Ultrafine starch or cereal-based wheat flour composition and related methods

Abstract

The method for forming an ultrafine starch / flour product includes at least one of steps (a) or (b), where step (a) comprises heating a mixture of water and native / modified starch / flour and extruding the mixture through a screw configuration including at least one low-shear forward conveying screw and at least one high-shear mixing screw in series to produce an extrudate, and step (b) comprises forming a mixture of water, lipid, and native / modified starch / flour and drying the mixture to produce a dried lipid-starch / flour intermediate. The starting starch / flour can be milled before or after step (a) or (b). The ultrafine starch / flour particle product has higher water solubility than a starch / flour particle product produced in a screw configuration lacking a high-shear mixing screw or the starch / flour intermediate produced in (b) without lipid. In one embodiment, the method lacks a chemical or enzymatic reaction.

Description

[Technical Field]

[0001] This invention relates to starch or cereal-based wheat flour compositions and related methods. [Background technology]

[0002] Starch and grain-based flours are natural ingredients made from agricultural raw materials. Starch has been refined in industry through grinding, sieving, and drying. Natural starch occurs as crystalline microscopic granules held together by molecular association. These granules typically have low solubility in cold water and become highly viscous when gelatinized. These poor solubility and high viscosity properties limit the use of natural starch and / or require further chemical modification. Because starch is environmentally friendly, starch microparticles, more specifically starch particles, have attracted commercial interest and have been proposed as a promising ingredient in a variety of fields, including food, beverages, coatings, cosmetics, and pharmaceuticals, as well as various composite materials used in food and industrial applications.

[0003] Various processes have been proposed to produce submicron-sized starch particles. U.S. Patent No. 6,677,386 discloses a chemically reactive extrusion process for preparing biopolymer nanoparticles, in which the biopolymer is plasticized using shear force and a crosslinking agent is added during the process. This patent discloses that exemplary crosslinking agents are dialdehydes and polyaldehydes that reversibly form hemiacetals, acid anhydrides and mixed anhydrides (e.g., succinic acid and acetic anhydride), etc. This patent discloses that preferred dialdehydes and polyaldehydes are glutaraldehyde, glyoxal, periodic acid-oxidized carbohydrates, etc., with glyoxal being a particularly preferred crosslinking agent. This patent describes ultrafine starch particles, aqueous dispersions of said particles, and extruded products prepared by the process.

[0004] PCT International Patent Publication 00 / 40617 discloses a method for preparing starch particles using a two-phase system, the method comprising: a) preparing a first phase containing a dispersion of starch in water; b) preparing a dispersion or emulsion of the first phase in a second liquid phase, provided that the second phase is not water; c) crosslinking of starch present in the first phase; and d) separating the starch particles thus formed. Disclosed examples of crosslinking agents include epichlorohydrin, glyoxal, trisodium trimetaphosphate, phosphoryl chloride, or anhydrides of dibasic or polybasic carboxylic acids.

[0005] U.S. Patent No. 9,828,441 discloses a process for preparing extruded gelatinized and partially hydrolyzed starch using an acid in an aqueous environment.

[0006] U.S. Patent No. 9,510,614 discloses a low-shear process for processing soluble whole grain flour (whole grain). Enzyme-treated oat flour is prepared by mixing a starting mixture of whole oat flour and a suitable enzyme solution in a mixer (sometimes called a preconditioner), and then heat-treating the mixture. The enzyme-treated mixture is then subjected to an extrusion process to gelatinize, hydrolyze, and cook the oat flour mixture. This patent discloses that low shear is applied to the mixture in the extruder. This patent discloses that high shear is not required in the process because the enzyme pre-treats the starch. This patent discloses that high shear makes it difficult to control the degree of hydrolysis and can also cause the dough temperature to rise excessively, which can overcook the dough and result in an excessive flavor of the cooked grain. This patent characterizes a low-shear extrusion process compared to high-shear extrusion using a high-moisture and low-shear screw design versus a low-moisture and high-shear screw design, and discloses that a typical screw speed for the low-shear process is 200–350 rpm.

[0007] Document CN102870853 discloses soy flour having a particle size of 6.5 μm ≤ D ≤ 13 μm. It states that soy flour is obtained by grinding soybeans, and that ultrafine soy flour is a soy product obtained mainly by pressing and extracting soybean meal, grinding it with an airflow, and then extracting soybean oil. This document states that ultrafine soy flour has high solubility and is easily absorbed and digested by the human body. This document also discloses a soy nutritional substitute meal prepared with ultrafine soy flour as the main ingredient, and that all ingredients are food grade.

[0008] A significant limitation is that conventional methods for preparing starch particles for useful applications are complex and require toxic or harmful organic solvents. Products from such conventional processes are generally not considered label-friendly for FDA purposes and typically cannot be characterized with a "clean" label in the food and other industrial sectors. Other limitations of conventional methods include expensive technology and often the use of large amounts of solvent and / or high energy. Conventional methods include acidification aqueous techniques, which are difficult to control and where the degree of modification of starch particles is affected by the influence of temperature, time, concentration, acid strength, procedure, and equipment. Furthermore, treating starch with acid requires the addition of large amounts of alkali for neutralization, which in itself introduces considerable disadvantages and difficulties. In addition, acidification methods are not applicable to wheat flour due to the presence of other components such as proteins, fibers, and ash. These components complicate the acid modification and negatively affect product quality, making them unsuitable for commercial use.

[0009] Conventional processes produce products that lack desirable high stability and water solubility, and often result in phase separation.

[0010] In addition to the challenges the industry faces, there is currently a growing demand for non-chemical or non-enzymatically modified products. There is a need for simple and reliable methods for preparing non-chemically modified grain / grain-based flours and starches, particularly ultrafine particles. [Overview of the Initiative]

[0011] The present invention offers advantages over conventional methods and products. In one embodiment, a method for forming ultrafine (also called submicron) starch or wheat flour particles comprises mixing starch or deembryed wheat flour, or a combination thereof, with liquid water or steam, or a combination thereof, to produce a mixture. As used herein, ultrafine or submicron is used to characterize particles having a diameter of less than one millionth of a meter.

[0012] In one embodiment, a method for forming an ultrafine starch or flour product comprises at least one of step (a) or (b). Step (a) includes heating a mixture of water and natural or modified starch or flour to a temperature in the range of 25 degrees Celsius to less than 200 degrees Celsius, and extruding the mixture through a screw configuration comprising at least one low-shear forward conveying screw and at least one high-shear mixing screw in series to produce an extruded product. As used herein, modified starch or modified flour means a starch or flour derivative prepared by physically treating natural starch or flour to alter its properties.

