Derivative works — US Patent 10912321

Defensive Disclosure and Prior Art Publication

Title: Methods, Systems, and Compositions for Controlled Hydration and Biocidal Treatment of Organic Tissues
Publication Date: April 26, 2026
Disclosure ID: DPD-ETCS-10912321-VAR

Abstract: This document discloses a series of derivative methods, systems, and applications related to the controlled hydration and antimicrobial treatment of porous organic materials, specifically animal tissues, by exposure to pH-modified peroxycarboxylic acid solutions. These disclosures are intended to enter the public domain and serve as prior art for future patent applications in this field. The variations expand upon the core principles of using alkaline peracetic acid (PAA) solutions by introducing alternative components, expanded operational parameters, cross-domain applications, integration with emerging technologies, and fail-safe operational modes.

Axis 1: Material & Component Substitution

1.1. Method Using Organic Amine Buffers for pH Control

Enabling Description: This method replaces common inorganic alkali sources (e.g., sodium hydroxide) with organic amine-based buffering agents for pH control in a poultry chill tank. A PAA solution is introduced into the chill tank water to a concentration of 20-200 ppm. The pH is then elevated and maintained in the range of 8.0 to 9.5 using a solution of tromethamine (Tris) or a combination of Tris and Bis-Tris. These organic buffers provide a high buffering capacity in the target pH range, offering more stable pH control against the influx of acidic biological matter from carcasses. The system uses an ion-selective electrode specifically calibrated for the chosen amine to monitor buffer concentration, in addition to a standard pH probe. The combination provides superior pH stability, which enhances the predictability of water uptake by muscle tissue.

flowchart TD
    A[Start: Poultry Carcasses Enter] --> B{Chill Tank with PAA Solution};
    B --> C[pH Sensor & Tris Concentration Sensor];
    C --> D{Control Logic Unit};
    D -- pH < 8.0 --> E[Dosing Pump: Tris/Bis-Tris Buffer];
    E --> B;
    D -- pH Stable --> F[Continue Chilling];
    F --> G[End: Hydrated & Disinfected Carcasses Exit];

1.2. In-Situ PAA Generation from Acetylated Polyols

Enabling Description: This variation generates PAA directly within the chill tank system using an acetylated polyol other than triacetin. The system utilizes glycerol diacetate (diacetin) as the acetyl precursor. A side-stream reactor is connected to the main chill tank circulation loop. In this reactor, diacetin is mixed with a 35% hydrogen peroxide solution at a molar ratio of 1:2.2 (diacetin:H2O2). The mixture is activated by passing it through a heated zone (50-60°C) containing a solid acid catalyst (e.g., Amberlyst-15 resin beads) to rapidly form a non-equilibrium PAA solution. This freshly generated PAA solution is then immediately injected back into the main chill tank, where a separate system controls the pH using potassium carbonate. This method allows for a more tunable PAA generation rate and avoids the transport and storage of liquid PAA concentrates.

sequenceDiagram
    participant MainLoop as Main Chill Tank Loop
    participant Reactor as Side-Stream Reactor
    participant Controller
    MainLoop->>Controller: Request PAA
    Controller->>Reactor: Initiate Generation Cycle
    Reactor->>Reactor: Pump Diacetin & H2O2
    Reactor->>Reactor: Pass mixture over Amberlyst-15 Catalyst at 55°C
    Reactor-->>MainLoop: Inject fresh PAA solution
    MainLoop->>MainLoop: Adjust pH with K2CO3

1.3. Water Treatment Using Ozonated Recycled Process Water

Enabling Description: This disclosure describes a method where the makeup water for the chill tank is sourced from pre-treated, recycled process water from other plant operations. The recycled water, high in organic load, first passes through a dissolved air flotation (DAF) unit to remove suspended solids. It is then injected with ozone (O3) at a concentration of 2-5 mg/L in a contact chamber to oxidize remaining organic contaminants and provide primary disinfection. This Ozonated Recycled Process Water (ORPW) is then used as the feed water for the PAA chill tank. The residual ozone catalytically decomposes, but the reduction in overall organic load decreases the demand on the PAA, allowing it to be effective at lower concentrations (15-50 ppm). The pH is subsequently adjusted to 8.5-9.5 with sodium hydroxide for tissue hydration. This integrated approach reduces fresh water consumption and overall chemical costs.

