Description:FIELD OF THE INVENTION
[0001] The present invention relates to the field of biowaste management. Specifically, the present invention relates to a continuous flow system for converting biowaste into high-quality biofeed. The system of the present invention integrates advanced pre-treatment technologies, biological optimization, and photo bioreactor cultivation of Spirulina and Chlorella, providing a sustainable and efficient biowaste management, while significantly enhancing the nutritional profile of the biofeed.

BACKGROUND OF THE INVENTION
[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] The global demand for sustainable and nutrient-rich animal feed continues to rise as a result of growing populations, increased demand for animal protein, and environmental pressures. Traditional feed sources rely heavily on grains and legumes, which contribute to deforestation, water overuse, and rising carbon emissions. In contrast, biowaste offers a vast, underutilized resource that can be converted into biofeed, reducing environmental impact and addressing waste management challenges.
[0004] However, current biowaste-to-biofeed conversion systems face several limitations, including:
● Slow Processing Times: Conventional methods such as composting and anaerobic digestion can take weeks or even months to convert biowaste, requiring significant space and infrastructure, making them inefficient for large-scale or time-sensitive applications.
● Inefficiencies in Nutrient Recovery: Nutrient retention is a major concern in existing conversion methods. The complex polymers in materials like bagasse, jute fibers, and agricultural residues resist breakdown, reducing the nutrient availability in the final biofeed.
● Difficulty in Handling Tough Organic Materials: Materials such as bones, egg shells, and fibrous plant residues (e.g., bagasse) are difficult to degrade biologically. Without proper pretreatment, these materials remain in the waste stream, compromising the quality of the resulting feed.
● Contamination and Feed Safety: Many biowaste streams contain pathogens, heavy metals, and other contaminants that require thorough detoxification. Current processes often fall short of completely eliminating these risks, leading to inconsistent feed quality.
● Lack of Sustainable Nutritional Enhancements: As the focus shifts toward producing nutrient-dense animal feed, especially in the aquaculture sector, the need for biofeed with added superfood qualities has become essential. Biofeed enriched with microalgae such as Spirulina and Chlorella has the potential to offer superior protein, vitamins, and essential fatty acids, improving animal health and growth.
[0005] Thus, there is an unmet need in the art to develop a biowaste management system that overcomes one or more drawbacks of traditional biowaste conversion methods.

OBJECTIVE OF THE INVENTION
[0006] An objective of the present invention is to provide a conversion of biowaste into biofeed through a continuous flow system using advanced pre-treatment technologies.
[0007] Another objective of the present invention is to provide a system that integrates mechanical, biological, and chemical treatments, utilizing a multistage bioreactor with innovations like biofloc technology, limestone, bagasse, and nano bubble generators to achieve efficient nutrient recovery and detoxification.
[0008] Another object of the invention is to provide a system that focuses on photobioreactor cultivation of Spirulina and Chlorella to enhance the nutritional profile of the final biofeed, making it suitable for both livestock and aquaculture.

SUMMARY OF THE INVENTION
[0009] The present invention relates to the field of biowaste management. Specifically, the present invention relates to a continuous flow system for converting biowaste into high-quality biofeed. The system of the present invention integrates advanced pre-treatment technologies, biological optimization, and photo bioreactor cultivation of Spirulina and Chlorella, providing a sustainable and efficient biowaste management, while significantly enhancing the nutritional profile of the biofeed.
[0010] In an aspect, the present invention provides a continuous flow system for converting biowaste into biofeed, comprising the steps of:
a) collecting and pretreating biowaste by subjecting to mechanical shredding and grinding to achieve a uniform particle size;
b) following mechanical treatment, the biowaste is subjected to biological and microbiological pretreatment to increase the efficiency of the biowaste breakdown and nutrient yield;
c) detoxifying chemically, post-biological treated biowaste to eliminate pathogens and residual organic pollutants, ensuring the safety and quality of the final biofeed product;
d) subjecting the chemical treated biowaste to physical treatments, namely hydrodynamic cavitation and ultrasonic treatment to enhance nutrient extraction and improve the efficiency of microbial digestion;
e) transferring the pretreated biowaste to a multistage bioreactor (MSBR), with integrated biofloc technology and substrates to facilitate continuous nutrient cycling and effective organic matter degradation;
f) detoxifying pretreated biowaste by inclusion of resins in the multistage bioreactor (MSBR) to enhance nutrient retention by removal of heavy metals and specific toxins;
g) integrating photobioreactor to cultivate Spirulina and Chlorella using nutrients derived from the biowaste;
h) adding enzymes, probiotics and mineral enhancements in the polishing stage to enhance the digestibility and nutrient value of the final biofeed product; and
i) packing the polished biofeed in eco-friendly, moisture-resistant bags to maintain quality during storage and transportation.
[0011] In another aspect of the present invention, the biowaste is collected from sources selected from agricultural residues (crop leftovers and fibrous plant materials), kitchen waste (food scraps and organic matter) and tough organic materials (bones, eggshells).
[0012] In another aspect of the present invention, the biological and microbiological pretreatment is done using substrates selected from limestone, bagasse, nano charcoal and biochar or a combination thereof.
[0013] In another aspect of the present invention, the microbiological pretreatment is done by inoculating a consortium of bacteria, fungi, and algae to efficiently degrade various types of organic waste.
[0014] In another aspect of the present invention, a consortium of microorganisms comprises Bacillus subtilis, Trichoderma harzianum, Aspergillus niger and Lactobacillus plantarum.
[0015] In another aspect of the present invention, the chemical detoxification is carried out using hydrogen peroxide (H₂O₂) and sodium peroxide (Na₂O₂).
[0016] In another aspect of the present invention, the ultrasonic treatment is carried out at frequencies ranging from 1 kHz to 100 kHz to achieve targeted cellular disruption and homogenization.
[0017] In another aspect of the present invention, the low frequencies (1-20 kHz) produce intense cavitation, effectively rupturing cell walls to release nutrients and higher frequencies (20-100 kHz) to produce controlled cavitation, ensuring uniform particle size and homogenizes the mixture.
[0018] In another aspect of the present invention, the pH is maintained in the range of 6.5 to 7.5.
[0019] In another aspect of the present invention, the bioreactor is housed within aluminum tanks, complemented by the external aluminum comb heat exchange system and insulation, utilizing geothermal energy for temperature management.
[0020] In another aspect of the present invention, the nano bubble generators are integrated within the bioreactor to provide sustained high levels of dissolved oxygen, maintaining optimal aerobic conditions for microbial activity.
[0021] In another aspect of the present invention, the hyperbaric oxygen conditions are maintained at a pressure range of 1 to 3 bar.
[0022] In another aspect of the present invention, the substrates integrated in the bioreactor are organic substrates selected from jute fibers, coconut powder, and bagasse or a combination thereof.
[0023] In another aspect of the present invention, the probiotics added during the polishing stage are selected from Lactobacillus acidophilus, Bifidobacterium bifidum, and Enterococcus faecium or a combination thereof.
[0024] In another aspect of the present invention, the enzymes added during the polishing stage are selected from amylases, proteases, lipases and cellulases or a combination thereof.
[0025] In another aspect, the present invention relates to a continuous flow process for converting biowaste into biofeed using a hybrid bioreactor system that integrates multi-organism microbial consortia, biofloc technology, nano bubble generators, enzymatic hydrolysis, and detoxification methods utilizing ion-exchange resins, biochar, nano charcoal, bagasse, and coconut powder.
[0026] Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments.