[0013] Step (b) includes forming a mixture of water, lipids, and natural or modified starch or wheat flour, and drying the mixture of water, lipids, and natural or modified starch or wheat flour to produce a dried lipid starch intermediate or a dried lipid wheat flour intermediate.

[0014] In one embodiment, the method comprises at least one of step (c) or (d). Step (c) comprises grinding natural or modified starch or flour before either step (a) or (b) to reduce the particle size of the natural or modified starch or flour. Step (d) comprises crushing the extruded product produced in (a) or crushing the dry lipid starch intermediate or flour intermediate produced in (b), and thus comprises producing a starch or flour particle product having higher water solubility compared to the starch or flour intermediate produced in (b) without lipids, produced by extruding the mixture in (a) with a screw configuration consisting of a low-shear forward conveying screw and lacking a high-shear mixing screw, and the method lacks chemical or enzymatic reactions. In one embodiment, crushing the extruded product produced in (a) or the dry lipid starch intermediate or flour intermediate produced in (b) is carried out by roll pressing, grinding, milling, or a combination thereof.

[0015] In one embodiment, the method involves heating a mixture to a temperature between 25°C and less than 200°C, extruding the mixture through a screw configuration, and thus producing ultrafine starch particles without chemical or enzymatic reactions. In one embodiment, the screw configuration includes at least one low-shear forward-conveying screw and at least one high-shear mixing screw in series. In one embodiment, the ultrafine (i.e., submicron) starch or flour particles have higher water stability compared to starch or flour particles extruded through a screw configuration consisting of a low-shear forward-conveying screw and lacking a high-shear mixing screw. In one embodiment, the method lacks a grinding step.

[0016] In one embodiment, the apparatus comprises a heat source and a screw configuration including at least one low-shear forward-conveying screw and at least one high-shear mixing screw section in series, wherein the heat source is configured to heat a mixture of starch or deembride wheat flour or a combination thereof with water to a temperature of 25 degrees Celsius to less than 200 degrees Celsius, and the screw configuration is configured to extrude the mixture to produce ultrafine starch particles without chemical or enzymatic reaction, compared to starch or wheat flour particles extruded by a screw configuration consisting of a low-shear forward-conveying screw and lacking a high-shear mixing screw. In one embodiment, the apparatus lacks a grinding device.

[0017] In one embodiment, the ultrafine starch or cereal-based particle extruded product comprises ultrafine starch or cereal-based particles characterized by a volume density of about 4% and a peak size of about 0.12 μm, and the extruded product preferably lacks chemical or enzymatic reactants.

[0018] In one embodiment, the ultrafine starch or grain-based particle extruded product comprises ultrafine starch or grain-based particles characterized by a water solubility ranging from approximately 75 to 95% for at least 48 hours.

[0019] In one embodiment, the method includes mixing extruded ultrafine starch particles with water to produce an aqueous solution that is substantially free from phase separation.

[0020] In one embodiment, the starch or grain-based wheat flour comprises ultrafine particles having high solubility and stability in aqueous solution.

[0021] In one embodiment, the starch or grain-based wheat flour comprises ultrafine particles having high solubility and stability in an oil solution.

[0022] In one embodiment, the aqueous solution comprises starch or grain-based wheat flour containing ultrafine particles lacking chemical or enzymatic reactants.

[0023] In one aspect, the method includes forming particulate starch products by mixing starch and water such that a non-chemically or non-enzymatically modified source is subjected to mechanical force and shear. The present invention provides a process by extrusion at a temperature of 25 degrees Celsius to less than 200 degrees Celsius during processing, and surprisingly produces products exhibiting high solubility and can be carried out without using any additives. In particular, this process need not be carried out under acidic conditions or alkaline conditions, or in the presence of chemical additives and / or enzymes.

[0024] In one aspect, a method of forming an ultrafine starch or flour product includes: (a) forming a mixture of water, lipid, and natural or modified starch or flour, and drying the mixture of water, lipid, and natural or modified starch or flour to produce a dried lipid starch intermediate or a dried lipid flour intermediate; and at least one of steps (b) or (c), where (b) is prior to step (a) and includes grinding natural or modified starch or flour to reduce the particle size of the natural or modified starch or flour, and (c) includes milling the dried lipid starch intermediate or flour intermediate produced in (a), thereby producing an ultrafine starch or flour product having high water solubility compared to the starch or flour intermediate produced in (b) without lipid. In one embodiment, this method lacks a chemical reaction or an enzymatic reaction.

[0025] In one aspect, the present invention relates to a novel starch or cereal-based flour composition comprising unique ultrafine particulate materials having unique solubility and stability in an aqueous system. The design and use of the process parameters of the present disclosure enable the formation of new and unique starch-based particles. The processes disclosed herein result in products and compositions that can be used in a variety of fields including the fields of drugs, cosmetics, coatings, and polymer compositions. In particular, the disclosed ultrafine product compositions and subsequent powder properties can be used in specific food and beverage products with the following improvements and uses. a. Improvement of sensory and functional properties in high-moisture food systems. b. Improvement of the supply of flavors, oils, and micro / macro nutrients due to increased surface area and activity as required for food and feed. c. The texture of specific foods such as bakery products, crackers, bars, gluten-free foods, etc. is improved, and the adhesion and texture functions are enhanced due to high solubility and stability. d. Improve the solubility of carbohydrates and proteins and provide nutritional functions to foods and feeds. e. Improved particulate compositions for coating paper, and improved adhesion required for products replacing latex and bioadhesives.

[0026] These and other aspects, embodiments, and related advantages will become apparent from the following detailed description.