graph LR
    subgraph Water Pre-Treatment
        A(Recycled Process Water) --> B(DAF Unit);
        B --> C(Ozone Contact Chamber);
    end
    subgraph Main Process
        C --> D[PAA Chill Tank];
        E(PAA Concentrate) --> D;
        F(NaOH Solution) --> D;
    end
    G(Poultry In) --> D --> H(Poultry Out);

1.4. Non-Contact Optical pH and ORP Monitoring System

Enabling Description: The system for monitoring the chill tank environment is modified to use non-contact optical sensors, eliminating probe fouling. The internal walls of the chill tank and recirculation pipes are coated with a silicone film impregnated with pH-sensitive (e.g., Bromothymol Blue) and ORP-sensitive (e.g., N,N-diethyl-p-phenylenediamine, DPD) chromophores. An array of external LED emitters and photosensors is positioned outside the transparent sections of the piping. The system measures the change in light absorbance through the film, which correlates directly to pH and Oxidation-Reduction Potential. This provides a real-time, spatially distributed reading of the chemical environment without physical probes, increasing reliability and reducing maintenance in high-fat, high-protein water.

classDiagram
    class OpticalSensorArray {
        +ledEmitterID
        +photoSensorID
        +location
        +readAbsorbance()
    }
    class SensorFilm {
        +chromophoreType : String
        +substrate : String
    }
    class ControlUnit {
        -sensorDataMap
        +calculatepH_ORP()
        +triggerDosingPumps()
    }
    OpticalSensorArray "n" -- "1" ControlUnit : Sends Absorbance Data
    SensorFilm "1" -- "n" OpticalSensorArray : Is read by

Axis 2: Operational Parameter Expansion

2.1. Hyperbaric Immersion for Rapid Hydration

Enabling Description: This method applies the alkaline PAA treatment in a hyperbaric environment to accelerate water absorption. Poultry carcasses are processed in a batch-wise manner in a pressure vessel rated to 200-500 kPa (2-5 atmospheres). The vessel is filled with a PAA solution (50 ppm) at 2°C, and the pH is adjusted to 9.0. The vessel is then sealed and pressurized with sterile compressed nitrogen gas. The elevated pressure overcomes the natural osmotic resistance of the cell membranes, forcing the alkaline solution into the muscle tissue at an accelerated rate. Residence time is reduced from 45-60 minutes to 10-15 minutes to achieve the same target weight gain, significantly increasing throughput.

stateDiagram-v2
    [*] --> Idle
    Idle --> Filling: Load Carcasses
    Filling --> Pressurizing: Vessel Sealed, Add PAA/Alkali
    Pressurizing --> Holding: Reach 400 kPa
    Holding --> Depressurizing: Timer Expired (12 min)
    Depressurizing --> Draining: Reach Atmospheric Pressure
    Draining --> Idle: Unload Carcasses

2.2. pH Cycling to Maximize Water Retention

Enabling Description: Instead of maintaining a constant alkaline pH, this method employs a programmed pH cycling regimen. Carcasses move through a multi-zone chill tank. In Zone 1, the pH is held at 9.0 for 15 minutes to open the protein structure and induce swelling. In Zone 2, the pH is rapidly dropped to 6.5 by injecting a food-grade acidulant like citric acid. This change in pH alters the isoelectric point of the muscle proteins, trapping the absorbed water more effectively within the protein matrix. In Zone 3, the pH is returned to a moderately alkaline state (pH 8.0) for the final 15 minutes of chilling. This cycling creates an osmotic pumping effect that results in higher final retained water content post-chilling compared to a constant pH process.

