterium
Acidicaldus
Acidiphilium Acidisoma Acidisphaera Acidocella Acidomonas Ameyamaea Asaia
Belnapia
Bombella Caldovatus Commensalibacter Craurococcus Crenalkalicoccus; Dankookia
Elioraea
Endobacter Gluconacetobacter; Gluconobacter Granulibacter Humitalea
Komagatabacter
Komagataeibacter Kozakia Muricoccus Neoasaia Neokomagataea Nguyenibacter
Paracraurococcus; Parasaccharibacter. Although a variety of bacteria can
produce acetic acid,
mostly members of Acetobacter, Gluconacetobacter, and Gluconobacter are used
commercially.
One skilled in the art would know which one(s) to choose for the fermentation
processes
depending on the final nutrient-rich product they desire to generate.
[0112] Lactic Acid Bacteria
[0113] Lactic acid bacteria (LAB) are an order of gram-positive, acid-
tolerant, generally
nonsporulating, non-respiring, either rod-shaped (bacilli) or spherical
(cocci) bacteria that belong
29
Date recue/Date received 2023-05-04
to the order Lactobacillales and share common metabolic and physiological
characteristics.
Lactic acid bacteria are used in the food industry for a variety of reasons
such as the production
of cheese and yogurt nutrient-rich products. The genera that comprise the LAB
are at its core
Lactobacillus, Leuconostoc, Pediococcus, Lactococcus, and Streptococcus, as
well as the more
peripheral Aerococcus, Carnobacterium, Enterococcus, Oenococcus,
Sporolactobacillus,
Tetragenococcus, Vagococcus, and Weissella.
[0114] The Processing Container
101151 The system comprises one or more processing containers configured for:
ease of use to
collect fruit marc at a winery, the ability to conduct aerobic fermentation of
fruit marc in an
autonomous and/or semi-autonomous manner, requiring minimal oversight; and
conforms to the
minimal requirements for the food safety and quality regulations of the
jurisdictions in which the
ultimate products will be directly and/or indirectly sold.
[0116] One embodiment of the processing container's design features conforms
to the minimal
requirements for the food safety and quality regulations (e.g., as a
foodstuff, health supplement,
and/or a food ingredient). For example, the system is designed such that mold
and other
microbial contamination does not infiltrate the system and cause toxic
substances such as
mycotoxins and microbial volatile organic compounds (mVOC's) to contaminate
the ultimate
products of the system. For example, when constructing the system and
incorporating various
elements therein attention needs to be provided to all aspects, especially
those surfaces which are
hard to clean, for example, weld joints, which are somewhat rough and
sometimes may even
have excessive pitting, resulting in a portion of the weld joint which is very
hard to clean. Soil
and other impurities get trapped in this area and attract microbial growth.
This can become a
significant problem if not taken care of in the early stage of the microbial
growth. Thus, even the
welding of the container need follow the standards for the practice known as
sanitary welding, as
provided for by example, the American Welding Society (AWS).
[0117] In general, food processing operations and retailers must comply with
the various Hazard
Analysis Critical Control Point (HACCP) sanitary standards and regulations
promulgated by
Date recue/Date received 2023-05-04
various state and local Health Departments, Food processing operations are
certified by a third-
party agency who will list the sampling points and provide safety
certification. Examples of
certifications comprise Good Manufacturing Practices (GMP), HACCP or the
International
Standards Organization (ISO).
[0118] One embodiment of the design and construction of the processing
container could follow
the recommendations of 3-A Sanitary Standards, Inc. This organization
maintains a large
inventory of design criteria for equipment and processing systems developed
for the so-called
sanitary market using a modern consensus process based on ANSI requirements to
promote
acceptance by USDA, FDA and state regulatory authorities. One example pertains
to sanitary
rotary positive displacement pump types, which are designed with certain
common
characteristics to facilitate sanitation. Among these are an ability to
rapidly tear down or open the
fluid flow pathway of the pump for easy and thorough inspection and cleaning,
often without the
need for tools; the extensive use of stainless steels to assure non-
contaminating and non-
corroding liquid pumpage contact surfaces; the use of simple sanitary seal
structures; the
minimization or elimination of areas within the interior of the pump which
could cause
contamination of the pumpage; low RPM operation for gentle liquid handling;
ability to operate
at elevated temperatures; an ability to pump liquids ranging from very low
viscosity to very high
viscosity; and conformance to generally recognized sanitary standards,
particularly the Standards
For Centrifugal and Positive Rotary Pumps For Milk and Milk Products, 02-09,
as promulgated
in the US by the 3-A Sanitary Standards Symbol Administrative Council. This
standard applies
not only to dairy uses but also is the de facto standard for most sanitary
pump uses.
