Alpha-Prolamin Extraction via Enzymatic Hydrolysis
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Solution Overview
Problem
Current methods for extracting α-prolamin from corn gluten meal using organic solvents face challenges such as high energy consumption, solvent loss, and the formation of harmful substances due to high temperatures, as well as the need for decolorization and deodorization steps, which can affect the quality and safety of the final product.
Innovation Solution
A method involving milling and slurrying of the raw material, followed by protease or hydrolase treatment to hydrolyze non-α-prolamin components, filtration to separate the hydrolysate, and subsequent washing and drying to produce a high-purity α-prolamin product without the use of organic solvents, maintaining a mild pH and controlled conditions to minimize degradation and gelation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If organic solvents (isopropanol or ethanol) are used for extracting α-prolamin from corn gluten meal, then extraction efficiency is improved, but solvent loss and high energy consumption occur during evaporation and drying
Solution Approach 1:
The patent changes the extraction parameter from organic solvent to water, fundamentally altering the extraction system. Water extraction at controlled pH and temperature achieves sufficient α-prolamin extraction without the need for energy-intensive evaporation and drying steps required for organic solvent removal, thus resolving the contradiction between extraction efficiency and energy consumption
Solution Approach 2:
The patent replaces expensive and hazardous organic solvents with water, a cheap and safe alternative. This substitution eliminates solvent loss and reduces energy consumption while maintaining effective extraction through optimized water-based conditions, addressing both the productivity and energy loss concerns
2Productivity
If high temperature is used during processing, then extraction rate is improved, but harmful substances (acrylamide) are formed from amino acid reactions
Solution Approach 1:
The patent changes the temperature parameter from high to low (below 60°C), fundamentally altering the processing conditions. This low-temperature water extraction maintains adequate extraction rate through extended time and optimized pH while preventing the formation of harmful substances like acrylamide that require high temperatures for their formation
Solution Approach 2:
The patent converts the limitation of low extraction rate at low temperature into an advantage by using extended extraction time and optimized pH conditions. This approach prevents harmful substance formation while achieving sufficient extraction, effectively converting what could be seen as a disadvantage (slow extraction) into a benefit (safe processing)
3Manufacturing precision
If strong base or acid treatment is used for decolorization and deodorization, then product purity is improved, but protein structure degradation occurs
Solution Approach 1:
The patent changes the pH treatment from strong base/acid to mild conditions (pH 2-12 range using food-grade acids or bases). This mild pH treatment achieves decolorization and deodorization through controlled protein precipitation and filtration without causing excessive protein structure degradation, thus resolving the contradiction between purity improvement and structure stability
Solution Approach 2:
The patent uses mild pH adjustment as an intermediary step to achieve decolorization and deodorization. By controlling pH within a narrow range and using food-grade acids or bases, the process achieves purification through controlled precipitation and filtration while minimizing direct exposure of proteins to harsh conditions that would cause degradation
4Quantity of substance
If γ-prolamin is present in the extract, then total protein content is improved, but gelation occurs during processing
Solution Approach 1:
The patent changes the pH parameter to specific ranges (pH 2-4 or pH 9-12) where γ-prolamin remains soluble or precipitates controllably. This pH control prevents gelation by avoiding the isoelectric point of γ-prolamin while maintaining its presence in the extract, thus resolving the contradiction between maintaining total protein content and preventing gelation
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method achieves a high-purity α-prolamin product with improved color and odor characteristics, reduced energy consumption, and safer processing conditions, while avoiding the use of hazardous solvents, thus expanding the product's application range and reducing production costs.
Implementation Method 1
protease or hydrolase treatment to hydrolyze non-α-prolamin components
Data Source
AI summary
A protein product and an extraction method for making the protein product. Raw materials of the product optionally contains macromolecular carbohydrates and/or fat, and the method does not use organic solvents. The protein product contains prolamin and carbohydrates, wherein the prolamin accounts for 70 wt % or above of the protein (dry-basis), the α-prolamin accounts for 75 wt % or above of the prolamin, the β-prolamin accounts for 20 wt % or below of the prolamin, and the γ-prolamin accounts for 6 wt % or below of the prolamin.