BRIEF DESCRIPTION OF FIGURES
[0027] Figure 1 depicts the schematic layout for the continuous flow system for converting biowaste into biofeed of the present invention.
[0028] Figure 2 depicts a representative stirrer, a component present in every chamber of the continuous flow system for converting biowaste into biofeed.
[0029] Figure 3 depicts an outside view of the continuous flow system setup.
DETAILED DESCRIPTION OF THE INVENTION
[0030] The following is a full description of the disclosure's embodiments. The embodiments are described in such a way that the disclosure is clearly communicated. The level of detail provided, on the other hand, is not meant to limit the expected variations of embodiments; rather, it is designed to include all modifications, equivalents, and alternatives that come within the spirit and scope of the current disclosure as defined by the attached claims. Unless the context indicates otherwise, the term "comprise" and variants such as "comprises" and "comprising" throughout the specification are to be read in an open, inclusive meaning, that is, as "including, but not limited to."
[0031] When "one embodiment" or "an embodiment" is used in this specification, it signifies that a particular feature, structure, or characteristic described in conjunction with the embodiment is present in at least one embodiment. As a result, the expressions "in one embodiment" and "in an embodiment" that appear throughout this specification do not necessarily refer to the same embodiment. Furthermore, in one or more embodiments, the specific features, structures, or qualities may be combined in any way that is appropriate.
[0032] Unless the content clearly demands otherwise, the singular terms "a," "an," and "the" include plural referents in this specification and the appended claims. Unless the content explicitly mandates differently, the term "or" is normally used in its broad definition, which includes "and/or."
[0033] All processes described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
[0034] The headings and abstract of the invention provided herein are for convenience only and do not interpret the scope or meaning of the embodiments.
[0035] All publications herein are incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.
[0036] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description that follows, and the embodiments described herein, is provided by way of illustration of an example, or examples, of particular embodiments of the principles and aspects of the present disclosure. These examples are provided for the purposes of explanation, and not of limitation, of those principles and of the disclosure.
[0037] It should also be appreciated that the present invention can be implemented in numerous ways, including as a system, a method or a device. In this specification, these implementations, or any other form that the invention may take, may be referred to as processes. In general, the order of the steps of the disclosed processes may be altered within the scope of the invention.
[0038] Various terms as used herein are shown below. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.
[0039] In a general embodiment, the present invention relates to a continuous flow system for converting biowaste into high-quality biofeed. The system of the present invention integrates advanced pre-treatment technologies, biological optimization, and photo bioreactor cultivation of Spirulina and Chlorella, providing a sustainable and efficient biowaste management, while significantly enhancing the nutritional profile of the biofeed.
[0040] In another embodiment, the present invention provides a continuous flow process for converting biowaste into biofeed using a hybrid bioreactor system that integrates multi-organism microbial consortia, biofloc technology, nano bubble generators, enzymatic hydrolysis, and detoxification methods utilizing ion-exchange resins, biochar, nano charcoal, bagasse, and coconut powder. This system combines multiple advanced technologies in a continuous flow configuration, significantly enhancing the speed and efficiency of biowaste conversion while enriching nutrient profiles with natural substrates.
[0041] In an embodiment, the present invention provides a continuous flow system for converting biowaste into biofeed, comprising the steps of:
a) collecting and pretreating biowaste by subjecting to mechanical shredding and grinding to achieve a uniform particle size;
b) following mechanical treatment, the biowaste is subjected to biological and microbiological pretreatment to increase the efficiency of the biowaste breakdown and nutrient yield;
c) detoxifying chemically, post-biological treated biowaste to eliminate pathogens and residual organic pollutants, ensuring the safety and quality of the final biofeed product;
d) subjecting the chemical treated biowaste to physical treatments, namely hydrodynamic cavitation and ultrasonic treatment to enhance nutrient extraction and improve the efficiency of microbial digestion;
e) transferring the pretreated biowaste to a multistage bioreactor (MSBR), with integrated biofloc technology and substrates to facilitate continuous nutrient cycling and effective organic matter degradation;
f) detoxifying pretreated biowaste by inclusion of resins in the multistage bioreactor (MSBR) to enhance nutrient retention by removal of heavy metals and specific toxins;
g) integrating photobioreactor to cultivate Spirulina and Chlorella using nutrients derived from the biowaste;
h) adding enzymes, probiotics and mineral enhancements in the polishing stage to enhance the digestibility and nutrient value of the final biofeed product; and
i) packing the polished biofeed in eco-friendly, moisture-resistant bags to maintain quality during storage and transportation.
[0042] In another embodiment of the present invention, the biowaste is collected from sources selected from agricultural residues (crop leftovers and fibrous plant materials), kitchen waste (food scraps and organic matter) and tough organic materials (bones, eggshells).
[0043] In another embodiment of the present invention, the biological and microbiological pretreatment is done using substrates selected from limestone, bagasse, nano charcoal and biochar or a combination thereof.
[0044] In another embodiment of the present invention, the biowaste undergoes initial mechanical grinding, biological, and chemical pre-treatment stages to reduce particle size, initiate decomposition, and prepare complex materials (e.g., lignocellulosic compounds) for further processing. Adjustments to pH and selective chemical agents are applied to enhance the subsequent breakdown of materials.
[0045] In another embodiment of the present invention, the process integrates mechanical, biological, and chemical pre-treatment, hydraulic cavitation, ultrasonic treatment, advanced biofloc technology, anaerobic and aerobic processes, enzyme production, and final polishing steps (Figure 1). The following steps cover the entire process:
1. Mechanical Treatment includes shredding, grinding, and milling to reduce particle size. It breaks down raw biowaste into smaller, manageable fragments for downstream processing. The particle size objective is >1000 µm. The conditions are ambient pressure, moderate temperature (25-40°C). The output is coarse slurry with large biowaste fragments and fibrous material.
2. Enzyme Electrolysis includes enzymatic hydrolysis using enzymes (cellulase, protease, lipase) to degrade fibers, proteins, and fats. It partially breaks down or loosen complex organic molecules into simpler, bioavailable nutrients. Remove COD, partially loosen complex organic molecules, and enable toxin absorption. The particle size objective is 20-10 µm. The conditions are Controlled pH (6.5-7.0) and temperature (50-60°C). The output is Amino acids, sugars, and fatty acids.
3. Targeted Fermentation includes anaerobic fermentation targeting cellulose, proteins, and lipids. It converts complex organic molecules into simpler, bioavailable nutrients like amino acids and sugars. Remove COD, partially loosen complex organic molecules, absorb toxins, and produce volatile fatty acids (VFAs) and other bioactive compounds through microbial activity. The particle size objective is not specified; nutrient breakdown is the primary goal. The conditions are anaerobic environment, 35-40°C, vacuum-sealed chambers. The output is volatile fatty acids (VFAs), amino acids, and bioactive compounds.
4. Microbiological Detoxification and Hydraulic Cavitation includes microbial detoxification followed by high-pressure hydraulic cavitation. It removes toxins and enhances nutrient bioavailability through cell disruption and detoxification. The particle size objective is 50-20 µm. The conditions are hyperbaric pressure (1-3 bar), 35-40°C. The output is detoxified slurry free of toxins, with enhanced nutrient bioavailability.
5. Chemical Treatment includes oxidation using ozone (O₃), hydrogen peroxide (H₂O₂), or sodium peroxide (Na₂O₂). It breaks down recalcitrant organics and stabilizes the slurry by oxidizing harmful compounds. The particle size objective is 20-10 µm. The conditions are an oxidative environment, pH 7-8. The output is detoxified slurry with enhanced bioavailability.
