System for preparing resistant dextrin and polydextrose from corn starch

Abstract

The utility model relates to a system for preparing resistant dextrin and polydextrose by utilizing corn starch, which comprises a raw material tank, a starch milk tank, an enzymolysis kettle, a first wiped-film evaporator, a first polymerization reaction kettle, a dissolving tank, a decolorizing tank, an ion exchange device, a chromatographic separation device, a second wiped-film evaporator, a vacuum belt type drying device and a polydextrose preparation component, the chromatographic separation device is respectively provided with a chromatographic extracting solution outlet and a chromatographic raffinate outlet, the chromatographic extracting solution outlet is communicated with a feed port of the second wiped-film evaporator, the chromatographic raffinate outlet is communicated with an input port of the polydextrose preparation assembly, and a discharge port of the vacuum belt type drying device outputs a resistant dextrin finished product. The polydextrose preparation assembly is used for polymerizing the chromatographic raffinate to prepare polydextrose, and the output end of the polydextrose preparation assembly outputs a polydextrose finished product. According to the utility model, the yield and the light transmittance of the resistant dextrin are improved, a polydextrose product with high additional value is obtained, and the comprehensive utilization value of corn starch is improved.

Description

Technical Field

[0001] The utility model belongs to the technical field of biomass application, and particularly relates to a system for preparing resistant dextrin and polydextrose by utilizing corn starch. Background Art

[0002] Resistant dextrin is a commercially mature water-soluble dietary fiber product, which is widely used in various foods, beverages, dairy products and health products, playing the functional role of "reducing sugar, strengthening fiber, filling texture and prebiotics". In food industry production, it is used as a fat substitute, high-quality sugar substitute filler, antifreeze, moisture retainer, source of water-soluble dietary fiber, etc. Resistant dextrin is generally made from starch as raw material. It is a low-calorie glucan extracted and refined by industrial technology from the indigestible components of baked dextrin. In recent years, polymerization methods have also been used to prepare resistant dextrin, in which resistant dextrin is prepared by liquefying starch and then polymerizing it. When resistant dextrin is currently prepared using corn starch as raw material, the starch utilization rate is low, the purity of resistant dextrin is low, and the color is yellow. Utility Model Content

[0003] The technical problem to be solved by the utility model is to provide a system for preparing resistant dextrin and polydextrose from corn starch, adopt a composite enzyme to liquefy corn starch and degrade the protein in the corn starch, improve the content and transmittance of resistant dextrin after polymerization reaction, and then prepare polydextrose from the glucose in the chromatographic residual liquid, which not only improves the yield and transmittance of resistant dextrin, but also obtains a high-value-added polydextrose product, thereby significantly improving the comprehensive utilization value of corn starch.

[0004] The utility model is implemented as follows: a system for preparing resistant dextrin and polydextrose using corn starch is provided, comprising a raw material tank, a starch milk tank, an enzymolysis kettle, a first scraped film evaporator, a first polymerization reactor, a dissolution tank, a decolorization tank, an ion exchange device and a chromatographic separation device which are sequentially connected through pipelines; a second scraped film evaporator and a vacuum belt drying device which are sequentially connected through pipelines; and a polydextrose preparation component. The chromatographic separation device is provided with a chromatographic extract outlet and a chromatographic raffinate outlet respectively. The chromatographic extract outlet is connected to the feed port of the second scraped film evaporator through a pipeline, and the chromatographic raffinate outlet is connected to the input port of the polydextrose preparation component through a pipeline. The vacuum belt drying device is used to dry the resistant dextrin solution into a resistant dextrin solid, and its discharge port outputs the resistant dextrin finished product. The polydextrose preparation component is used to polymerize the chromatographic raffinate to prepare polydextrose. , and its output end outputs the polydextrose finished product; the raw material tank is used to store corn starch raw materials, the starch milk tank is used to dissolve corn starch into starch milk and adjust the Baume degree of the starch milk, the enzymatic hydrolysis kettle is used to liquefy the starch in the starch milk and degrade the protein, the first scraped film evaporator is used to concentrate the sugar solution after enzymatic hydrolysis into corn syrup, the first polymerization reactor is used to polymerize the corn syrup to prepare resistant dextrin crude product, the dissolution tank is used to dissolve the resistant dextrin crude product, the decolorization tank is used to decolorize the resistant dextrin crude product solution, the separation device is used to desalt the decolorized resistant dextrin crude product solution, the chromatographic separation device is used to separate the resistant dextrin crude product solution after separation into a chromatographic extract and a chromatographic raffinate, the second scraped film evaporator is used to concentrate the chromatographic extract (i.e., the resistant dextrin solution) at low temperature, and the vacuum belt drying device is used to dry the concentrated chromatographic extract (i.e., the resistant dextrin solution) into a resistant dextrin solid.