Brief Description of the Drawings

[0027] [Figure 1] Shows a part of a low-shear conveying screw according to an aspect of the present invention. [Figure 2] Shows a part of a high-shear mixing screw according to an aspect of the present invention. [Figure 3] Shows a part of two parallel triple flight cone screws according to an aspect of the present invention. [Figure 4] Shows a part of two parallel feed screws according to an aspect of the present invention. [Figure 5] Shows a part of a shear lock screw with a front feed lobe according to an aspect of the present invention. [Figure 6] Shows a part of a reverse lobe shear lock screw according to an aspect of the present invention. [Figure 7] Shows a screw configuration according to an aspect of the present invention. [Figure 8] A graph of bulk density (%) vs. size class (μm), showing the wet particle size distribution of starch particles manufactured according to an aspect of the present invention compared to the wet particle size distribution of natural dent corn starch. [Figure 9] This graph shows the solubility % over time, illustrating the stability of various particles manufactured according to embodiments of the present invention, based on real-time (RT) solubility %. [Figure 10] This shows a starch product manufactured according to an embodiment of the present invention. [Figure 11] This shows a wheat flour product manufactured according to an embodiment of the present invention, which has higher solubility in aqueous solution compared to conventional wheat flour products in aqueous solution. [Figure 12] The X-ray diffraction (XRD) pattern of a cornstarch sample prepared according to an embodiment of the present invention is shown. [Modes for carrying out the invention]

[0028] Figure 1 shows a portion of a low-shear conveying screw 100 according to an embodiment of the present invention. The low-shear conveying screw 100 is positioned inside a pipe or tube (not shown). The low-shear conveying screw 100 is used to move or convey material through the pipe or tube. The low-shear conveying screw 100 has a helical surface 102 surrounding a central shaft 104. The helical surface 102 includes external threads 106. The threads 106 are of equal dimensions and are aligned in the same manner as each adjacent thread 106. The shaft surface 108 is positioned between adjacent threads 106. As the low-shear conveying screw 100 rotates around the axis of the central shaft 104, the material inside the pipe or tube is moved through the pipe or tube by the low-shear conveying screw 100.

[0029] Figure 2 shows a portion of an exemplary high-shear mixing screw 200 according to an embodiment of the present invention. The high-shear mixing screw 200 is placed inside a pipe or tube (not shown) and has an asymmetrical surface 202 surrounding a central shaft 204. The asymmetrical surface 202 includes threads 206 that are offset from each adjacent thread 206. As the high-shear mixing screw 200 rotates around the axis of the central shaft 204, the material inside the pipe or tube is mixed by the high-shear mixing screw 200. In Figure 2, eight threads 206 are shown. However, in embodiments of the present invention, more or less threads 206 may be used.

[0030] Figure 3 shows a portion of two parallel triple flight cone screws 300 according to an embodiment of the present invention.

[0031] Figure 4 shows a portion of two parallel feed screws of combination 400 according to an embodiment of the present invention. Figure 4 shows two low-shear conveying screws shown in Figure 1, where the screws are aligned such that the threads 106 of one screw align with the shaft surface 108 between the two threads 106 of the other screw.

[0032] Figure 5 shows a portion of a forward-feed lobe shear lock screw 500 according to an embodiment of the present invention. As shown in Figure 1, the thread 106 is extruded relatively slowly during conveying, and the paddle (shear lock) of the lobe shear lock screw 500 is extruded more quickly. The paddle 502 is an elliptical component that is an inadequate conveying element, even when configured as part of a group of elements set up for "forward conveying". Since forward conveying is about aligning the paddle 502, the general direction of progression of the longest dimension of the paddle (lobe) continues the direction of the conveying elements. Neutral conveying (not shown) basically sets up the paddle so that the lobe is offset by 90 degrees from one paddle to the next in the profile.

[0033] Figure 6 shows a portion of a shear lock screw 600 with reverse feeding lobes according to an embodiment of the present invention. Since reverse conveying essentially aligns the paddles 602, the general direction of lobe progression is opposite to the direction of the conveying element.

[0034] Those skilled in the art who benefit from the present disclosure will recognize that paddles 502 (shown in Figure 5) and 602 (shown in Figure 6) can be constructed in sets equal in length 0.5D. Generally, when the length is 0.5D, blocks of elements may be offset by 90 degrees, so in the case of forward and reverse conveying paddles, each paddle may be offset by 30 degrees from the upstream paddle. Those skilled in the art will recognize that one way to see the conveying direction of a paddle is to look at the top or bottom of a group of paddles as the paddles rotate in the extruder. If the generated “wave” moves from left to right, the parts are carried forward (in the direction of the extruder flow). If the generated “wave” moves from right to left, the parts are carried in the reverse direction (in the opposite direction of the extruder flow).

[0035] The present invention is more specifically illustrated by the following examples and comparative examples. [Examples]

[0036] material Unique ultrafine starch microparticles can be produced from starch or deembryonic flour, or combinations thereof, as well as from water or steam, or combinations thereof, using the non-chemical and non-enzymatic modification processes disclosed herein. An exemplary but not limiting example of dent corn starch is ADM 106 (Archer Daniels Midland). An exemplary example of deembryonic flour is deembryonic corn flour. The starch in deembryonic flour may be derived from plant sources selected from the group consisting of corn, wheat, peas, rice, tapioca, potatoes, and other cereals such as rye, barley, and oats, as well as from certain legumes such as soybeans, peanuts, and combinations thereof.

[0037] Mixing process Natural starch is mixed with water with sufficient shearing and gentle heating to achieve a characteristic particle size distribution. Water can be added in the form of steam or liquid water. During the process, the temperature is in the range of 25 degrees Celsius (i.e., room temperature, "RT") to less than 200 degrees Celsius, preferably in the range of 25 degrees Celsius to less than 140 degrees Celsius. The mixing process can be batch mixing or continuous mixing. This initial mixing process pre-conditions the starch to achieve desirable properties such as moisture content, pH, and temperature for further processing of the starch.

[0038] Example 1 Extrusion process. Starch particles demonstrating high solubility and stability were produced using a pilot-scale TX-57Magnum co-rotating two-screw extruder system (Wenger Manufacturing, Sabetha, KS), which can be fitted with screw shafts and barrels of various lengths and can be equipped with water cooling and steam heating. Two screw configurations were used for the screw configuration identified as the conventional screw configuration (conveyor screw). The two screw configurations were used for a new ADM screw configuration identified as the ADM screw configuration (a combination of a shear lock with forward and reverse feeding rods, a forward cut-flight screw, and a shallow groove cut-flight cone). Figure 7 shows the new ADM screw configuration used in the extrusion process described above.

[0039] The novel ADM screw configuration, shown as screw configuration 700 in Figure 7, was used to investigate the effect of higher mechanical shear on the final properties of the product. Those skilled in the art who benefit from the present disclosure will recognize that suitable extruder systems useful for the present invention are not limited to a specific screw type and may include, for example, uniscrew, ram, or other similar extrusion methods.