6. Secondary Enzyme Electrolysis includes further enzymatic hydrolysis to solubilize nutrients. It extracts and concentrates bioavailable nutrients such as amino acids and VFAs. The particle size objective is 10-5 µm. The conditions are controlled by pH and temperature (50-60°C). The output is Solubilized nutrients such as amino acids and VFAs.
7. Secondary Targeted Fermentation includes final microbial fermentation. It degrades residual organic material to generate bioactive metabolites. The particle size objective is 5-1 µm. The conditions are anaerobic environment, 35-40°C. The output is fully degraded organic slurry.
8. Secondary Detoxification includes further detoxification using advanced chemical or biological methods. It removes any remaining toxins and stabilizes the slurry further. The particle size objective is <1 µm. The conditions are an oxidative or microbial detoxification environment. The output is fully stabilized and detoxified slurry.
9. Buffer Tank includes temporary storage for slurry stabilization. It allows for pH and temperature equilibrium before further processing. The particle size objective is not applicable; stabilization only. The conditions are controlled temperature and pH.
10. High-Pressure Homogenization and Ultrasonic Treatment includes homogenization to micronize nutrients and ultrasonic treatment for enhanced molecular breakdown. It achieves molecular-level breakdown of nutrients for higher bioavailability. The particle size objective is 1-0.1 µm. The conditions are high pressure (20-40 bar) and ultrasonic frequencies. The output is micronized and molecularly enhanced nutrients.
11. Chemical Treatment and Vacuum Tank for Oxygen Removal includes chemical stabilization followed by vacuum treatment to remove oxygen. It prevents oxidation and stabilizes the slurry for anaerobic fermentation. The particle size objective is not specified; oxygen removal is the primary goal. The conditions are a vacuum-sealed environment. The output is oxygen-free, stabilized slurry.
12. Targeted Anaerobic Fermentation includes fermentation under strict anaerobic conditions to produce bioactive compounds. It controls the process to avoid release of useful nutrients, such as carbon, in the form of CO₂, H₂S, or hydrogen. The particle size objective is molecular level breakdown. The conditions are anaerobic environment, 35-40°C. The output is VFAs and other bioactive metabolites.
13. Oxygenation and Buffering Tank includes oxygenation and buffering for aerobic fermentation preparation. It ensures proper oxygenation and pH adjustment for aerobic processes. The particle size objective is not applicable; oxygenation only. The conditions are controlled oxygen levels and pH.
14. Controlled Oxygen Aerobic Fermentation, Buffering, and Oxygenation Tank includes aerobic fermentation to produce bioactive compounds and metabolites. This step is done under highly limited oxygen to avoid any conversion of useful simplest nutrients to any other form. The particle size objective is Molecular level. The conditions are controlled oxygen levels, 25-35°C. The output is bioactive compounds, amino acids, and metabolites.
15. Enzyme Production, Algae Production, and Biofloc Production Mixing includes mixing for integrated production of enzymes, algae (e.g., Chlorella, Spirulina), and biofloc. It is distributed into three parts as defined. The particle size objective is not applicable; product mixing. The output is high-value products for food, feed, and industrial applications.
16. Filtration, Drying, and Packaging includes vacuum ceramic filtration to remove water and impurities. It concentrates and purifies the final product for drying and packaging. The particle size objective is <0.01 µm. Solar drying under controlled conditions. Packing with secure biodegradable materials for storage and transport.
[0046] In another embodiment of the present invention, the microbiological pretreatment is done by inoculating a consortium of bacteria, fungi, and algae to efficiently degrade various types of organic waste. Preferably, the consortium of microorganisms comprises Bacillus subtilis, Trichoderma harzianum, Aspergillus niger and Lactobacillus plantarum.
[0047] In another embodiment of the present invention, the system utilizes high-surface-area biomedia, like Mutag BioChip, which provides an extensive surface area for microbial colonization. The biomedia significantly improves microbial biofilm formation, nutrient cycling, and organic matter degradation, increasing the efficiency of the biowaste breakdown and nutrient yield.
[0048] In another embodiment, the present invention provides a novel method for COD removal during biological pretreatment, using chemical agents and the presence of biochar to reduce organic pollutant loads prior to microbial degradation.
Unlike traditional methods, this invention introduces a COD removal phase integrated within biological pretreatment, enhanced by biochar, leading to cleaner feedstock and improved microbial digestion efficiency.
[0049] In another embodiment of the present invention, the chemical detoxification is carried out using hydrogen peroxide (H₂O₂) and sodium peroxide (Na₂O₂).
[0050] In another embodiment of the present invention, the hydraulic cavitation is applied following pre-treatment to further reduce particle size, improving accessibility for microbial and enzymatic treatment. This minimizes power requirements for ultrasonic treatment by breaking down particles more efficiently before introducing ultrasonic waves, making it highly energy-efficient.
[0051] In another embodiment of the present invention, the ultrasonic treatment is carried out at frequencies ranging from 1 kHz to 100 kHz to achieve targeted cellular disruption and homogenization. Ultrasonic treatment across a frequency range (1-100 kHz) achieves precise cell disruption and consistent particle homogenization, increasing nutrient bioavailability and producing a uniform biofeed product. Further, the low frequencies (1-20 kHz) to produce intense cavitation, effectively rupturing cell walls to release nutrients and higher frequencies (20-100 kHz) to produce controlled cavitation, ensuring uniform particle size and homogenizes the mixture, enhancing nutrient bioavailability and consistency in the final biofeed product.
[0052] In another embodiment, the present invention provides a process for optimizing particle size in biowaste prior to microbial processing by employing hydraulic cavitation and variable frequency ultrasonic treatment, enhancing the breakdown of organic materials and increasing their surface area for microbial degradation. Nutrient-rich substrates, such as bagasse and coconut powder, are incorporated to further enhance the nutrient profile of the biowaste. This introduces a unique integration of hydraulic cavitation and variable frequency ultrasonic treatment specifically designed to improve particle size and surface area, facilitating enhanced microbial access and degradation. The inclusion of nutrient-rich substrates ensures an optimal environment for microbial activity, setting it apart from conventional methods.
[0053] In another embodiment, the present invention provides a pretreatment process that combines mechanical size reduction, biological treatment, chemical detoxification, and physical treatments (hydrodynamic cavitation and ultrasonic waves) to prepare biowaste for microbial processing, incorporating biochar and nano charcoal to enhance treatment efficiency. The synergistic use of cavitation and ultrasonic treatments, alongside chemical detoxification with biochar and nano charcoal, enhances nutrient release and improves microbial efficiency.
[0054] In another embodiment, the present invention incorporates advanced biofloc technology within the bioreactor, which cultivates beneficial microbial communities that recycle nutrients and improve organic matter degradation. The biofloc system boosts microbial activity, enhances water quality, and reduces waste in the system. Specific microorganisms such as Bacillus subtilis, Trichoderma harzianum, Aspergillus niger, and Lactobacillus plantarum are introduced to target specific biowaste components, maximizing nutrient release, organic matter breakdown, and biofeed quality.
[0055] In another embodiment, the present invention provides a system utilizing a consortium of bacteria, fungi, and algae to efficiently degrade various types of organic waste, including those enhanced with bagasse and coconut powder as nutrient substrates. Targeting specific waste materials with specialized microorganisms and incorporating nutrient-rich substrates optimizes the bioconversion process. The incorporation of biofloc technology to enhance microbial interaction and nutrient cycling within the bioreactor, utilizing substrates like bagasse and coconut powder to support microbial colonization. Biofloc technology improves microbial efficiency, creating a more dynamic environment for waste degradation, particularly when supported by carbon-rich substrates.
