Applied Sciences, Vol. 15, Pages 7106: Development and Evaluation of Modified Rotor–Stator Knives for Enhanced Fine Grinding of Chicken Meat–Bone Raw Material in Colloid Mill

Applied Sciences doi: 10.3390/app15137106

Authors:
Zhanibek Yessimbekov
Rasul Turagulov
Aitbek Kakimov
Anuarbek Suychinov
Eleonora Okuskhanova
Assemgul Baikadamova

The growing demand for cost-effective, high-quality protein ingredients in the meat industry highlights the need for advanced processing methods capable of producing uniform, functional meat–bone pastes from poultry by-products. This study investigates the optimization of colloid milling parameters for the fine grinding of chicken meat–bone by-products, with a focus on improving particle size distribution, rheological properties, and processing efficiency. A modified rotor–stator system with teeth inclined at 20° and a reduced pitch (0.5 mm) was compared to a conventional configuration (45° inclination, 1.5 mm pitch). Experiments were conducted at rotor speeds ranging from 1000 to 4000 rpm, with a fixed clearance of 0.1 mm. The results showed that the modified design significantly enhanced grinding efficiency, reducing the proportion of bone fragments > 1 mm and yielding over 70% of particles under 0.1 mm at 3000 rpm. Viscosity and shear stress measurements indicated that grinding at 3000 rpm yielded a dynamic viscosity of 71,507 Pa·s and a shear stress of 43,531 mPa·s, values that were significantly lower (p < 0.05) than those observed at other tested speeds, thereby producing a paste consistency with the most favorable balance of elasticity and flowability. At 4000 rpm, the temperature rise (up to 32 °C) led to partial denaturation of muscle proteins, accompanied by emulsion destabilization and disruption of the protein gel matrix, resulting in reductions in the viscosity and water-binding capacity of the paste. Comparative analysis confirmed that tool geometry and rotor speed have critical effects on grinding quality, energy use, and thermal load. The optimal operating parameters, 3000 rpm with modified rotor–stator teeth, achieve the finest, most homogeneous bone paste while preserving protein functionality and minimizing energy losses. These findings support the development of energy-efficient grinding equipment for the valorization of poultry by-products in emulsified meat formulations.

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