[0040] As shown in Figure 7, the screw 700 has two screws 702 and 704. Each screw 702, 704 has a first segment 706 containing a forward cut flight, 1d screw, i.e., a screw configuration shown in Figure 4. Each screw 702, 704 has a second segment 708 containing a 4×45° forward shear lock screw configuration shown in Figure 5. Each screw 702, 704 has a third segment 710 containing a forward cut flight, 1d screw, i.e., a screw configuration shown in Figure 4. Each screw 702, 704 has a fourth segment 712 containing a 3×45° forward shear lock screw configuration (similar to the configuration shown in Figure 5, but with three shear locks or paddles instead of the four shear locks or paddles shown in Figure 5). Each screw 702, 704 has a fifth segment 714 containing a 3 × 45° reverse shear lock screw configuration (similar to the configuration shown in Figure 6, but with three shear locks or paddles instead of the four shear locks or paddles shown in Figure 6). Each screw 702, 704 has a sixth segment 716 containing a 2 × 45° reverse shear lock screw configuration. Each screw 702, 704 has a seventh segment 718 containing a 3 × 30° forward shear lock screw configuration. Each screw 702, 704 has a sixth segment 716 containing a 2 × 45° reverse shear lock screw configuration. Each screw 702, 704 has a seventh segment 718 containing a 3 × 30° forward shear lock screw configuration. Each screw 702, 704 has an eighth segment 720 containing a 3 × 45° forward shear lock screw configuration. Each screw 702, 704 has a ninth segment 722, which includes a shallow groove cut flight cone configuration. The segment 722 has the same configuration as the parallel tripole flight cone screw 300 shown in Figure 300.Zones 1, 2, 3, 4, and 5 (referred to as barrels 1, 2, 3, 4, and 5 in Figure 7) have extrusion temperatures as identified in Figure 7.

[0041] Example 2 Formulations. Different formulations designed and prepared for the development and evaluation of extruded wheat flour and starch according to embodiments of this disclosure, and these formulations are summarized in Table 1. Tests were conducted at pH 6. As screw configuration 700, the ADM screw configurations listed in Table 1 are shown in Figure 7. The conventional screw configurations listed in Table 1 are screw configurations consisting only of conventional conveyor screws. [Table 1]

[0042] result The starch particle distribution was determined for Sample 4 (prepared using the ADM screw configuration 700) and Sample 3 (prepared using a conventional screw configuration consisting only of conventional transport screws). Sample 4, prepared according to this disclosure, had a unique starch particle distribution with >50% of particles in the submicron range. See Table 2 and Figure 8 below. As shown in Table 2, Sample 4 (prepared using the ADM screw configuration 700) had 67% of particles with a D90 (μm) of 0.591 (peak 1), while Sample 3 (prepared using a conventional screw configuration consisting only of conventional transport screws) had only 1.72% with a D90 (μm) of 0.84 (peak 3). [Table 2]

[0043] Wet particle size distribution. Figure 8 is a graph of volume density (%) versus size class (pm) showing the wet particle size distribution of starch particles produced according to an embodiment of the present invention (i.e., with 20% water added and extruded with the new ADM screw configuration 700, Sample 4 in Table 1) compared with the wet particle size distribution of natural dent corn starch extruded using a conventional screw configuration consisting only of a conventional transport screw (i.e., Sample 3 in Table 1 with 20% water added). As shown in Figure 8, the ultrafine starch particles produced with the new ADM screw configuration 700 and lacking chemical or enzymatic reactants are characterized by a volume density of about 4% and a peak size of about 0.12 μm. As shown in Figure 8, the particles produced according to an embodiment of the present invention, i.e., Sample 4 in Table 1, have a much larger volume density % and a smaller size class (see Peak 1) than natural dent corn starch (i.e., Sample 3 in Table 1) extruded using a conventional screw configuration consisting only of a conventional transport screw (Peak 3).

[0044] Solubility is determined by mixing with water. In a preferred embodiment, the product prepared according to the present invention will also be substantially completely soluble in cold water, i.e., soluble in water at 25°C (i.e., room temperature). The method for determining solubility is described below. According to a preferred method for determining cold water solubility, 4.0 g (dry basis) of the product is dispersed in 80.0 g of distilled water. After stirring at 25°C for 10 minutes, the slurry is transferred to a 100 mL graduated cylinder and diluted to volume. The graduated cylinder is inverted three times and left to stand at 25°C for 12 minutes. Next, one 20 g aliquot of the supernatant is transferred to a pre-weighed pan. Next, the pan is placed on a hot plate and evaporated to dryness. Next, the weight of the pan is weighed and recorded as the dry sample weight. Solubility is calculated using the following formula: Solubility = [(Dry Sample Weight) / 0.8 * 100]. If the solubility is at least about 70%, more preferably at least about 80%, the product is considered to have high solubility. The products prepared according to the present invention have excellent cold water solubility and are particularly useful in relation to food, coatings, cosmetics, pharmaceuticals, and various composite materials.

[0045] Solubility over time. Figure 9 is a graph of solubility % over time, showing the stability by solubility % in water at room temperature (RT), i.e., 25°C, for various particles manufactured according to embodiments of the present invention. As shown in Figure 9, products manufactured according to this disclosure (Samples 2 and 4, i.e., extruded with the new ADM screw configuration 700, see Table 1) have much higher solubility % in water over time than corresponding products manufactured using a conventional screw configuration consisting only of a conventional conveyor screw (Samples 1 and 3, see Table 1). Sample 4 had a solubility of over 80% after about 2 hours and over 75% after 48 hours, compared to the corresponding sample 3, which had a solubility % of about 40% after about 2 hours and about 10% after 48 hours. Sample 2 had a solubility of over 60% after about 2 hours and about 43% after 48 hours, compared to the corresponding sample 1, which had a solubility of less than 30% after about 2 hours and about 10% after 48 hours.

[0046] Example 3 High stability of starch product in aqueous solution. Figure 10 is a diagram showing starch product 1002 (i.e., sample 4 in Table 1, extruded with a new ADM screw configuration 700) produced according to an embodiment of the present invention after being mixed with water according to the process described above in the heading "Mix with water to determine solubility". As shown in Figure 10, starch product 1002 exhibits no phase separation and high stability in aqueous solution. The photograph of starch product 1002 in water shown in Figure 10 was taken 24 hours after mixing starch product 1002 with water.