flowchart LR
    A(Carcass In) --> B(Zone 1: pH 9.0, 15 min);
    B --> C(Zone 2: pH 6.5, 10 min);
    C --> D(Zone 3: pH 8.0, 15 min);
    D --> E(Carcass Out);
    
    subgraph Chemical Dosing
    F(NaOH Pump) --> B;
    G(Citric Acid Pump) --> C;
    H(NaOH Pump) --> D;
    end

2.3. Aerosolized Alkaline PAA Treatment of Individual Poultry Parts

Enabling Description: This disclosure details the application of the technology at a micro-scale for treating individual, cut-up poultry parts (e.g., tenders, wings, thighs). The parts travel on a conveyor belt through a chamber where an aerosolized solution of alkaline PAA is applied. The solution, containing 500 ppm PAA and buffered to a pH of 9.2 with potassium phosphate, is atomized into 20-50 micron droplets using ultrasonic nebulizers. This aerosol envelops the poultry parts, providing rapid surface disinfection and allowing for moisture absorption through exposed muscle tissue. The process is followed by a flash-chilling tunnel. This method is suitable for products where full immersion is undesirable and allows for precise control of final moisture content.

graph TD
    A[Poultry Parts on Conveyor] --> B[Aerosol Chamber];
    C[Ultrasonic Nebulizer Array] -- 500ppm PAA, pH 9.2 --> B;
    B --> D[Flash-Chilling Tunnel];
    D --> E[Packaging];

Axis 3: Cross-Domain Application

3.1. Aerospace: Rehydration System for Long-Duration Mission Foodstuffs

Enabling Description: This system adapts the principle for rehydrating and sterilizing dehydrated protein-based food bricks (e.g., meat, tofu) for astronauts. The food brick is placed in a sealed, flexible pouch. A pre-packaged ampoule containing a sterile, concentrated PAA/Tris-buffer mixture is broken inside the pouch, mixing with injected water. The resulting solution (10 ppm PAA, pH 8.5) rehydrates the food brick. The alkaline pH accelerates water uptake and tenderizes the protein matrix, improving palatability. The low PAA concentration ensures sterility without leaving harmful residuals. The entire process occurs within a contained pouch, minimizing free-floating liquids in a zero-gravity environment.

sequenceDiagram
    participant Astronaut
    participant RehydrationPouch
    participant WaterDispenser
    Astronaut->>RehydrationPouch: Insert Dehydrated Food Brick
    Astronaut->>WaterDispenser: Connect Pouch
    WaterDispenser-->>RehydrationPouch: Inject 150mL Sterile Water
    Astronaut->>RehydrationPouch: Crush internal PAA/Tris Ampoule
    RehydrationPouch->>RehydrationPouch: Solution forms (pH 8.5) and hydrates food

3.2. AgTech: Post-Harvest Turgor Enhancement for Leafy Greens

Enabling Description: This application aims to increase the shelf-life and marketable weight of harvested leafy greens (e.g., spinach, lettuce). Immediately after harvesting, the greens are immersed for 60-90 seconds in a cold water bath (4°C) containing a low concentration of PAA (5 ppm) and buffered to a pH of 8.2 using food-grade potassium bicarbonate. The slightly alkaline condition facilitates water uptake into the plant cells through the stomata, increasing turgor pressure and making the leaves appear crisper and fresher. The PAA provides surface disinfection, reducing spoilage from common agricultural bacteria. This "crisping" process adds 3-5% to the saleable weight and extends shelf stability by 2-3 days.

flowchart TD
    A[Harvested Lettuce] --> B{Immersion Tank};
    B -- Water @ 4°C, 5ppm PAA, pH 8.2 --> B;
    B -- Residence Time: 90s --> C[Dewatering Shaker];
    C --> D[Packaging];

3.3. Textiles: pH-Controlled Fiber Swelling in Leather Tanning

Enabling Description: This method is applied during the "bating" stage of leather production. After dehairing, raw hides are placed in a rotating drum filled with a solution containing 100 ppm PAA and a borax buffer to maintain a pH of 9.0. The alkaline environment causes the collagen fiber bundles within the hide to swell and separate, which is critical for achieving softness in the final product. The PAA serves as a powerful disinfectant to prevent bacterial putrefaction during this sensitive stage. This controlled, antimicrobial swelling allows for deeper and more uniform penetration of subsequent tanning agents, improving the quality and consistency of the finished leather.