[0056] In another embodiment of the present invention, combining advanced biofloc technology, high-surface-area biomedia, and ultrasonic treatment ensures high nutrient recovery, yielding a biofeed that is nutrient-dense and bioavailable. Advanced biofloc technology not only enhances microbial activity but also improves water quality, reducing waste and maintaining a stable bioreactor environment, which supports higher nutrient recovery and quality in the biofeed.
[0057] In another embodiment of the present invention, the multi-stage membrane filtration system is designed to optimize the biowaste-to-biofeed conversion process by integrating sequential filtration stages—microfiltration, ultrafiltration, and nanofiltration, each serving a specific purpose. Microfiltration removes coarse debris, ensuring smooth processing in subsequent stages. Ultrafiltration concentrates nutrients by separating smaller bioavailable molecules like amino acids and sugars from suspended solids. Nanofiltration focuses on selectively allowing the simplest nutrients to pass through while retaining complex molecules within the stage until they are adequately processed and reduced to the desired form. Additionally, detoxification of the biofeed, including the removal of heavy metals and toxins, is achieved through ion-exchange resins and nano charcoal rather than filtration. The system operates continuously with recycling mechanisms for undigested materials, ensuring complete conversion and maximum nutrient recovery, offering a sustainable and efficient solution for high-quality biofeed production.
[0058] In another embodiment of the present invention, the comprehensive process integrates mechanical, biological, and chemical pre-treatment, hydraulic cavitation, ultrasonic treatment, advanced biofloc technology, targeted anaerobic and aerobic processes, enzyme production, and final polishing steps. The design includes nano-bubble aeration, pouches for pH control and toxin removal, and membrane filtration at various stages. The biowaste-to-biofeed process is maintained as a continuous bioreactor system through the integration of gravity-driven and pressure-driven membrane filtration at various stages. This ensures uninterrupted processing and optimal separation of components. It incorporates specialized components and membrane types at every stage, ensuring maximum nutrient recovery, detoxification, and biofeed production (Table 1).
● Mechanical Pre-Treatment wherein there is no filtration and preparation phase. Process is shredding and grinding to create a slurry for downstream filtration.
● Biological Pre-Treatment wherein membrane type is microfiltration (100-50 µm). Process is the slurry passes through microfiltration membranes to remove large debris and maintain continuous flow under gravity.
● Chemical Pre-Treatment wherein membrane type is ultrafiltration (50-30 µm). Process is an oxidized slurry undergoes ultrafiltration to remove suspended solids while allowing soluble organics and nutrients to pass through.
● Enzymatic Hydrolysis wherein membrane type is ultrafiltration (30-20 µm). The hydrolyzed slurry is filtered to concentrate amino acids and sugars while recycling undigested materials back into the system.
● Targeted Limited Fermentation wherein membrane type is nanofiltration (20-5 µm). The fermented slurry undergoes nanofiltration to retain volatile fatty acids (VFAs) while removing residual toxins.
● Microbiological Detoxification & Hydraulic Cavitation wherein membrane type is nanofiltration (5-1 µm). Process is toxins and microbial residues are filtered out using high-pressure-driven nanofiltration membranes, maintaining continuous slurry flow.
● Chemical Treatment (Secondary) wherein membrane type is nanofiltration (<1 µm). Process is further polishing removes fine toxins, heavy metals, and micropollutants.
● Secondary Enzymatic Hydrolysis wherein membrane type is ultrafiltration (0.5-0.1 µm). Process concentrates bioavailable nutrients such as amino acids and VFAs while recycling undigested material.
● Secondary Targeted Fermentation wherein membrane type is reverse osmosis (<0.1 µm). Process separates bioavailable compounds from waste residues, ensuring maximum nutrient recovery.

Table 1
Step Process Particle Size After Process Outputs Optimized Membrane Type Proposed Pore Size (µm) Evaluation and Adjustments
1 Mechanical Treatment 500–100 µm Slurry with hydrated particles Microfiltration 100–50 Valid: Removes large debris
2 Enzymatic Hydrolysis 100–50 µm Solubilized proteins, VFAs Microfiltration 50–30 Adjust: Finer filtration for better isolation
3 Targeted Fermentation 50–20 µm VFAs, sugars, organics Ultrafiltration 30–20 Valid: Captures microbial cells
4 Detoxification 20–10 µm Detoxified slurry Nanofiltration 10–5 Adjust: Enhanced impurity removal
5 Hydraulic Cavitation 10–5 µm Intracellular nutrients released Microfiltration 5–3 Valid: Efficient cell rupture
6 Chemical Treatment 5–2 µm Stabilized slurry Nanofiltration 2–1 Adjust: Finer residue removal
7 Secondary Hydrolysis 2–1 µm Proteins, VFAs Ultrafiltration 1–0.5 Valid: Retains undigested material
8 Secondary Fermentation 1–0.5 µm VFAs, amino acids, sugars Ultrafiltration 0.5–0.2 Valid: Separates microbial biomass
9 Detoxification (2) 0.5–0.1 µm Purified slurry Nanofiltration 0.3–0.1 Adjust: Fine-level purification
10 High-Pressure Homogenization 0.5–0.1 µm Micronized nutrients Ultrafiltration 0.2–0.1 Adjust: Better particle isolation
11 Ultrasonic Treatment 0.1–0.01 µm Molecular nutrients Nanofiltration 0.05–0.01 Valid: Molecular-level purification
12 Anaerobic Fermentation 0.01–0.005 µm VFAs, gases, biomass Microfiltration 0.01–0.005 Valid: Biomass separation
13 Aerobic Fermentation 0.005–0.001 µm Amino acids, metabolites Ultrafiltration 0.005–0.001 Valid: Isolates bioactive compounds

[0059] In another embodiment of the present invention, the biowaste-to-biofeed conversion process from Biological Pre-Treatment to nutrient separation into three specialized outputs operates as a continuous bioreactor due to automatic material transfer facilitated by gravity- and pressure-driven membrane filtration. The Core Principles are:
● Automated Transfer through Membrane Filtration: At each filtration stage, the slurry passes through membranes with progressively smaller pore sizes. Larger particles that cannot pass through remain in the current chamber for further processing. Fully processed slurry with the desired particle size automatically moves to the next stage.
● Gravity-Driven Filtration: Gravity pulls the slurry downward through the membranes in the initial biological, chemical, and enzymatic pre-treatment stages. This passive flow reduces energy consumption while ensuring continuous material processing.
● Pressure-Driven Filtration: Advanced stages like nanofiltration, reverse osmosis, and vacuum ceramic filtration use applied pressure to force the slurry through fine membranes. This ensures precise nutrient separation while maintaining high throughput.
● Integrated Recycling System: Rejected materials are continuously recycled back into earlier processing chambers, allowing complete material utilization. This feedback loop prevents blockages and maximizes nutrient extraction.
● Seamless Flow Maintenance: By designing filtration as a staged, self-regulating process, each phase transitions into the next without manual intervention. The automated slurry flow ensures minimal downtime and consistent output quality.
With these integrated systems, the biowaste-to-biofeed process functions as a fully continuous bioreactor, supporting uninterrupted nutrient conversion, filtration, and separation from initial pre-treatment to final product packaging.