[0047] Example 4 High stability of flour products in aqueous solutions. Figure 11 is a drawing showing flour product 1102 (i.e., extruded with a new ADM screw configuration 700) manufactured according to an aspect of the present invention after being mixed with water according to the process described above in the heading “Mix with water to determine solubility,” and exhibits high solubility in aqueous solutions compared to conventional flour product 1104 in aqueous solutions. As shown in Figure 11, flour product 1102 manufactured according to this disclosure exhibits no phase separation and high stability in aqueous solutions compared to conventional flour product 1104 extruded using a conventional screw configuration consisting only of a conventional conveyor screw, which exhibits significant phase separation with more solid than the upper phase 1108 as shown in the lower phase 1106. Photographs of flour product 1102 in water and the conventional flour product shown in Figure 11 were taken 24 hours after mixing with water, respectively.

[0048] Example 5 A formulation of starch / wheat flour and lipids. Embodiments of the present invention include a starch / wheat flour mixture combined with a lipid formulation.

[0049] Composition of lipid compounds.

[0050] The process includes the preparation of lipid formulations according to the following:

[0051] (1) Microemulsion (ME): 5 grams of monoglyceride was added to a 5% glycerol solution in DI water and mixed well. Next, 2 grams of soy lecithin was added to the solution and mixed well. Then, 12 grams of medium-chain triglycerides ("MCT") were added to the solution and mixed well.

[0052] (2) Emulsifier blend (EM): 12.6 grams of monoglyceride was added to a 12% glycerol solution and mixed well. Next, 5 grams of soy lecithin was added to the solution and mixed well.

[0053] (3) Palmitic acid formulation (PAF): 2.5 grams of monoglyceride was added to 15 grams of DI water and mixed well. Next, 2.5 grams of palmitic acid was added to the solution and mixed well.

[0054] Table 3 shows the composition of the lipid compound in weight percent. [Table 3]

[0055] The starch / wheat flour mixture is mixed with a lipid formulation preparation. The process involves a starch / wheat flour mixture with a desired lipid formulation preparation, as follows: (1) A 10% dry solids (DS) slurry was prepared by adding 30 grams DS of the desired starch / wheat flour to deionized (DI) water; (2) In the case of a sample with added lipid formulation, 6 grams of the desired lipid formulation was added to the slurry; (4) The slurry was dried using a Buchi B290 spray dryer at an inlet temperature of 100 degrees Celsius, an outlet temperature of approximately 60 degrees Celsius, and a pump speed of 1.1-1.4 mL / min. In the case of spray drying, the liquid sample is pumped to the spray drying nozzle.

[0056] Example 6 Grinding. Ultrafine starch or flour was produced using a fluidized bed jet mill (Netzsch Condux CGS 10). The starch or flour was introduced into the mill by a volumetric feeder and ground by compressed gas supplied to three grinding nozzles at 6 bar. Particle size could be adjusted by adjusting the rotation speed of the internal classifier. At a classifier speed of 14,000 rpm, starch or flour was produced with a D50 of 3-4 μm and a D90 of less than 10 μm (Table 4). Particle size could also be adjusted by adjusting the grinding time. Grinding cornstarch-1 and grinding cornstarch-2 had the same starting material, but grinding cornstarch-1 was ground for a longer time than grinding cornstarch-2.

[0057] Powder particle size and surface area. The particle size and surface area of ​​the powder were analyzed using a Malvern Mastersizer 3000 dry module. Changes in the particle size and surface area of ​​the dry powder were monitored. The particle size and surface area are shown in Table 4. As shown in Table 4, the adjustable process technology for manufacturing ultrafine products according to this disclosure is 318m 2 Compared to a substrate in which a surface area of ​​13.0 μm / kg and a particle size D10 of 13.0 μm were derived, reducing the particle size of D10 to 1.42 μm resulted in a maximum of 3,278 m 2 Increases the surface area per kg. See comparison of ground rice flour with natural rice flour. The ultrafine products of the present invention have the following improved properties compared to the base materials from which they are derived: (i) ground corn starch-1, a 79% reduction in particle size D10 (1.82 / 8.80) and a 7.6-fold increase in surface area (3073 / 401); (ii) ground corn starch-2, an 80.7% reduction in particle size D10 (1.70 / 8.8) and a 4.7-fold increase in surface area (1892 / 401); (iii) ground modified tapioca starch, an 80% reduction in particle size D10 (1.7 / 8.67) and a 5.7-fold increase in surface area (3286 / 573); (iv) ground rice flour, an 89.1% reduction in particle size D10 (1.42 / 13.0) and a 10.3-fold increase in surface area (3278 / 318). Those skilled in the art who benefit from this disclosure will realize that a tunable process technology for manufacturing ultrafine products in accordance with this disclosure reduces the particle size of D10 to 1 μm, thereby reducing it by up to 4,000 m compared to the substrate from which it is derived. 2 It will be recognized that this can provide an increased surface area of ​​100-4,000 m² / kg. In one embodiment, the ultrafine product according to the present disclosure is 100-4,000 m². 2 It may have a surface area of ​​ / kg and a particle size D10 of 1 to 200 μm. [Table 4]

[0058] Particle size and dispersion surface area were analyzed using the Malvern Mastersizer 3000 wet module. Table 5 shows the effects of different lipid formulations on particle size and surface area of ​​the pulverized material. As shown in Table 5, spray drying of the pulverized material with lipid formulations reduced particle size and increased surface area compared to the case without lipid formulations. [Table 5]

[0059] Example 7 Color and whiteness of the dried powder. Color characteristics were analyzed using a colorimeter, namely HunterLab ColorFlex EZ. Changes in whiteness (L*) of the dried powder were monitored. The color characteristics are shown in Table 6. As shown in Table 6, suitable process techniques combined with the addition of lipid formulations, such as grinding, spray drying, and PAF formulations, provide products with retained whiteness characteristics compared to the substrate from which they are derived. [Table 6]

[0060] Example 8 The color properties were analyzed using a HunterLab ColorFlex EZ. The change in whiteness (L*) of a 10% SS aqueous dispersion was monitored by heating it in a water bath at 60 degrees Celsius for 30 minutes. The color properties are shown in Table 7. As shown in Table 7, suitable lipid formulations, such as PAF formulations, provide protection against the decrease in whiteness of ultrafine starch or wheat flour particle products, particularly spray-dried pulverized modified tapioca starch, pulverized rice flour, spray-dried pulverized rice flour, pulverized corn starch, and spray-dried pulverized corn starch, except for pulverized modified tapioca starch (without spray drying). As shown in Table 7, suitable lipid formulations, such as PAF formulations, provide protection against the decrease in whiteness of ultrafine starch or wheat flour particle products prepared using spray drying. Ultrafine starch or wheat flour particle products prepared with PAF formulations and by spray drying exhibit improved thermal stability, as evidenced by the less decrease in whiteness compared to products prepared by spray drying without PAF formulations. [Table 7]