[0119] One embodiment of the processing container 300 is depicted in FIG. 8.
In one
embodiment, the processing container 300 is a version of a food-grade
intermediate bulk
container (IBC), commonly referred to as an IBC tote, with a holding capacity
of about 1,040 or
1,250 litres (275 and 330 US gal), capable of being stacked, which has been
appropriately
modified for use with the methods and processes within this system 200.
[0120] One embodiment of a processing container 300 comprises and inner compat
.. talent 330
and an outer support structure 302. The outer support structure has four
"walls" or cage-walls,
31
Date recue/Date received 2023-05-04
(front 304, back 306, right 308, left not shown or referenced), a rectangular
base 310, which are
all interconnected. The outer walls may be solid or cage-like, the latter
which is described in this
non-limiting embodiment. The base 310 may incorporate the function of a pallet
312 into the
structure of the outer base 310 of the support structure.
[0121] According to one embodiment, the inner compartment 330 has four walls
(only the right
side is visible in FIG 8), a retractable lid 334. which is attached via
hinging means 337 and
attached to the back wall of the inner compai tinent 330 of the processing
container 300. A top
access port 338 may be attached to the retractable lid 306, providing entry
into the inner
compartment 330, without having to retract the lid 334. The inner compai __
tnient 330 has a lower
access port 340, providing entry into the lower portion of the inner
compartment 330.
[0122] The container has an aerator 360, attached to support means 362, that
gains access to the
biomass through the lower access port 340, and forces air into the bottom of
the container
allowing air to percolate up through the mixture, encouraging aerobic
fermentation. The aerator
360 could either be powered via external electric power means 364 or
solar/battery power (not
shown).
[0123] Optionally, multiple sensory devices to monitor temperature, pH level
and Brix, as well
as other fermentation activities could be attached to the container, and could
optionally be
monitored by using WiFi. The optional monitors would either be powered via
external electric
power or solar/battery power.
[0124] The advantage of modified IBC totes is that most wineries already use
unmodified totes
and have equipment that allows them to move and stack them on their property.
The modified
totes can be sealed to minimize food contamination and placed in an external
part of the
property, either in or adjacent to the vineyard. One of the advantages of in-
vineyard placement is
CO2 sequestering by the vines and undergrowth. In one embodiment, the filled
processing
containers can be transferred to a centralized location such as a vacant field
or parking lot to
periodic monitoring during the fermentation period.
32
Date recue/Date received 2023-05-04
[0125] According to one embodiment, one or more processing container(s) 300
are delivered to a
winery prior to crush for integration into their winemaking and processing
facilities and
processes. The numbers of containers 300 would be based on the following
ratio: anticipated red
grape tonnage x 25%, which is the average percentage of marc 109 generated
during Step C 108.
[0126] The Use of the System
[0127] There are a number of different ways that the business structured the
relationship with a
winery to appropriately integrate the system, method, and processes described
herein in with the
processes and facilities of a winery.
[0128] One embodiment as outlined in FIG. 12, entails the following steps. At
step 602, a
business delivers one or more processing container(s) 300 to a winery prior to
crush. At step
604, winery staff transfers marc to one or more processing container(s) 300.
In one embodiment,
a business representative or employee will transfer marc to one or more
processing container(s)
300. At step 606, winery staff rehydrates marc until berries swell, optionally
grinds the biomass
into a meal, inoculates with microbials, and allows it to ferment at some
location either at, near
or remote from the winery facility. In one embodiment, a business
representative or employee
will rehydrate the marc until the crushed fruit (e.g., berries) swell,
optionally grinds the biomass
into a meal, inoculates with microbials, and allows it to ferment at some
location either at, near
or remote from the winery. In one embodiment, at step 608 winery staff
transfers lees to the one
or more processing container(s) 300 comprising fermenting meal. In one
embodiment, a
business representative or employee will inoculate and/or add lees to the
processing container(s)
300 at the appropriate time. At step 610 winery staff optionally emulsifies
the lees and
fermenting meal to generate purée, inoculates the purée and allows it to
ferment at winery
facility. In one embodiment, a business representative or employee will
optionally emulsify the
lees and fermenting meal to generate purée, inoculates the purée and allows it
to ferment at
winery facility or transfers the processing container to an off-site location.