graph LR
    A(Raw Hides) --> B(Rotating Drum);
    C(PAA/Borax Solution - pH 9.0) --> B;
    B -- Process Time: 4-6 hours --> D(Rinsing);
    D --> E(Tanning Stage);

Axis 4: Integration with Emerging Tech

4.1. AI-Driven Predictive Control of Hydration

Enabling Description: An AI control system optimizes the poultry chilling process in real-time. An input station uses a 3D vision system and hyperspectral imaging to determine the size, weight, and estimated fat/protein ratio of each carcass entering the chill tank. This data is fed to a machine learning model (e.g., a trained neural network) that predicts the optimal pH (within 8.0-9.5), PAA concentration (30-150 ppm), and residence time to achieve a target weight gain with minimal chemical usage. The model continuously adjusts the setpoints for the NaOH and PAA dosing pumps based on the real-time load and organic feedback from in-tank turbidity and ORP sensors.

flowchart TD
    A[Carcass In] --> B(3D & Hyperspectral Scanner);
    B -- Carcass Data --> C(AI Predictive Model);
    D[In-Tank Sensors: pH, ORP, Turbidity] -- Real-time Feedback --> C;
    C -- Optimal Setpoints --> E(Dosing Pump Controllers);
    E -- Control Signals --> F(NaOH & PAA Pumps);
    F --> G{Chill Tank};
    A --> G;
    G --> H[Carcass Out];

4.2. IoT Sensor Mesh for Spatio-Temporal Process Mapping

Enabling Description: A network of 50-100 wireless, battery-powered IoT sensor nodes is deployed throughout the primary chill tank. Each node is encapsulated in a food-safe, neutrally buoyant polymer sphere and contains sensors for pH, temperature, and ORP. The nodes move freely with the water flow. They communicate their readings and location (via low-power acoustic triangulation) to gateway receivers mounted on the tank exterior using the LoRaWAN protocol. The data is aggregated in a cloud platform to generate a real-time 3D map of the tank's chemical and thermal conditions, highlighting areas of poor circulation or insufficient disinfectant concentration. This allows for targeted adjustments to water jets or agitator speeds to ensure process uniformity.

erDiagram
    CHILL_TANK ||--o{ IOT_NODE : contains
    IOT_NODE {
        string nodeID
        float pH
        float temperature
        float ORP
        string location
    }
    GATEWAY ||--|{ IOT_NODE : receives_data_from
    GATEWAY {
        string gatewayID
        string location
    }
    CLOUD_PLATFORM ||--|{ GATEWAY : aggregates_from
    CLOUD_PLATFORM {
        string tankID
        json 3D_map_data
        timestamp lastUpdate
    }

4.3. Blockchain Ledger for Farm-to-Fork Process Verification

Enabling Description: A private blockchain (e.g., Hyperledger Fabric) is used to create an immutable record of the chilling process for each batch of poultry. When a batch enters the chill tank, a new block is initiated. The AI control system acts as an oracle, writing validated data points (e.g., average pH, min/max temperature, residence time, average weight gain) to the blockchain at set intervals. The final data is cryptographically signed. A QR code on the consumer packaging, compliant with the GS1 Digital Link standard, links to a public-facing web interface. Consumers can scan the code to query the blockchain and view the certified processing parameters for that specific batch, ensuring transparency and verifying claims of humane and safe processing.

sequenceDiagram
    participant VisionSystem
    participant AI_Controller
    participant Blockchain
    participant Consumer
    VisionSystem->>AI_Controller: Batch ID and Carcass Data
    AI_Controller->>Blockchain: Initiate New Block (Batch ID)
    loop Every 5 minutes
        AI_Controller->>Blockchain: Write Signed Data (pH, Temp, etc.)
    end
    AI_Controller->>Blockchain: Finalize and Seal Block
    Consumer->>Consumer: Scan QR Code on Package
    Consumer->>Blockchain: Query Batch ID
    Blockchain-->>Consumer: Display Certified Process Data