[0061] Example 13 Differential Scanning Calorimeter (DSC). The thermal properties of the dried product were monitored using a TA instrument, DSC2500. A 10 mg sample of DS and 30 mg of DI water were added to a DSC pan and equilibrated overnight (approximately 16–20 hours) at room temperature. DSC parameters were set to a rate of 5 degrees Celsius / minute from 30 degrees Celsius to 170 degrees Celsius. Peak temperatures, which are the temperatures associated with the gelatinization process, were analyzed on the DSC thermogram using Trios software. The peak temperature characteristics analyzed by DSC are shown in Table 8. As shown in Table 8, the grinding and addition of lipid formulations, e.g., PAF formulations, provide improved thermal stability, characterized by higher DSC peak temperatures compared to the substrates from which they are induced. [Table 8]

[0062] Example 14 The X-ray diffraction (XRD) patterns of corn starch samples are shown in Figure 12. The crystallinity and amylose-lipid complex formation characteristics of the dried products were monitored using a Bruker D8 Advance equipped with a Cu Kα radiation source λ = 1.5406 Å operating at 40 kV and 40 mA. The dried products were corn starch or derived from corn starch, and the relative crystallinity % (RC) and relative intensity % (RI) at 2θ = 19.8° (%) were specified as follows. a) Native, RC 38%, RI 0%, b) Ground, RC 36.9%, RI 4.1%, c) Dry mix combined with PAF formulation, RC 35%, RI 6.8%, d) Freeze-dried slurry mix combined with PAF formulation, RC 38.0%, RI 16.7%, e) Spray-dried slurry mix combined with PAF formulation, RC 36.8%, RI 17.1%, and f) Paste, RC 0%, RI NA. The relative intensity was recorded in the scattering angle range (2θ) of 4.0 - 34.0° using a scintillation counter at a scan rate of 0.02° per minute in the combined 2-theta scan type. 1 The relative crystallinity (RC) is expressed as a percentage and calculated from the crystals (I c -I a ) / I c ×100 using the following formula for each diffraction pattern, where I c is the crystalline and I a is the amorphous region.

[0063] The paste was prepared by cooking the starting components in deionized (DI) water at 95 °C for 30 minutes and then immediately freeze-drying. The X-ray diffraction of the paste was used as the amorphous region (I a ) with RC of 0% (as shown in Figure 12).

[0064] Referring to Figure 12, the peak intensity reflects at 2θ = 15, 17, 18, and 23° are associated with the A-type pattern of the native crystal structure. The diffraction peak at 2θ = 19.8° was due to the formation of a starch-lipid complex, while the peak at 2θ = 21.3° was due to free and uncomplexed lipids (see Chao, C., Yu, J., Wang, S., Copeland, L., Wang, S., (2017)). Mechanisms underlying the formation of complexes between maize starch and lipids. Journal of Agricultural and Food Chemistry 66(1), 272-278).

[0065] Table 9 shows the relative crystallinity (RC) characteristics analyzed by XRD. As shown in Table 9, granular integrity was maintained by grinding and combining with lipid formulations, such as PAF formulations. The original crystallinity of the product was retained at 88% or more compared to the substrate from which it was derived. [Table 9]

[0066] Example 15 X-ray diffraction (XRD). The amount of amylose-lipid complex formation was analyzed from the intensity of the peak at 2θ = 19.8°. Table 10 shows the relative intensity at 2θ = 19.8° compared to the substrate from which it originated. As shown in Table 10, combinations with lipid formulations, e.g., PAF formulations, increased complex formation by up to 25% compared to the substrate from which it originated. [Table 10]

[0067] Example 16 X-ray diffraction (XRD). The effect of particle size on the amount of amylose-lipid complex formation was analyzed from the intensity of the peak at 2θ = 19.8°. Table 11 shows the relative intensity at 2θ = 19.8° compared to the substrate from which it originated. As shown in Table 9, the claimed process technology for producing ultrafine products enhanced amylose-lipid complex formation even under ambient conditions, but products with smaller particle sizes, such as corn starch, showed higher amylose-lipid complex formation compared to larger particle sizes. As shown in Table 11, increasing the moisture content, e.g., dry mix vs. slurry mix, enhanced the interaction between the lipid formulation and the base micronizing material, increasing amylose-lipid complex formation by up to 16.7%. As shown in Table 11, increasing the drying temperature, e.g., using spray drying vs. freeze drying, enhanced the interaction between the lipid formulation and the base micronizing material, increasing amylose-lipid complex formation by up to 17.1%. [Table 11]

[0068] Example 17 Color absorbance. The absorption capacity of the product was monitored by the absorbed color using spectrophotometric analysis. A 1% w / w solution of the dye, e.g., brilliant green, was prepared in DI water. 0.1 g of DS starch / wheat flour and 9.9 g of DI water were added to a centrifuge tube and mixed well. The tube was then centrifuged at 1000 x g for 5 minutes, and the supernatant was analyzed at 625 nm using an Agilent Cary60 UV-Vis. Relative color absorbance was calculated using the following formula: Relative color absorbance (%) = 100 × (absorbance of brilliant green - absorbance of sample) / absorbance of brilliant green, with higher relative color absorbance indicating higher absorption capacity of the sample. The characteristics of relative color absorbance are shown in Table 12. As shown in Table 12, an improvement in adsorption capacity of up to 90% was observed. [Table 12]

[0069] The advantages of this disclosure are as follows: a. A method for developing a thermally stable lipid complex by improving the interaction between lipids and ultrafine starch / wheat flour due to an increase in surface area, thereby maintaining granular integrity and original crystallinity. b. A modifiable process technology is disclosed for increasing the surface area and incorporating lipid formulations while maintaining a high degree of product whiteness. c. By incorporating the requested lipid formulation into ultrafine starch / wheat flour, improvements in dispersion / opacity were observed. d. Preservation of crystallinity and granular integrity was observed when the product was ground and combined with lipid-based products. e. For starch / wheat flour with smaller particle sizes (determined using XRD), a higher amylose-lipid complex formation ability was observed, and f. The disclosed technology enables the formation of amylose-lipid inclusion complexes with readily oxidizable lipids, as well as heat-sensitive components such as flavors, colors, and plant extracts.