[0060] In another embodiment of the present invention, the stirrer systems (Figure 2) are specialized systems designed for cultivating microorganisms, cells, or biochemical processes under controlled conditions. Below is a detailed explanation of the components and their functions:
1. Pressure-Resistant Vessel: Contains the fermentation process under controlled high-pressure conditions. Constructed from stainless steel 316L or other high-grade alloys. Designed to withstand pressures up to 10 bar. Ensures safety and durability during high-temperature enzyme fermentations. The pressure-resistant vessel serves as the backbone of the Stirrer System, providing a robust and safe environment for high-pressure fermentation. It prevents leaks and ensures the integrity of the system under extreme conditions.
2. Motor: Drives the impeller for effective mixing and aeration. Integrated with mechanical seals to prevent leaks under pressure. The motor ensures continuous and consistent mixing of the culture medium, facilitating uniform nutrient distribution and oxygenation.
3. Impellers: Mixes the culture medium to evenly distribute nutrients and oxygen. Enhanced blade designs for efficient mixing. Supports mini, macro, and nano bubble distribution. Impellers play a vital role in maintaining homogeneous conditions, crucial for optimal microbial growth and biochemical reactions.
4. pH Probe: Monitors and controls the pH levels within the Stirrer System. Integrated with automated systems for pH adjustments. The pH probe ensures that the environment remains conducive to enzyme activity and microbial growth by maintaining optimal acidity or alkalinity levels.
5. Dissolved Oxygen Probe: Measures and monitors dissolved oxygen levels. Compatible with high-pressure conditions. Works in conjunction with the aeration system. This probe ensures adequate oxygen levels are maintained, which is critical for aerobic fermentation processes.
6. Advanced Aeration System: Supplies oxygen using mini, macro, and nano bubble technology. Mini Bubbles provide initial oxygenation for high-demand phases. Macro Bubbles deliver rapid oxygen during peak fermentation. Nano Bubbles enhance oxygen solubility for prolonged durations. The aeration system is critical for efficient gas transfer, ensuring that microorganisms receive sufficient oxygen to sustain their activity.
7. Blower Unit: Supplies compressed air or gas for aeration. Modified for high-pressure airflow. The blower works in tandem with the aeration system to maintain a steady supply of air or gas, facilitating effective oxygen transfer.
8. Air Filter: Prevents contamination by filtering incoming air. Sterile-grade filters suitable for compressed gases. Air filters ensure that only sterile air enters the Stirrer System, minimizing the risk of contamination.
9. Gas Supply System: Provides pressurized air, oxygen, or nitrogen. Includes pressure-regulated inlets and flow controls. The gas supply system allows precise control over the type and amount of gas introduced into the Stirrer System.
10. Gas Exhaust System: Safely vents gases while maintaining pressure stability. Pressure-regulated exhausts prevent overpressure. This system ensures the safe release of excess gases, maintaining stable internal conditions.
11. Cooling Jacket: Regulates the internal temperature. Circulates coolant to dissipate heat. The cooling jacket prevents overheating, ensuring that the fermentation process occurs within optimal temperature ranges.
12. Cooling Water In/Out: Supplies and removes coolant for temperature regulation. Designed to handle high heat loads. This system ensures efficient heat exchange, maintaining a stable internal environment.
13. Temperature Sensor and Control Unit: Monitors and maintains the temperature. Integrated with heating and cooling systems. Temperature sensors provide real-time monitoring, allowing precise adjustments to prevent thermal stress on microorganisms.
14. Pressure Sensor and Control System: Monitors and regulates internal pressure. Automated alarms for overpressure conditions. Manual monitoring via pressure gauges. Pressure sensors are critical for maintaining safe operating conditions, especially in high-pressure fermentation processes.
15. High-Pressure Valves: Regulate fluid inputs, outputs, and sampling under pressure. Designed for durability and safety. These valves ensure controlled and secure management of materials entering or exiting the Stirrer System.
16. Safety Features: Prevent accidents due to overpressure. Pressure relief valves and rupture discs. Integrated alarm systems. Safety systems provide multiple layers of protection, ensuring the Stirrer System operates safely under all conditions.
17. Membrane Filtration System: Retains fine particles and recycles nutrients. Operates under pressure to filter impurities while retaining valuable components. Membrane filtration enables continuous operation by removing waste products without disrupting the fermentation process.
18. Sealed Sampling System: Allows sterile sampling under pressure. Maintains system integrity to prevent contamination. This system enables periodic monitoring of the fermentation process without compromising sterility or pressure.
19. Harvest Line: Collects the final product after fermentation. Pressure-rated outlets ensure safe product removal. The harvest line facilitates the efficient and secure collection of the Stirrer System’s output.
20. Agitator Seal Upgrade: Prevents leakage under pressure. High-pressure-rated mechanical seals. This upgrade enhances the Stirrer System’s durability and efficiency, especially in high-pressure operations.
21. Mutag Biomedia: Provides surface area for microorganisms' growth and formation of colonies. High-performance media for microbial attachment. Promotes efficient biofilm formation, enhancing overall microbial activity.
22. Selective Resin Pouches: Absorbs toxic or toxin materials. Customizable resin composition for targeted absorption. Maintains a safe environment for microbial growth by removing harmful substances.
23. Nano Charcoal Pouches: Supports microorganisms' growth and toxin absorption. High surface area for microbial attachment and toxin capture. Improves system efficiency by facilitating microbial activity and removing contaminants.
24. Nutrient Pouches: Slow release of nutrients for microorganisms' growth and colony formation. Composed of heat-treated egg and bone powder, limestone, jute powder, coconut shell powder, and bagasse powder. Provides sustained nutrient availability, supporting microbial health and activity.
25. Temperature Control: Ensures optimal temperature for fermentation. Automated heating and cooling systems. Prevents temperature fluctuations that could disrupt microbial processes.
[0061] In another embodiment of the present invention, the stepwise process of the stirrer system operation is shown in Table 2. Stirrer Systems rely on a synergy of advanced components to ensure optimal fermentation conditions. From precise aeration systems to robust safety mechanisms, each element plays a vital role in achieving efficient and reliable biochemical processes.
Table 2
Step Description
Preparation Loading the pressure-resistant vessel with culture medium, nutrients, and inoculum.
Sterilization Using high-pressure steam or chemical agents to sterilize the system.
Initialization Starting the motor and impellers for initial mixing.
Aeration Activating the advanced aeration system with mini, macro, and nano bubbles.
Monitoring Continuous measurement of pH, dissolved oxygen, and temperature using probes.
Nutrient Addition Introducing slow-release pouches (egg powder, bone powder, etc.) for growth.
Temperature Regulation Cooling jackets maintain optimal heat levels.
Pressure Management Pressure sensors and high-pressure valves ensure stability.
Filtration Membrane filtration removes waste and cycles nutrients.
Sampling Sealed sampling system collects sterile samples for analysis.
Harvesting Harvest line collects the final product under pressure.
Cleaning System is cleaned and sterilized for the next cycle.

[0062] In another embodiment of the present invention, the nano bubble generators are integrated within the bioreactor to provide sustained high levels of dissolved oxygen, maintaining optimal aerobic conditions that enhance microbial activity. Nano bubbles support efficient nutrient cycling, improve microbial metabolic rates, and foster a stable environment for aerobic digestion, which contributes to accelerated biowaste conversion. Also, the hyperbaric oxygen conditions are maintained at a pressure range of 1 to 3 bar.
[0063] In another embodiment of the present invention, the hydraulic cavitation reduces the energy load for the ultrasonic phase, while nano bubble oxygenation supports aerobic digestion with minimal power consumption, creating an energy-efficient biowaste processing method.
