Continuous Plug Flow Process for Liquefying Cereal Proteins
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Solution Overview
Problem
Existing hydrolysis processes for cereal proteins, particularly those with visco-elastic properties like vital wheat gluten, face challenges such as lump formation, uneven hydrolysis, and inefficient processing due to back mixing, resulting in hydrolysates with varying molecular weights and undesirable taste or phase separation issues.
Innovation Solution
A continuous plug flow process for liquefying cereal proteins, followed by controlled incubation, which involves adding hydrolytic enzymes and processing aids to break down visco-elastic lumps into a homogeneous state, ensuring all proteins undergo similar treatment times and achieving uniform hydrolysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If continuous back mixing is used in the liquefaction step, then the process can handle visco-elastic protein materials, but part of the incoming proteins is constantly recycled and remains in the liquefaction step for a longer period of time than desired while other material leaves too early
Solution Approach 1:
The continuous process is divided into distinct functional zones: a liquefaction zone with high shear mixing to handle visco-elastic lumps, followed by a hydrolysis zone with controlled back mixing. This segmentation allows each zone to perform its specific function optimally without the negative effects of mixing throughout the entire process, thereby achieving both adaptability to visco-elastic materials and uniformity of hydrolysis.
Solution Approach 2:
Different mixing conditions are applied in different parts of the process: intense local mixing in the liquefaction zone to break down lumps, and controlled local back mixing in the hydrolysis zone to ensure uniform enzyme contact. This local differentiation of mixing quality allows the process to handle visco-elastic materials effectively while maintaining uniform hydrolysis throughout the product.
2Reliability
If continuous back mixing is used in the incubation step, then the process can maintain enzyme activity, but some material is constantly recycled and is incubated for a longer period of time than desired resulting in highly hydrolysed proteins with low molecular weight
Solution Approach 1:
The process separates the incubation step into a controlled back-mixing zone that maintains enzyme activity, followed by a separation zone that prevents over-incubation. This segmentation allows the system to benefit from continuous enzyme action while controlling the residence time distribution to avoid excessive hydrolysis and low molecular weight fractions.
Solution Approach 2:
The continuous process maintains enzyme activity throughout the incubation zone through controlled back mixing, ensuring that all material receives adequate enzymatic treatment. However, the continuous flow ensures that material progresses through the zone and is not indefinitely recycled, maintaining reliability of enzyme action while controlling the degree of hydrolysis.
3Ease of manufacture
If high processing volumes and times are used in existing processes, then the process can handle lump formation, but the processing efficiency is reduced
Solution Approach 1:
The process applies preliminary high-shear mixing and conditioning in the liquefaction zone to break down visco-elastic lumps before the main hydrolysis process. This preliminary action prevents lump formation from interfering with subsequent hydrolysis, allowing the process to handle difficult materials efficiently without requiring excessive processing volumes or times.
Solution Approach 2:
The process uses parameter changes in the liquefaction zone, including temperature adjustment and high-shear mixing intensity, to modify the rheological properties of visco-elastic lumps. These parameter changes facilitate lump breakdown and improve flow characteristics, enabling efficient continuous processing without requiring excessive volume or time.
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 process produces hydrolysed cereal proteins with a consistent degree of hydrolysis, reducing processing time and avoiding lump formation, resulting in a hydrolysate with improved digestibility and stability suitable for food, feed, and industrial applications.
Implementation Method 1
Adding one or more hydrolytic enzymes and/or processing aids to the composition
Implementation Method 2
The enzymatic hydrolysis may be done by adding enzymes to a protein containing substrate in aqueous suspension
Implementation Method 3
Homogenizing the composition, wherein the product leaving the liquefaction process is liquefied and homogeneous and no more lumps are present
Data Source
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AI summary
The present invention relates to a process for liquefying cereal proteins. A process for making hydrolysed cereal protein is also disclosed. A composition comprising hydrolysed cereal proteins obtained by the process of the present invention and its uses in food and feed applications are also disclosed. Particularly, the use of a composition comprising hydrolysed wheat proteins as partial or total replacement of animal protein in calf milk is disclosed.