[0005] Furthermore, the polydextrose preparation component includes a glucose collecting tank, a third scraped film evaporator, a second polymerization reactor, a pulverizing device and a mixing tank which are sequentially connected through pipelines. The glucose collecting tank is used to collect the chromatographic raffinate (i.e., glucose solution). The third scraped film evaporator is used to concentrate the chromatographic raffinate (i.e., glucose solution) at low temperature. The second polymerization reactor is used to polymerize the concentrated chromatographic raffinate (i.e., glucose solution) to prepare polydextrose. The pulverizing device is used to pulverize the polydextrose solid. The mixing tank is used to dissolve the pulverized polydextrose and adjust the pH of the polydextrose to obtain a polydextrose finished product.

[0006] Compared with the prior art, the system for preparing resistant dextrin and polydextrose using corn starch in the utility model has the following characteristics:

[0007] 1. The comprehensive utilization rate of corn starch reaches over 95% by preparing polydextrose from the chromatographic raffinate in the process of preparing resistant dextrin from corn starch. While improving resource utilization, high value-added polydextrose products are also prepared, greatly improving the comprehensive utilization value of corn starch.

[0008] 2. Through the improvement and optimization of the entire process system, corn starch is first degraded into protein with enzyme preparations and then prepared into resistant dextrin, which effectively avoids the entry of protein into the chromatographic extract and increases the content of resistant dextrin in the extract. The resistant dextrin content after chromatographic separation can be stably controlled. The final resistant dextrin content can reach more than 90%, which provides technical guarantee for the preparation of superior resistant dextrin and avoids the influence of fluctuations in raw corn syrup on the quality of resistant dextrin products.

[0009] 3. The use of scraped film evaporator and vacuum drying equipment can effectively avoid the yellowing of resistant dextrin products caused by high temperature, improve the light transmittance of resistant dextrin products, and play a positive role in subsequent applications and product quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 This is a schematic diagram of the structural principle of the system for preparing resistant dextrin and polydextrose using corn starch in the utility model;

[0011] Figure 2 for Figure 1 Schematic diagram of the change process of raw materials in the system. DETAILED DESCRIPTION

[0012] In order to make the technical problems, technical solutions and beneficial effects to be solved by the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0013] Please also refer to Figure 1 as well as Figure 2 As shown, a preferred embodiment of the system of the utility model for preparing resistant dextrin and polydextrose using corn starch includes a raw material tank 1, a starch milk tank 2, an enzymatic hydrolysis kettle 3, a first scraped film evaporator 4, a first polymerization reactor 5, a dissolution tank 6, a decolorization tank 7, an ion exchange device 8 and a chromatographic separation device 9 which are sequentially connected through pipelines, and also includes a second scraped film evaporator 10 and a vacuum belt drying device 11 which are sequentially connected through pipelines, and also includes a polydextrose preparation component 12.

[0014] The chromatographic separation device 9 is provided with a chromatographic extract outlet and a chromatographic raffinate outlet (not shown in the figure), the chromatographic extract outlet is connected to the feed port of the second scraped film evaporator 10 through a pipeline, and the chromatographic raffinate outlet is connected to the input port of the polydextrose preparation component 12 through a pipeline. The vacuum belt drying device 11 is used to dry the resistant dextrin solution into a resistant dextrin solid, and its outlet outputs the resistant dextrin finished product A. The polydextrose preparation component 12 is used to polymerize the chromatographic raffinate to prepare polydextrose, and its output end outputs the polydextrose finished product B.