[0064] In another embodiment of the present invention, the limestone pouches are strategically positioned throughout the bioreactor to stabilize pH by neutralizing acids produced during the breakdown of organic material, maintaining an optimal pH range of 6.5-7.5. Nano charcoal and biochar contribute to detoxification by adsorbing harmful contaminants and providing surfaces for microbial attachment, ensuring nutrient-rich and safe biofeed. With limestone pouches stabilizing pH and nano charcoal and biochar absorbing toxins, the process ensures safe, high-quality biofeed by preventing pH swings and capturing harmful contaminants.
[0065] In another embodiment, the present invention provides a method of detoxifying biowaste utilizing biochar and nano charcoal to absorb harmful compounds, thereby enhancing nutrient availability during the conversion process.
The combined use of biochar and nano charcoal creates a dual-action mechanism for detoxification and nutrient enhancement, optimizing the environment for microbial activity.
[0066] In another embodiment of the present invention, the substrates integrated in the bioreactor are organic substrates selected from jute fibers, coconut powder, and bagasse or a combination thereof. Organic substrates like jute powder, coconut powder, and bagasse serve as carbon-rich scaffolds, promoting biofilm formation and microbial growth. These substrates enhance microbial breakdown of lignocellulosic fibers, improve aeration, and support nutrient recovery in the biofeed.
[0067] In another embodiment, the present invention provides an incorporation of bagasse and coconut powder as carbon-rich substrates within the bioreactor to enhance microbial colonization and nutrient cycling. Utilizing these substrates as slow-release nutrient sources provides essential energy and nutrients, optimizing microbial growth and activity.
[0068] In another embodiment of the present invention, the inclusion of specialized resins enables selective removal of heavy metals and specific toxins, further purifying the biofeed and ensuring it is safe for animal consumption. The use of ion-exchange resin to detoxify biowaste by absorbing heavy metals and other contaminants while releasing essential nutrients, facilitated by the presence of biochar and nano charcoal for enhanced detoxification. The dual functionality of detoxification and nutrient release, combined with the adsorptive properties of biochar and nano charcoal, optimizes microbial growth and ensures safe biofeed production.
[0069] In another embodiment of the present invention, in the final stage, enzymes and probiotics are introduced to optimize digestibility and nutrient uptake. Probiotics support gut health in animals, while enzymes improve the breakdown of complex molecules, enhancing biofeed quality for livestock and aquaculture. Further, the probiotics added during the polishing stage are selected from Lactobacillus acidophilus, Bifidobacterium bifidum, and Enterococcus faecium or a combination thereof. Furthermore, the enzymes added during the polishing stage are selected from amylases, proteases, lipases and cellulases or a combination thereof.
[0070] In another embodiment, the present invention provides a polishing stage that uses enzymes and probiotics to detoxify and enhance the nutrient profile of the biofeed, incorporating components like bagasse and coconut powder to support digestive health. The inclusion of probiotics during polishing ensures enhanced animal health through digestive support, alongside the nutritional contributions of bagasse and coconut powder, a step that is missing in conventional biofeed production.
[0071] In another embodiment of the present invention, the bioreactor is housed within aluminum tanks with a diameter of 8 meters and a height of 6 meters, of which 1 meter is above ground while the remaining 5 meters are below ground, effectively utilizing geothermal energy for temperature management. An aluminum comb system is integrated externally to the tank and at the bottom, facilitating efficient heat exchange. The aluminum structure enables optimal heat conduction and distribution throughout the tank. The upper 4 meters of the tank are insulated to minimize heat loss, maintaining stable internal temperatures conducive to microbial activity. This setup (Figure 3) allows the system to leverage low geothermal energy, stabilizing the temperature within the bioreactor and enhancing microbial metabolic rates, which are crucial for efficient biowaste conversion. The aluminum tank design, complemented by the external aluminum comb heat exchange system and insulation, effectively utilizes geothermal energy to maintain stable temperatures, thus promoting optimal microbial activity and enhancing the efficiency of biowaste conversion.
[0072] In another embodiment, the present invention relates to a continuous flow process for converting biowaste into biofeed using a hybrid bioreactor system that integrates multi-organism microbial consortia, biofloc technology, nano bubble generators, enzymatic hydrolysis, and detoxification methods utilizing ion-exchange resins, biochar, nano charcoal, bagasse, and coconut powder. Thus, the present invention provides an optimized continuous flow process for transforming biowaste into superfood-enriched biofeed.
[0073] In another embodiment, the present invention provides an advanced, continuous-flow system for converting biowaste into nutrient-dense biofeed. The system integrates cutting-edge mechanical, biological, and chemical treatments within a multistage bioreactor, achieving efficient biowaste breakdown, nutrient recovery, and detoxification to produce a biofeed suitable for animal and aquaculture applications. The present invention addresses limitations in traditional biowaste conversion methods by incorporating a multistage approach that optimizes microbial activity, energy efficiency, and nutrient density.
[0074] In another embodiment, the present invention provides an integrated, efficient, and sustainable approach to biowaste conversion, yielding a nutrient-enriched, safe biofeed. Through the combination of advanced biofloc technology, high-surface-area biomedia, and controlled ultrasonic treatment, the invention represents a significant improvement over traditional waste processing systems. The innovative temperature management system utilizing geothermal energy further enhances the overall efficiency and sustainability of the process, while the incorporation of photobioreactor technology ensures that the biofeed is enriched with valuable nutrients from microalgae.
[0075] In another embodiment, the process of the present invention reduces landfill waste and pollution by transforming biowaste into biofeed, making it a sustainable, cost-effective solution for biowaste management.
[0076] In another embodiment of the present invention, the applications in Biofeed Production includes: Extraction of VFAs, amino acids, and sugars for biofeed enrichment and technologies: UF and NF for molecular-level separation (Nutrient Recovery), Elimination of harmful microorganisms to ensure feed safety and technologies: MF and UF for efficient sterilization (Pathogen Removal),and Capture and purification of biogas for energy or industrial use and technologies: Gas separation membranes for selective gas recovery (Gas Utilization).
[0077] In another embodiment, the present invention biowaste-to-biofeed conversion process stands out from existing methods through its integration of advanced technologies (like hydrodynamic cavitation and ultrasonic treatment), tailored microbial consortia, and a strong emphasis on nutrient customization. While many existing studies focus on singular aspects of waste management or bioconversion, the present method uniquely combines multiple innovative approaches to optimize feed quality and environmental sustainability. This multi-faceted approach not only improves the efficiency and effectiveness of biowaste processing but also addresses significant environmental challenges, marking a notable advancement in the field.
[0078] While the foregoing describes various embodiments of the disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.
EXAMPLES
[0079] The present invention is further explained in the form of the following examples. However, it is to be understood that the following examples are merely illustrative and are not to be taken as limitations upon the scope of the invention.
[0080] Example 1: Biowaste collection and mechanical treatment
The process initiates with the systematic collection of biowaste from diverse sources, including agricultural residues (such as crop leftovers and fibrous plant materials), kitchen waste (food scraps and organic matter), and tough organic materials (bones, eggshells). These materials are characterized by high lignin and cellulose content, which can pose challenges in microbial digestion. To enhance the subsequent treatment phases, the collected biowaste undergoes mechanical shredding and grinding to achieve a uniform particle size. This size reduction not only increases the surface area available for microbial and enzymatic action but also promotes more effective penetration of treatments, thereby facilitating the release of encapsulated nutrients and accelerating decomposition.