At step 612 winery
staff monitors the progress of fermenting purée and notifies the company when
the fermentation
has completed. In one embodiment, a business representative or employee will
monitor the
progress of fermenting purée and notifies the company when the fermentation
has completed. At
33
Date recue/Date received 2023-05-04
step 614, the business picks up the one or more processing container(s) 300
and continues
processing the fermented purée at the business facility.
[0129] In one embodiment, the business and the winery may choose to further
process the
fermented purée at the winery facility. In one embodiment, the business may
choose to pick-up
the processing containers prior to adding the lees, and conduct the further
steps at the business
facility or at another location off-site from the primary business and
business processing center.
In one embodiment, the business may choose to collect the lees from the winery
when it is ready
and add it to the fermenting meal 212 in the processing container(s) 300 at
the business facility.
In one embodiment, the business may collect lees from one winery and use it in
different
fermentations.
[0130] One skilled in the art would appreciate that there are many different
ways that this
business relationship could be structured to optimize the resources of the
business and the
winery, such that these embodiments are considered to be non-limiting examples
of how the
work-flow of the business relationship could be designed.
[0131] One embodiment as described in Example 1, entails the business
delivering processing
containers to a winery prior to Step A 102 of the winemaking process, and
retrieving them after
fermentation has been completed and fermented purée 225 has been generated
within processing
container(s) 300. The business benefits by having the initial steps of the
process conducted on
site at the Winery. This point saves the business from having to construct
facilities on its
location for Steps 1 and 2, and can focus the design of the Business
facilities to processing the
various nutrient-rich products under GRAS Conditions.
[0132] The business could pay the winery for: a) the amount of properly
fermented purée
potentially adjusted for: i) level of solids with purée, ii) type of varietal
grapes used in the purée,
iii) whether the grapes are organic, iv) from a publicly recognized premium
district, estate or
vineyard, v) distance from the processing center; b) additional work or
services independent of
the amount of purée acquired, such as providing electrical power to the
location or providing
34
Date recue/Date received 2023-05-04
access to vineyard property during off hours.; and/or c) participating in
nutrient-rich product
development field testing.
[0133] In addition, the winery benefits by: a) reduction of waste and costs
associated therewith;
b) possibly the acquisition of Carbon Credits; c) an additional revenue
stream; d) incorporation
of named winery purée into premium foods; and/or e) eliminating methane
emissions caused by
disposal in buried landfills.
101341 The winery also benefits by diverting the substances from waste
management and
disposal processes to the conversion process, because these bioactive by-
products are subject to
numerous local health, environmental and worker safety regulations in the post-
production
treatment and disposal. The impact of these regulations on the winery are
minimized.
EXAMPLES
101351 Example I
[0136] With reference to Table 1 presented in FIG. 11, this example describes
one non-limiting
manner in which the system, methods, processes and nutrient-rich products 200
made thereby
can be incorporated into a winery producing grape wine. The Business is used
to denote the
business practicing the business methods described herein. The Winery is used
to denote the
wine production business within which this system, methods, and processes 200
is integrated.
[0137] PHASE I. AT THE WINERY
[0138] Table 1 presented in FIG. 11 shows the main stages in column 1, wherein
the employees
of the Winery (referred to herein as "cellar-hand") are instructed to perform
task(s) involved in
the processes of this system, methods, processes 200. The Business activities
are presented in
column 2, the Winery's activities in column 3, and estimated cellar-hand time
per container in
column 4. It is estimated that cellar-hand activities will be less than one
hour per container over
the z,=140 days that the containers are on site at the Winery.
Date recue/Date received 2023-05-04
[0139] Stage I. Pre-Crush
[0140] The Business drops processing containers 300 at the winery prior to
crush. The
processing container 300 may already have an initial microbial cocktail
encased in the interior
compaituient of the processing container 300, which will become activated once
water is added
to the processing container 300.
[0141] The numbers of processing containers 300 could be based on the
following ratio:
anticipated red grape tonnage x 25% (average percentage of marc 109). For
example, if a winery
accepts 100 tons of red grapes, the Business could deliver 25 processing
containers 300. Empty
processing containers 300 could be stacked 2¨ 3 high in a place where they
least impact crush
activities. One non-limiting example of where empty processing containers 300
could be stored
on the grounds of the Winery is illustrated in FIG. 1.