[0015] The raw material tank 1 is used to store corn starch C raw material, the starch milk tank 2 is used to dissolve corn starch C into starch milk and adjust the Baume degree of the starch milk, the enzymatic hydrolysis kettle 3 is used to liquefy the starch in the starch milk and degrade the protein, the first scraped film evaporator 4 is used to concentrate the sugar solution after enzymatic hydrolysis into corn syrup D, the first polymerization reactor 5 is used to polymerize corn syrup D to prepare resistant dextrin crude product E, and the dissolving tank 6 is used to dissolve the resistant dextrin crude product E. The decolorizing tank 7 is used to decolorize the resistant dextrin crude product E solution, and the deionization device 8 is used to desalt the decolorized resistant dextrin crude product E solution.

[0016] The chromatographic separation device 9 is used to separate the resistant dextrin crude product E solution after separation into a chromatographic extract F and a chromatographic raffinate G. The chromatographic extract F is a resistant dextrin solution with a content of 90%, and the chromatographic raffinate G is a glucose solution. The second scraped film evaporator 10 is used to concentrate the chromatographic extract F (i.e., the resistant dextrin solution) at low temperature, and the vacuum belt drying device 11 is used to dry the concentrated chromatographic extract F (i.e., the resistant dextrin solution) into a resistant dextrin solid, i.e., a resistant dextrin finished product A.

[0017] The polydextrose preparation assembly 12 includes a glucose collection tank 13, a third scraped film evaporator 14, a second polymerization reactor 15, a crushing device 16 and a mixing tank 17 which are sequentially connected through pipelines. The glucose collection tank 13 is used to collect the chromatographic raffinate G (i.e., glucose solution), the third scraped film evaporator 14 is used to concentrate the chromatographic raffinate G (i.e., glucose solution) at low temperature, the second polymerization reactor 15 is used to polymerize the concentrated chromatographic raffinate G (i.e., glucose solution) to prepare polydextrose, the crushing device 16 is used to crush the polydextrose solid, and the mixing tank 17 is used to dissolve the crushed polydextrose and adjust the pH of the polydextrose to obtain the polydextrose finished product B.

[0018] The utility model also discloses a method for preparing resistant dextrin and polydextrose using corn starch. The method adopts the system for preparing resistant dextrin and polydextrose using corn starch as described above. The method comprises the following steps:

[0019] Step 1: The corn starch C in the raw material tank 1 is conveyed to the starch milk tank 2 by a belt for milking, the starch milk Baume degree is adjusted, and then the corn starch is conveyed to the enzymolysis kettle 3 for enzymolysis.

[0020] Step 2: The enzymolysis liquid in the enzymolysis kettle 3 is transported to the first scraped film evaporator 4 and the first polymerization reactor 5 in sequence through pipelines, and then a polymerization reaction is carried out in the first polymerization reactor 5 to generate the resistant dextrin crude product E.

[0021] Step 3: The crude resistant dextrin E is sequentially transported to the dissolution tank 6, the decolorization tank 7, and the separation device 8 through pipelines for dissolution, decolorization, and desalination, and then sent to the chromatographic separation device 9 for chromatographic separation to obtain chromatographic extract F and chromatographic raffinate G. The chromatographic extract F is a high-purity 90% resistant dextrin liquid, and the chromatographic raffinate G is a low-purity 80% glucose liquid.

[0022] Step 4: The chromatographic extract F is sequentially transported to the second scraped film evaporator 10 and the vacuum belt drying device 11 through pipelines to prepare the resistant dextrin finished product A. The purity of the resistant dextrin finished product is >90%, and the transmittance is above 95%.

[0023] Step 5: The chromatographic raffinate G is transported to the polydextrose preparation component 12 through a pipeline to prepare a polydextrose finished product B. The purity of the polydextrose finished product is >90%.