Axis 5: The "Inverse" or Failure Mode

5.1. Limited Functionality "Biocidal Rinse" Mode

Enabling Description: This describes a safe operational mode for periods of system maintenance or sensor failure. In this mode, the automated pH control is disabled. The PAA concentration is elevated to a fixed high level (e.g., 250 ppm) to ensure antimicrobial efficacy across a wider pH range. A slow-release, solid acid buffer (e.g., blocks of sodium bisulfate) is placed in the circulation system to maintain the pH in a slightly acidic range (5.0-5.5). In this state, water absorption by the carcasses is minimal, but FSIS pathogen control standards are still met. The system prioritizes food safety over the economic benefit of weight gain when full process control is not available.

stateDiagram-v2
    state "Normal Operation" as Normal {
        description "pH: 8.5-9.5, PAA: 50ppm"
    }
    state "Limited Functionality Mode" as Limited {
        description "pH: 5.0-5.5, PAA: 250ppm"
    }
    [*] --> Normal
    Normal --> Limited: Sensor Failure OR Manual Override
    Limited --> Normal: System Restored & Calibrated

5.2. Reversible Hydration for Product Specification Targeting

Enabling Description: This method allows for precise targeting of final product weight. First, the carcasses undergo the standard alkaline PAA hydration process (pH 9.0) to achieve maximum weight gain. After exiting the primary chill tank, they pass through a secondary, smaller "finishing chill tank." The water in this second tank contains a neutral pH but is a slightly hypertonic solution, created by adding a food-grade solute such as sodium lactate or potassium phosphate to an osmolarity of 300-400 mOsm/L. This controlled osmotic differential draws a predictable amount of the previously absorbed water out of the tissue. By adjusting the residence time in the finishing tank (3-10 minutes), the final weight can be precisely controlled to meet specific customer or product specifications (e.g., "Max 8% retained water").

flowchart TD
    A[Carcass In] --> B(Primary Chill Tank - pH 9.0);
    B -- Max Hydration --> C(Finishing Chill Tank - Neutral pH, Hypertonic);
    C -- Controlled Dehydration --> D(Dripline);
    D --> E[Final Packaging];

Combination Prior Art Scenarios

1. Integration with OPC Unified Architecture (OPC-UA): The entire poultry chilling system, including the PAA/alkali dosing pumps, pH/ORP/temperature sensors (whether optical or electrode-based), and control valves, is disclosed as a system where each component communicates via the open-source OPC-UA standard. The control unit acts as an OPC-UA server, exposing data tags for all process variables (e.g., Tank1.pH, Pump.NaOH.FlowRate). Any plant-wide SCADA or ERP system can act as an OPC-UA client to read and write to these tags, ensuring vendor-agnostic interoperability for process control and data logging.

2. Integration with MQTT for Lightweight Sensor Data Transmission: The IoT sensor mesh described in section 4.2 is implemented using the open-source MQTT (Message Queuing Telemetry Transport) protocol. Each sensor node acts as an MQTT client, publishing its data (e.g., { "nodeID": "A73F", "pH": 8.7, "temp": 1.5 }) to a specific topic (e.g., plant/chiller1/nodes/A73F). A central MQTT broker on the plant network receives these messages and forwards them to subscribers, such as the AI control system and the cloud data platform. This leverages a standard, low-power protocol ideal for wireless, battery-operated devices.

3. Integration with GS1 Digital Link for Supply Chain Traceability: The blockchain verification system described in section 4.3 is combined with the open GS1 Digital Link standard. The QR code on the final product is a valid URI structured as https://brand.example.com/gtin/01234567890123?batch=XYZ987. When a consumer's device resolves this URI, the brand's web service uses the batch number (XYZ987) to query its internal blockchain ledger and presents the immutable processing history for that specific batch in a human-readable format, creating a direct, standardized link between the physical product and its digital record.