[0081] Example 2: Biological and microbiological pretreatment with Limestone, Bagasse, and Nano Charcoal
Following mechanical treatment, the biowaste is subjected to biological and microbiological pretreatment, which plays a pivotal role in the overall efficiency of the conversion process. The key components introduced during this phase include:
● Limestone Pouches: Calcium carbonate (CaCO₃) in the form of limestone is strategically used to regulate the pH levels during the biological treatment. As biowaste decomposes, it generates organic acids that can lower pH, inhibiting microbial activity. The limestone reacts with these acids, neutralizing them and maintaining optimal pH levels between 6.5 and 7.5. This stable environment fosters the growth of beneficial microorganisms, especially those involved in the breakdown of calcium-rich materials like bones and eggshells.
● Bagasse Pouches: Bagasse, a by-product of sugarcane processing, acts as a carbon-rich substrate that enhances the growth of microbial communities. Its fibrous structure promotes aeration within the biowaste matrix, supporting the development of biofilms. These biofilms enhance microbial interactions and optimize the degradation of lignocellulosic materials, contributing to improved nutrient recovery.
● Nano Charcoal and Biochar: The introduction of nano charcoal and biochar serves several essential functions. Nano charcoal, with its high surface area, enhances the adsorption of toxins and provides a favorable environment for microbial colonization. Biochar, produced through the pyrolysis of organic materials, acts as a stable carbon source, facilitating nutrient retention and enhancing the final quality of the biofeed by sequestering carbon and improving soil health.
● Microbial Inoculation: A diverse consortium of microorganisms, including Bacillus subtilis, Trichoderma harzianum, Aspergillus niger, and lactic acid bacteria such as Lactobacillus plantarum, is introduced to the biowaste. These microorganisms possess specific enzyme capabilities: proteases for protein breakdown, cellulases for cellulose degradation, and lignin-degrading enzymes that collectively enhance the decomposition of complex organic compounds. The introduction of these microbes accelerates the conversion of biowaste into bioavailable nutrients.
● Oxygen Conditions: The biological pretreatment phase is conducted under controlled oxygen conditions, incorporating both normal and hyperbaric oxygen environments. Hyperbaric oxygen conditions stimulate the metabolic activities of aerobic microbes, which enhance the degradation of organic matter and improve nutrient recovery.
[0082] Example 3: Chemical detoxification with Limestone, Nano Charcoal, and Biochar
Post-biological treatment, the biowaste is subjected to chemical detoxification using hydrogen peroxide (H₂O₂) and sodium peroxide (Na₂O₂), in conjunction with limestone. This critical step aims to eliminate pathogens and residual organic pollutants, ensuring the safety and quality of the final biofeed product. Limestone not only stabilizes pH but also reacts with acids produced during the decomposition process, promoting calcium ion availability. This calcium is crucial for the physiological functions of livestock and aquaculture species, enhancing their growth and health. Both nano charcoal and biochar are instrumental in detoxifying the biowaste. Nano charcoal, with its extensive surface area, binds to harmful contaminants, including heavy metals and organic toxins, effectively reducing their bioavailability. Biochar contributes to soil enhancement by improving nutrient retention and microbial activity, further supporting the overall sustainability of the process.
[0083] Example 4: Advanced physical treatments (Hydrodynamic cavitation and Ultrasonic treatment)
The next stage involves advanced physical treatments, namely hydrodynamic cavitation and ultrasonic treatment, which aim to enhance nutrient extraction and improve the efficiency of microbial digestion.
● Hydrodynamic Cavitation: This process generates microbubbles through rapid changes in pressure and temperature within a fluid. The implosion of these bubbles creates localized high temperatures and shear forces, effectively disrupting the cell walls of fibrous materials, such as bagasse. This disruption facilitates the release of encapsulated nutrients, making them more accessible to microbes in subsequent stages.
● Ultrasonic Treatment: Following hydrodynamic cavitation, ultrasonic treatment employs frequencies ranging from 1 kHz to 100 kHz to achieve targeted cellular disruption and homogenization. At low frequencies (1-20 kHz), intense cavitation occurs, rupturing cell walls and releasing intracellular nutrients. This phase is particularly effective for breaking down tough fibrous materials, enabling enhanced nutrient availability for microbial digestion. Controlled cavitation at higher frequencies (20-100 kHz) ensures uniform particle size distribution and homogenization of the treatment mixture. This uniformity enhances the accessibility of nutrients to microbes, thereby improving the overall degradation process.
[0084] Example 5: Multistage bioreactor operation with biofloc technology
In this crucial stage, the pretreated biowaste is transferred to a multistage bioreactor (MSBR), where biofloc technology is integrated to facilitate continuous nutrient cycling and effective organic matter degradation. The bioflocs, consisting of aggregates of microorganisms, enhance nutrient recycling and stimulate microbial activity. These flocks provide a stable microbial community that effectively degrades organic materials while simultaneously serving as a nutrient source for livestock and aquaculture species. The dynamic interactions within the biofloc community optimize nutrient cycling and promote a healthier growth environment.
The operation within the bioreactor continues under both normal and hyperbaric oxygen conditions, enhancing microbial activity and facilitating efficient degradation of organic materials. The maintenance of high dissolved oxygen levels is critical for the success of aerobic microbial processes. The incorporation of nano bubble generators ensures that high levels of dissolved oxygen are maintained within the bioreactor, creating an optimal aerobic environment for microbial activity. The presence of nanobubbles significantly improves mass transfer and enhances the efficiency of microbial degradation.
Limestone, Nano Charcoal, and Biochar pouches play vital roles in maintaining pH stability, detoxifying the biowaste, and facilitating nutrient cycling throughout the bioreactor. Their continued presence ensures that the microbial community thrives, optimizing the degradation of organic matter and enhancing the final biofeed product. Various organic substrates, including jute fibers, coconut powder, and bagasse, are integrated into the bioreactor. These substrates not only improve microbial colonization but also contribute to the nutrient profile of the final biofeed by providing essential carbohydrates and fibers.
[0085] Example 6: Resin utilization for enhanced nutrient retention
The inclusion of resin in the biowaste treatment process is a novel and critical innovation that significantly enhances nutrient retention and overall process efficacy. Resin particles encapsulate key nutrients, preventing their loss during treatment and ensuring a steady release of nutrients over time. This controlled release mechanism enhances the bioavailability of essential nutrients in the final biofeed, promoting better growth in livestock and aquaculture species. The resin contributes to the stabilization of the microbial community within the bioreactor, providing a supportive environment that fosters microbial growth and activity. This stability is essential for maintaining high degradation rates and ensuring consistent nutrient profiles in the biofeed. The adsorptive properties of the resin assist in binding and neutralizing harmful substances, contributing to the detoxification of the biowaste. By reducing the presence of toxins, the resin enhances the safety and quality of the final biofeed product.
[0086] Example 7: Photobioreactor integration for Spirulina and Chlorella cultivation using biowaste and available minerals
Before the final polishing stage, a photobioreactor is integrated into the system to cultivate Spirulina and Chlorella using nutrients derived from the biowaste. The photobioreactor leverages nitrogen, phosphorus, potassium, and trace elements (such as iron, magnesium, and calcium) available in the biowaste to support the growth of microalgae. This approach eliminates the need for synthetic fertilizers, promoting a sustainable nutrient cycle. The photobioreactor is designed to utilize both solar light and high-efficiency LED lighting to maximize photosynthesis and growth rates of Spirulina and Chlorella. The dual lighting system enhances energy efficiency and productivity, allowing for year-round microalgae cultivation.
Spirulina and Chlorella are cultivated under controlled conditions to optimize growth and nutrient content. Once harvested, they can be processed through filtration or centrifugation to obtain a concentrated biomass rich in proteins, essential fatty acids, vitamins, and antioxidants. Both species are exceptionally rich in nutrients, providing significant health benefits to livestock and aquaculture species. The incorporation of this microalgae biomass into the biofeed enhances its nutritional profile, promoting growth, health, and immune response in animals.