[0024] Specifically, in step 1, the dry matter mass percentage concentration of corn starch C is 85-90wt%, the pH is 5.0-7.0, and during the emulsion treatment, reverse osmosis water is added to adjust the starch emulsion Baume degree to 18-22°Bé, and sodium hydroxide is used to adjust the pH to 5.5-6.5. During the enzymatic hydrolysis treatment, 0.2-0.4% of commercial α-amylase and protease are added as catalysts, and the enzymatic hydrolysis reaction temperature is controlled from 50-60°C for 1-3h, and then raised to 80-90°C for 1-3h.

[0025] Specifically, in step 2, when the first scraped film evaporator 4 performs scraped film concentration treatment, the evaporation pressure is 5-7 bar, the vacuum degree is 80-90 kPa, and the corn syrup D is evaporated to a refractive index of 70-80%; when the polymerization reaction is performed in the first polymerization reactor 5, 1-3% citric acid needs to be added as a catalyst, and the reaction process is controlled as follows: first, the temperature is raised to 90-110° C. and the vacuum degree is controlled to 50-70 kPa, the corn syrup D is concentrated to a refractive index of 85%, and then the reaction temperature is adjusted to 120-140° C., the reaction time is 1-3 hours, and the vacuum degree is 55-65 kPa.

[0026] Specifically, in step three, the process of further purifying the resistant dextrin crude product E is to first transport the resistant dextrin crude product E to the dissolution tank 6, and then pass through the decolorization tank 7, the ion exchange device 8 and the chromatographic separation device 9 in sequence through the feed pump for chromatographic separation treatment. During the decolorization treatment, 2% activated carbon is used as a decolorant, the decolorization temperature is 50~70°C, and the decolorization time is 1.0~2.0 hours. During the ion exchange treatment, ensure that the conductivity of the ion exchange output is <100μS / cm and the transmittance is >90%. The temperature of the chromatographic separation process is 40~60°C and the pressure is 2~3bar.

[0027] Specifically, in step four, when the second scraped film evaporator 10 performs scraped film evaporation treatment, the evaporation pressure is 5~7 bar and the vacuum degree is 80~90 kPa; when the vacuum belt drying device 11 performs vacuum drying, low-temperature vacuum drying is adopted, the temperature is 80~90°C, the drying time is 4~6 hours, and the vacuum degree is 85~95 kPa.

[0028] Specifically, in step 5, the polydextrose preparation assembly 12 includes a glucose collection tank 13, a third scraped film evaporator 14, a second polymerization reactor 15, a crushing device 16 and a mixing tank 17 which are sequentially connected through pipelines, and the chromatographic raffinate G is sequentially passed through the glucose collection tank 13, the third scraped film evaporator 14, the second polymerization reactor 15, the crushing device 16 and the mixing tank 17 to prepare the polydextrose finished product B. When the third scraped film evaporator 14 performs scraped film evaporation, the evaporation pressure is 4-5 bar, the vacuum degree is 80-90 kPa, and the solution is evaporated to a refractive index of 80-85%. When the polymerization reaction is carried out in the second polymerization reactor 15, 1-2% citric acid and 13-17% sorbitol need to be added as catalyst and reaction stop agent during the polymerization reaction. The reaction process is regulated as follows: first, the temperature is raised to 90-110°C and the vacuum degree is controlled to 80-90kpa, the glucose solution is concentrated to 90% refractive index, and then the reaction temperature is adjusted to 140-160°C, the reaction time is 1-3 hours, the vacuum degree is 85-95kpa, and the material is directly discharged and cooled after the reaction is completed. During the crushing process, the polydextrose is crushed into 100-200 mesh as needed. In the mixing tank 17, the polydextrose powder is evenly mixed with the sodium carbonate powder, and the pH is 5-7 after dissolution.

[0029] The following is a specific example to further illustrate the system of the present invention for preparing resistant dextrin and polydextrose using corn starch. Example 1

[0030] The first embodiment of the method for preparing resistant dextrin and polydextrose using corn starch of the utility model comprises the following steps:

[0031] Step 1, convey the corn starch C in the raw material tank 1 to the starch milk tank through a belt for milk preparation, adjust the starch milk Baume degree, and then send it to the enzymolysis kettle 3 for enzymolysis treatment. The dry matter mass percentage concentration in corn starch C is 87wt%, and the pH is about 6.5. During the milk preparation process, reverse osmosis water is added to adjust the starch milk Baume degree to 22°Bé, and sodium hydroxide is used to adjust the pH to 5.5. During the enzymolysis treatment, 0.4% by mass of commercial α-starch complex enzyme and protease are added as catalysts, and the reaction temperature is controlled from 60°C for 1h, then raised to 85°C for 2h.