[0070] The present invention provides a simple, clean, and cost-effective selection of processes and conditions for producing a variety of ultrafine starch / flour particles exhibiting over 75% water solubility and stability for at least approximately 48 hours. These stability and solubility of the ultrafine starch / flour particles of the present invention surpass those typical of conventional products on the market. The ultrafine starch / flour particles of the present invention offer improved utility in food and industrial applications that cannot be achieved with conventional products. Those skilled in the art who benefit from this disclosure will recognize that the unique ultrafine (also known as submicron) starch / flour particles and products, compositions, and powder formulations disclosed herein offer the following advantages: a. Use of ultrafine starch particles manufactured using a simple, cost-effective, and chemically unmodified process as a bulking agent for specific food applications such as dry mixes and sweeteners. b. Improvement of sensory and sensory functions in certain high-moisture foods such as bakery filings and icings, cereal bars, extruded snacks, margarine, low-fat spreads, shortening, confectionery, sour cream, yogurt, cheese, processed cheese, and beverages. c. Use as a carrier for flavors, micro / macronutrients, enzymes, and dietary supplements. d. Improved texture delivery in food by setting a wide range of solubility and stability to improve adhesion and create desirable textures such as crispness and crunch, which are important for the end user's dining experience. e. Improved carbohydrate and protein solubility for favorable nutritional function of food and feed. f. Improved particulate composition and improved adhesion for industrial, cosmetic, and paper coating applications.

[0071] Color absorbance. Those skilled in the art who have the advantages of this disclosure will recognize that the method of the present invention provides novel ultrafine starch particles useful for food applications, as carriers, and for coating applications.

[0072] This disclosure has been described with reference to certain exemplary embodiments, compositions, and their uses. However, it will be recognized by those skilled in the art that various substitutions, modifications, or combinations of any of the exemplary embodiments can be made without departing from the spirit and scope of this disclosure. Accordingly, this disclosure is not limited by the description of the exemplary embodiments, but rather by the claims submitted initially.

Claims

1. A method for forming ultrafine starch or wheat flour products, Step (a) Heat a mixture of water and natural or modified starch or wheat flour to a temperature in the range of 25 degrees Celsius to less than 200 degrees Celsius, and extrude the mixture using a screw configuration including at least one low-shear forward conveying screw and at least one high-shear mixing screw in series to produce an extruded product, and Step (c) or (d), (c) Before step (a), grind the natural or modified starch or wheat flour to reduce the particle size of the natural or modified starch or wheat flour, or (d) Crushing the extruded material produced in (a), Therefore, the extrusion of the mixture in (a) is characterized by producing an ultrafine starch or flour particle product having higher water solubility compared to a starch or flour particle product produced with a screw configuration consisting of a low-shear forward conveying screw and lacking a high-shear mixing screw. The above method lacks a chemical reaction or an enzymatic reaction. The ultrafine starch or wheat flour product comprises particles having a diameter of less than 1 / 1,000,000 of a meter. The at least one low-shear conveying screw is a forward-cut flight screw, and the at least one high-shear mixed screw is a forward-shear lock screw. The particle size D10 of the aforementioned ultrafine starch or wheat flour particle product is 3.71 μm or less, and the surface area is 100 to 4,000 m². ２ / kg, The screw configuration includes, in series, a first low-shear forward conveying screw including a forward cut-flight screw, a first high-shear mixed screw including a forward shear lock screw, a second low-shear forward conveying screw including a forward cut-flight screw, a second high-shear mixed screw including a forward shear lock screw, a third high-shear mixed screw including a reverse shear lock screw, a fourth high-shear mixed screw including a reverse shear lock screw, a fifth high-shear mixed screw including a forward shear lock screw, and a sixth high-shear mixed screw including a forward shear lock screw. A method wherein the first, second, third, fourth, fifth, and sixth high-shear mixed screws are each selected from the group consisting of 4 × 45° forward shear lock screws, 3 × 45° forward shear lock screws, 3 × 45° reverse shear lock screws, 2 × 45° reverse shear lock screws, 3 × 30° forward shear lock screws, and combinations thereof.

2. The method according to claim 1, wherein the whiteness of the ultrafine starch or wheat flour particle product is 97 or less on the L* colorimetric scale.

3. The method according to claim 1, wherein the gelatinization temperature of the ultrafine starch or wheat flour particle product is in the range of 70.0 to 77.4 degrees Celsius.

4. The method according to claim 1, wherein step (a) is used to ensure that the ultrafine starch or wheat flour particle product retains a degree of crystallinity in the range of 85 to 98% compared to the natural or modified starch or wheat flour from which it is derived.

5. The method according to claim 1, wherein the ultrafine starch or wheat flour particle product has an absorption capacity of up to 90%.

6. The method according to claim 1, wherein the starting natural or modified starch or wheat flour contains at least 30% by weight of starch, and is selected from the group consisting of corn, wheat, barley, rice, potato, tapioca, waxy tapioca, peas, broad beans, and lentils.

7. A method for producing a food product, comprising introducing the ultrafine starch or wheat flour particle product produced according to claim 1, wherein the food product is selected from the group consisting of soup products, dairy products, processed meat products, yogurt products, dressing products, frozen foods, juice products, confectionery products, and bakery products.

8. A method for forming an ultrafine starch or wheat flour particle product, (a) Mixing starch or degerminated wheat flour, or any combination thereof, with water to produce a mixture, (b) Heating the mixture to a temperature in the range of 25 degrees Celsius to less than 200 degrees Celsius, (c) Extruding the mixture with a screw configuration comprising at least one low-shear forward conveying screw and at least one high-shear mixing screw in series to produce an extruded product, (d) Crushing the extruded material to produce an ultrafine starch or flour particle product having higher water solubility compared to a starch or flour particle product produced by a screw configuration in which the extrusion of the mixture consists of a low-shear forward conveying screw and lacks a high-shear mixing screw, The above method lacks a chemical reaction or an enzymatic reaction. The ultrafine starch or wheat flour product comprises particles having a diameter of less than 1 / 1,000,000 of a meter. The at least one low-shear conveying screw is a forward-cut flight screw, and the at least one high-shear mixed screw is a forward-shear lock screw. The particle size D10 of the aforementioned ultrafine starch or wheat flour particle product is 3.71 μm or less, and the surface area is 100 to 4,000 m². ２ / kg, The screw configuration includes, in series, a first low-shear forward conveying screw including a forward cut-flight screw, a first high-shear mixed screw including a forward shear lock screw, a second low-shear forward conveying screw including a forward cut-flight screw, a second high-shear mixed screw including a forward shear lock screw, a third high-shear mixed screw including a reverse shear lock screw, a fourth high-shear mixed screw including a reverse shear lock screw, a fifth high-shear mixed screw including a forward shear lock screw, and a sixth high-shear mixed screw including a forward shear lock screw. A method wherein the first, second, third, fourth, fifth, and sixth high-shear mixed screws are each selected from the group consisting of 4 × 45° forward shear lock screws, 3 × 45° forward shear lock screws, 3 × 45° reverse shear lock screws, 2 × 45° reverse shear lock screws, 3 × 30° forward shear lock screws, and combinations thereof.