[0087] Example 8: Final Polishing Stage with Enzymes, Probiotics, and Mineral Enhancements
The last step in the biowaste-to-biofeed conversion process involves a polishing stage where probiotics and enzymes are added to enhance the digestibility and nutrient value of the final product. Recognized strains such as Lactobacillus acidophilus, Bifidobacterium bifidum, and Enterococcus faecium are introduced at this stage. These probiotics play a crucial role in supporting digestive health, enhancing nutrient absorption, and improving immune function in animals.
Enzymes such as amylases, proteases, and cellulases are added to further break down complex carbohydrates and proteins, enhancing the biofeed's digestibility and nutrient availability. Specific enzymes, including amylases, proteases, and lipases, are incorporated to further enhance nutrient breakdown and absorption. This enzymatic activity improves the overall digestibility of the biofeed, allowing for better nutrient utilization by livestock and aquaculture species.
Essential minerals and vitamins are incorporated into the biofeed to ensure it meets the nutritional requirements of livestock and aquaculture species. This may include calcium, phosphorus, and trace minerals, contributing to the overall health and growth of the animals. Rigorous quality control measures are implemented to ensure the safety and nutritional adequacy of the final biofeed product. Comprehensive testing for microbial contamination, nutrient content, and toxin levels is conducted to verify compliance with regulatory standards. The final biofeed product is characterized based on its nutrient composition, digestibility, and functional properties. This comprehensive characterization ensures that the biofeed meets the specific needs of various livestock and aquaculture species, maximizing their growth potential and health.
[0088] Example 9: Product Recover Packaging and Distribution
Once the biofeed is polished and tested, it is carefully packaged in eco-friendly, moisture-resistant bags to maintain quality during storage and transportation. Distribution is executed in a timely manner to ensure the freshness of the product, aiming to reach livestock farms and aquaculture operations as quickly as possible.
Centrifugation and filtration techniques are employed to separate the biofeed from excess liquids and solid residues. This step ensures a high-quality end product with optimal nutrient content. The final biofeed product is packaged in moisture-proof containers to maintain its quality during storage and transportation. Proper packaging ensures the biofeed remains fresh and free from contaminants until it reaches the end-users.
Throughout the entire process, sustainability remains a core focus. The integration of eco-friendly practices, such as minimizing waste and utilizing renewable resources, underscores the commitment to environmental stewardship and sustainable agriculture. The system is designed for continuous improvement, incorporating feedback from end-users and ongoing research to enhance the conversion process further. This commitment to innovation ensures that the biowaste-to-biofeed system remains at the forefront of sustainable agricultural practices.

ADVANTAGES OF THE PRESENT INVENTION
[0089] The present invention provides a continuous flow process that significantly reduces the time required for biowaste conversion compared to traditional methods, allowing for rapid nutrient recovery and biofeed production.
[0090] The present invention provides an integration of Spirulina and Chlorella cultivations enriching the biofeed with essential nutrients, offering a sustainable alternative to conventional feed sources.
[0091] The present invention addresses the challenges of biowaste management by converting waste into high-quality biofeed, reducing landfill use and environmental impact.
[0092] The present invention provides a multi-faceted detoxification process that ensures the final biofeed is safe for animal consumption, free from contaminants and pathogens.
[0093] The present invention provides a modular design of the bioreactor that allows for scalability, making it suitable for both small-scale and large-scale operations.
, Claims:1. A continuous flow system for converting biowaste into biofeed, comprising the steps of:
a) collecting and pretreating biowaste by subjecting to mechanical shredding and grinding to achieve a uniform particle size;
b) following mechanical treatment, the biowaste is subjected to biological and microbiological pretreatment to increase the efficiency of the biowaste breakdown and nutrient yield;
c) detoxifying chemically, post-biological treated biowaste to eliminate pathogens and residual organic pollutants, ensuring the safety and quality of the final biofeed product;
d) subjecting the chemical treated biowaste to physical treatments, namely hydrodynamic cavitation and ultrasonic treatment to enhance nutrient extraction and improve the efficiency of microbial digestion;
e) transferring the pretreated biowaste to a multistage bioreactor (MSBR), with integrated biofloc technology and substrates to facilitate continuous nutrient cycling and effective organic matter degradation;
f) detoxifying pretreated biowaste by inclusion of resins in the multistage bioreactor (MSBR) to enhance nutrient retention by removal of heavy metals and specific toxins;
g) integrating photobioreactor to cultivate Spirulina and Chlorella using nutrients derived from the biowaste;
h) adding enzymes, probiotics and mineral enhancements in the polishing stage to enhance the digestibility and nutrient value of the final biofeed product; and
i) packing the polished biofeed in eco-friendly, moisture-resistant bags to maintain quality during storage and transportation.
2. The continuous flow system as claimed in claim 1, wherein the biowaste is collected from sources selected from agricultural residues (crop leftovers and fibrous plant materials), kitchen waste (food scraps and organic matter) and tough organic materials (bones, eggshells).
3. The continuous flow system as claimed in claim 1, wherein the biological and microbiological pretreatment is carried out using substrates selected from limestone, bagasse, nano charcoal and biochar or a combination thereof.
4. The continuous flow system as claimed in claim 1, wherein the microbiological pretreatment is carried out by inoculating a consortium of bacteria, fungi, and algae to efficiently degrade various types of organic waste.
5. The continuous flow system as claimed in claim 4, wherein the consortium of microorganisms comprises Bacillus subtilis, Trichoderma harzianum, Aspergillus niger and Lactobacillus plantarum.
6. The continuous flow system as claimed in claim 1, wherein the chemical detoxification is carried out using hydrogen peroxide (H₂O₂) and sodium peroxide (Na₂O₂).
7. The continuous flow system as claimed in claim 1, wherein the ultrasonic treatment is carried out at frequencies ranging from 1 kHz to 100 kHz to achieve targeted cellular disruption and homogenization.
8. The continuous flow system as claimed in claim 7, wherein the low frequencies (1-20 kHz) produces intense cavitation, effectively rupturing cell walls to release nutrients and higher frequencies (20-100 kHz) produces controlled cavitation, ensuring uniform particle size and homogenizes the mixture.
9. The continuous flow system as claimed in claim 1, wherein the pH is maintained in the range of 6.5 to 7.5.
10. The continuous flow system as claimed in claim 1, wherein the bioreactor is housed within aluminum tanks, complemented by the external aluminum comb heat exchange system and insulation, utilizing geothermal energy for temperature management.
11. The continuous flow system as claimed in claim 1, wherein the nano bubble generators are integrated within the bioreactor to provide sustained high levels of dissolved oxygen, maintaining optimal aerobic conditions for microbial activity.
12. The continuous flow system as claimed in claim 11, wherein the hyperbaric oxygen conditions is maintained at a pressure range of 1 to 3 bar.
13. The continuous flow system as claimed in claim 1, wherein the substrates integrated in the bioreactor are organic substrates selected from jute fibers, coconut powder, and bagasse or a combination thereof.
14. The continuous flow system as claimed in claim 1, wherein the probiotics added during polishing stage are selected from Lactobacillus acidophilus, Bifidobacterium bifidum, and Enterococcus faecium or a combination thereof.
15. The continuous flow system as claimed in claim 1, wherein the enzymes added during polishing stage are selected from amylases, proteases, lipases and cellulases or a combination thereof.