[0032] Step 2: The enzymolysis liquid in the enzymolysis kettle 3 is sequentially transported to the first scraped film evaporator 4 and the first polymerization reactor 5 through a pipeline, and then a polymerization reaction is carried out in the first polymerization reactor 5 to generate a resistant dextrin crude product E. When the first scraped film evaporator 4 is subjected to scraped film evaporation treatment, the evaporation pressure is 6 bar, the vacuum degree is 85 kpa, and the corn syrup is evaporated to a refractive index of 75%. When the first polymerization reactor 5 is subjected to polymerization reaction, 2% citric acid needs to be added as a catalyst, and the reaction process is controlled as follows: first, the temperature is raised to 100°C and the vacuum degree is controlled to 70 kpa, the corn syrup is concentrated to a refractive index of 85%, and then the reaction temperature is adjusted to 130°C, the reaction time is 1 hour, and the vacuum degree is 60 kpa.

[0033] Step 3, the resistant dextrin crude product E is transported to the dissolution tank 6, the decolorization tank 7, and the ion exchange device 8 through the pipeline in sequence for dissolution, decolorization, and desalination, and then sent to the chromatographic separation device 9 for chromatographic separation treatment to obtain chromatographic extract F and chromatographic residual liquid G respectively. The process of further purifying the resistant dextrin crude product E is to first transport the resistant dextrin crude product E to the dissolution tank 6, and then pass through the decolorization tank 7, the ion exchange device 8 and the chromatographic separation device 9 in sequence through the feed pump for chromatographic separation treatment. During the decolorization treatment, 2% activated carbon is used as a decolorant, the decolorization temperature is 70°C, and the decolorization time is 2 hours. During the ion exchange treatment, the conductivity of the ion exchanged material is guaranteed to be <100μS / cm and the transmittance is >90%. The temperature of the chromatographic separation process is 60°C and the pressure is 3bar. The chromatographic extract F is a resistant dextrin liquid with a higher purity of 92%, and the chromatographic residual liquid G is a glucose liquid with a lower purity of 82%, which also contains 7% maltose components.

[0034] Step 4, the chromatographic extract F is transported to the second scraped film evaporator 10 and the vacuum belt drying device 11 through pipelines to prepare the resistant dextrin finished product A. When the second scraped film evaporator 10 performs scraped film evaporation, the evaporation pressure is 6 bar and the vacuum degree is 85 kpa. When the vacuum belt drying device 11 performs vacuum drying, low-temperature vacuum drying is adopted, the temperature is 85 ° C, the drying time is 4 hours, and the vacuum degree is 85 kpa. The final resistant dextrin finished product has a purity of 92%, a transmittance of more than 95%, and other indicators meet national standards.

[0035] Step 5, the chromatographic raffinate G is transported to the polydextrose preparation component 12 through a pipeline to prepare the polydextrose finished product B. The chromatographic raffinate G is sequentially passed through the glucose collection tank 13, the third scraped film evaporator 14, the second polymerization reactor 15, the crushing device 16 and the mixing tank 17 to prepare the polydextrose finished product B. During the scraped film evaporation treatment, the evaporation pressure is 5 bar, the vacuum degree is 90 kpa, and the solution is evaporated to a refractive index of 85%. During the polymerization reaction, 1% citric acid and 15% sorbitol need to be added as catalysts and reaction terminators during the polymerization reaction. The reaction process is regulated as follows: first, the temperature is raised to 110 ° C and the vacuum degree is controlled to 90 kpa, the glucose solution is concentrated to 90% refractive index, and then the reaction temperature is adjusted to 145 ° C, the reaction time is 1.5 hours, the vacuum degree is 85 kpa, and the reaction is directly discharged and cooled after completion. During crushing, the polydextrose is crushed into 200 mesh as needed. In the mixing tank, the polydextrose powder is evenly mixed with the sodium carbonate powder, and the pH is 6.0 after dissolution. The final polydextrose purity reached 92%, and other indicators met national standards. The comprehensive utilization rate of corn starch was as high as 95%.