9. The method according to claim 8, wherein the starch or deembryed wheat flour is selected from the group consisting of corn, wheat, barley, rice, potato, tapioca, waxy tapioca, peas, broad beans, and lentils.

10. The method according to claim 8, wherein the screw configuration includes, in series, a first low-shear forward conveying screw, at least one high-shear mixed screw, and a second low-shear forward conveying screw.

11. The method according to claim 8, wherein the screw configuration includes, in series, a first low-shear forward conveying screw, a first high-shear mixing screw, a second low-shear forward conveying screw, and a second high-shear mixing screw, the second high-shear mixing screw being selected from the group consisting of a forward-shear locking screw, a reverse-shear locking screw, and combinations thereof.

12. The method according to claim 8, The first high-shear mixed screw is a 4 × 45° forward-shear lock screw, The second high-shear mixed screw is a 3 × 45° forward-shear lock screw, The third high-shear mixed screw is a 3 × 45° reverse shear lock screw. The fourth high-shear mixed screw is a 2 × 45° reverse shear lock screw, The fifth high-shear mixed screw is a 3 × 30° forward-shear lock screw, A method wherein the sixth high-shear mixed screw is a 3 × 45° forward-shear locking screw.

13. The method according to claim 8, further comprising a shallow groove cut flight cone screw following the sixth high-shear mixing screw in series.

14. The method according to claim 12, further comprising a shallow groove cut flight cone screw following the sixth high-shear mixed screw in series.

15. The method according to claim 8, wherein the screw configuration includes a first screw configuration and a second screw configuration, and the first screw configuration is parallel to the second screw configuration.

16. The method according to claim 8, wherein crushing the extruded material includes applying pressure to the extruded material.

17. The method according to claim 16, wherein the pressure applied to the extruded material is selected from the group consisting of roll pressing, grinding, milling, and combinations thereof.

18. An apparatus for forming ultrafine starch or wheat flour products, A heater configured to heat a mixture of starch or deembryed wheat flour, or a combination thereof, with water to a temperature in the range of 25 degrees Celsius to less than 200 degrees Celsius, A screw configuration comprising at least one low-shear forward conveying screw and at least one high-shear mixing screw in series, configured to extrude the mixture to produce an extruded product, The apparatus comprises at least one of a roll press, grinder, mill, or spray dryer, configured to crush the extruded material to produce an ultrafine starch or flour particle product without chemical or enzymatic reactions, wherein the ultrafine starch or flour particle product has higher water solubility compared to a starch or flour particle product lacking chemical or enzymatic reactions produced by a screw configuration consisting of a low-shear forward-conveying screw and lacking a high-shear mixing screw, The ultrafine starch or wheat flour product comprises particles having a diameter of less than 1 / 1,000,000 of a meter. The at least one low-shear conveying screw is a forward-cut flight screw, and the at least one high-shear mixed screw is a forward-shear lock screw. The particle size D10 of the aforementioned ultrafine starch or wheat flour particle product is 3.71 μm or less, and the surface area is 100 to 4,000 m². ２ / kg, The screw configuration includes, in series, a first low-shear forward conveying screw including a forward cut-flight screw, a first high-shear mixed screw including a forward shear lock screw, a second low-shear forward conveying screw including a forward cut-flight screw, a second high-shear mixed screw including a forward shear lock screw, a third high-shear mixed screw including a reverse shear lock screw, a fourth high-shear mixed screw including a reverse shear lock screw, a fifth high-shear mixed screw including a forward shear lock screw, and a sixth high-shear mixed screw including a forward shear lock screw. An apparatus in which the first, second, third, fourth, fifth, and sixth high-shear mixed screws are each selected from the group consisting of 4 × 45° forward shear lock screws, 3 × 45° forward shear lock screws, 3 × 45° reverse shear lock screws, 2 × 45° reverse shear lock screws, 3 × 30° forward shear lock screws, and combinations thereof.

19. The apparatus according to claim 18, wherein the at least one low-shear conveying screw is a forward cut flight screw, and the at least one high-shear mixing screw is a forward-shear lock screw.

20. The apparatus according to claim 18, wherein the screw configuration includes, in series, a first low-shear forward conveying screw, at least one high-shear mixing screw, and a second low-shear forward conveying screw.

21. The apparatus according to claim 18, wherein the screw configuration includes, in series, a first low-shear forward conveying screw, a first high-shear mixing screw, a second low-shear forward conveying screw, and a second high-shear mixing screw, the second high-shear mixing screw being selected from the group consisting of a forward-shear locking screw, a reverse-shear locking screw, and combinations thereof.

22. The apparatus according to claim 18, The first high-shear mixed screw is a 4 × 45° forward-shear lock screw, The second high-shear mixed screw is a 3 × 45° forward-shear lock screw. The third high-shear mixed screw is a 3 × 45° reverse shear lock screw. The fourth high-shear mixed screw is a 2 × 45° reverse shear lock screw, The fifth high-shear mixed screw is a 3 × 30° forward-shear lock screw, The apparatus wherein the sixth high-shear mixing screw is a 3 × 45° forward-shear locking screw.

23. The apparatus according to claim 18, further comprising a shallow groove cut flight cone screw following the sixth high-shear mixing screw in series.

24. The apparatus according to claim 22, further comprising a shallow groove cut flight cone screw following a sixth high-shear mixing screw in series.

25. The apparatus according to claim 18, wherein the screw configuration includes a first screw configuration and a second screw configuration, and the first screw configuration is parallel to the second screw configuration.

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