[0142] Stage II During Press (Crush): Transfer Marc to Processing Container
[0143] Pursuant to sub-step 202, the cellar-hand is instructed to collect,
transfer and deliver marc
109 generated during Step B 104 (crush), using a collection bin that is
normally used to collect
marc 109 from the press. Rather than discarding the marc 109 as per the usual
winemaking
process, wherein the marc 109 is usually dumped into a steel disposal bin, the
cellar-hand is
instructed to place the marc 109 into processing containers 300. The cellar-
hand is instructed to
fill the processing container 300 until the marc 109 fills up to the 800-1tr
level of the processing
container 300, and then instructed to add sufficient water to saturate and
cover the marc 109,
allowing the berries to swell as per sub-step 204, and to close and secure the
lid 334. This step
generally requires less than 6 minutes to for the cellar-hand to perform,
which is slightly longer
than if they were to dump the marc 109 into a disposal bin as per the
traditional process. After
the berries have swelled, the hydrated marc may be optionally macerated using
a motorized high-
sheer mixer that would break the seeds and skin. This accelerates the
fermentation process and
seed decomposition. This step may be delayed until after the lees are added.
36
Date recue/Date received 2023-05-04
[0144] If necessary, the cellar-hand can move and/or restack the processing
containers 300 to
minimize the impact of the presence of processing containers 300 on space
requirements of the
crush activities. One example of where processing containers 300 can be placed
is illustrated in
FIGS. 1, 9 and 10. The biomass in the processing containers 300 is allowed to
rest and begin
fermentation from natural bacteria and/or added microbials, while waiting for
first-rack lees 113.
[0145] Stage III: Transfer First Rack Lees to Processing Container
[0146] When Step E of the winemaking process is completed, the cellar-hand is
instructed to
collect and transfer the first-rack lees 113 to the processing container(s)
300, pursuant to sub-step
213 of the process. The time estimate for performing sub-step 213 is
approximately 1-2 minutes
x 19 ltr (five gallon) pails per container, which is generally takes less
amount of time than the
usual time required to dispose of first-rack lees 113. Once the lees are mixed
into the marc, the
combined material can be macerated using a high-sheer mixer, either for the
first time if this did
not happen in Stage II, of as secondary maceration to further break down the
purée.
[0147] Stage IV: Prior to Microbial Fermentation
[0148] After sub-step 224 has been performed, the cellar-hand is instructed to
place processing
container(s) 300 together in vineyard row(s) reasonably close to an electric
power source. The
cellar-hand is instructed to place processing container(s) 300 where it would
be convenient, and
where CO2 sequestering could be maximized. The more containers that are lined
up, the better as
they will maintain internal heat. A protective cover could then be placed over
a series of the
containers. The cover will be tamper-resistant, will capture solar heart, and
will retain heat from
both the fermentation process and solar capture. They can also be used as a
windbreak if
desired. One example of where processing containers 300 can be placed is
illustrated in FIGS. 1,
9 and 10. The cellar-hand is instructed to let processing container(s) 300
ferment for 60 ¨ 90
days.
[0149] Stage V: During Microbial Fermentation
37
Date recue/Date received 2023-05-04
[0150] During this fermentation period, the cellar-hand is instructed to
periodically check the PH
/ Brix measurements of the fermenting purée in the processing container(s)
300. Should the
purée in a specific container show signs of stabilization (pH and BRIX levels
stay constant for an
extended period), the winery would advise the Business of the situation.
[0151] Stage VI Post Microbial Fermentation
[0152] When the fermentation has been deemed to be finished, the Business
picks up the
processing container(s) 300 for processing at the Business facility. The
cellar-hand will
generally assist in this process, for example, using winery forklifts to
transfer the processing
container(s) 300 to the Business truck. This is likely 90 ¨ 120 day after marc
109 is pressed. For
example, if Merlot were pressed on Nov 1, the container could be ready between
Feb 1 and Mar
1. If Cabernet Sauvignon grapes were pressed Dec 1, the processing container
300 would be
ready for pick-up by the Business approximately March 1 ¨ April 1. The
processing container
300 would be ready for shipment from the winery to the Business at this time.
[0153] PHASE II: AT THE BUSINESS FACILITY
[0154] The fermented purée 225 is processed at the Business facility using
Business staff. In
brief, the steps generally include that Business staff: a) transfers the
processing containers to
Business facility; b) empties the contents of processing container(s) 300 into
a blending tank
with other varietals to achieve a consistent blend; c) emulsifies and
homogenize the fermented
purée 225 to mitigate and/or remove oversized grape seed husk; d) packages
stabilized nutrient-
rich product 240 new processing container(s) 300; and d) ships packaged
nutrient-rich product
244 to one or more food processor(s).
38
Date recue/Date received 2023-05-04