[0036] Comparative Example 1

[0037] The resistant dextrin is directly prepared using corn syrup as raw material. The specific steps include: after the corn syrup raw material in the raw material tank is transported to the polymerization reactor through a pipeline, 2% citric acid is added to start the polymerization reaction, the reaction temperature is 130°C, the reaction time is 1 hour, and then activated carbon decolorization, desalination, chromatography separation, evaporation concentration, and drying are performed to finally obtain the finished resistant dextrin with a purity of 85% and a transmittance of 85%. The chromatographic raffinate is sold as syrup, and the actual comprehensive utilization rate of corn starch is only 70%.

[0038] In summary, through the improvement of the entire system and the method for preparing polydextrose from the chromatographic extract, the comprehensive utilization rate of corn starch was increased from 70% to 95%, the purity of resistant dextrin was increased from 85% to 92%, and the transmittance was increased from 85% to 95%. While improving the comprehensive utilization value of corn starch, a high-value-added polydextrose product that meets national standards was prepared.

[0039] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A system for preparing resistant dextrin and polydextrose using corn starch, characterized in that: The invention comprises a raw material tank, a starch milk tank, an enzymolysis kettle, a first scraped film evaporator, a first polymerization reactor, a dissolving tank, a decolorizing tank, an ion exchange device and a chromatographic separation device which are sequentially connected through pipelines, a second scraped film evaporator and a vacuum belt drying device which are sequentially connected through pipelines, and a polydextrose preparation component. The chromatographic separation device is provided with a chromatographic extract outlet and a chromatographic raffinate outlet respectively. The chromatographic extract outlet is connected with the feed port of the second scraped film evaporator through a pipeline, and the chromatographic raffinate outlet is connected with the input port of the polydextrose preparation component through a pipeline. The vacuum belt drying device is used to dry the resistant dextrin solution into a resistant dextrin solid, and the discharge port thereof outputs the resistant dextrin finished product. The polydextrose preparation component is used to polymerize the chromatographic raffinate to prepare polydextrose, and the output end thereof outputs the polydextrose Finished sugar product; the raw material tank is used to store corn starch raw materials, the starch milk tank is used to dissolve corn starch into starch milk and adjust the Baume degree of the starch milk, the enzymatic hydrolysis kettle is used to liquefy the starch in the starch milk and degrade the protein, the first scraped film evaporator is used to concentrate the sugar solution after enzymatic hydrolysis into corn syrup, the first polymerization reactor is used to polymerize the corn syrup to prepare resistant dextrin crude product, the dissolution tank is used to dissolve the resistant dextrin crude product, the decolorization tank is used to decolorize the resistant dextrin crude product solution, the separation device is used to desalt the decolorized resistant dextrin crude product solution, the chromatographic separation device is used to separate the resistant dextrin crude product solution after separation into a chromatographic extract and a chromatographic raffinate, the second scraped film evaporator is used to concentrate the chromatographic extract at low temperature, and the vacuum belt drying device is used to dry the concentrated chromatographic extract into a resistant dextrin solid.

2. The system for preparing resistant dextrin and polydextrose using corn starch as claimed in claim 1, characterized in that: The polydextrose preparation component includes a glucose collecting tank, a third scraped film evaporator, a second polymerization reactor, a pulverizing device and a mixing tank which are connected in sequence through pipelines. The glucose collecting tank is used to collect chromatographic raffinate, the third scraped film evaporator is used to concentrate the chromatographic raffinate at low temperature, the second polymerization reactor is used to polymerize the concentrated chromatographic raffinate to prepare polydextrose, the pulverizing device is used to pulverize polydextrose solid, and the mixing tank is used to dissolve the pulverized polydextrose and adjust the pH of the polydextrose to obtain a polydextrose finished product.

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