Complex Bacteria for Corn Steeping Process Optimization
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Solution Overview
Problem
The corn steeping process in corn starch production is inefficient due to long steeping times and high sulfur dioxide (SO2) usage, leading to environmental pollution, equipment corrosion, and reduced production efficiency, with existing enzyme preparations being costly and difficult to control.
Innovation Solution
A complex bacteria strain combination capable of producing protease, cellulase, and hemicellulase is introduced into the steeping solution, reducing SO2 dosage and steeping time without requiring significant modifications to the existing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high concentration SO2 (2000-5000 ppm) is used for corn steeping, then the protein network disruption effect is improved and starch separation is enhanced, but environmental pollution increases, equipment corrosion occurs, and sulfurous acid residue in starch products becomes excessive
Solution Approach 1:
The patent introduces microbial fermentation products (enzymes and organic acids) as intermediary substances to mediate the steeping process. These intermediaries naturally disrupt the protein network and lower pH, replacing the need for high concentrations of harmful SO2 while achieving the same starch separation effect without environmental pollution or equipment corrosion
Solution Approach 2:
The patent changes the chemical parameters of the steeping solution by introducing microbial fermentation products that produce organic acids and enzymes. This shifts the mechanism from chemical oxidation (SO2) to biochemical action (enzymes and organic acids), reducing SO2 concentration from 2000-5000 ppm to below detection limits while maintaining effective starch separation
2Manufacturing precision
If conventional steeping process is used with high SO2 concentration, then starch separation is achieved, but the steeping time is excessively long (48-72 hours) and energy consumption is high
Solution Approach 1:
The patent changes the biochemical parameters of the steeping solution by introducing active microbial cultures that produce enzymes and organic acids. This accelerates the protein network disruption and starch separation processes, reducing steeping time from 48-72 hours to 24-48 hours while maintaining effective separation quality
Solution Approach 2:
The patent employs continuous microbial fermentation action during the steeping process, where microorganisms continuously produce enzymes and organic acids that act on the corn kernels. This continuous biochemical action maintains persistent pressure on the protein network, preventing reversal and ensuring complete starch separation within the reduced time frame
3Productivity
If single microbial strains are used for assisting steeping, then some steeping improvement is achieved, but the process requires multiple modifications and cannot fully optimize all steeping parameters simultaneously
Solution Approach 1:
The patent merges multiple microbial strains with complementary functions into a single fermentation system. The complex bacteria include strains that produce proteases for protein network disruption, cellulases for cell wall degradation, hemicellulases for hemicellulose breakdown, and organic acid producers for pH reduction. This combination achieves multiple steeping objectives simultaneously without requiring separate process modifications for each function
Solution Approach 2:
The patent creates a universal microbial consortium that performs multiple functions within a single steeping process: protein degradation, cell wall breakdown, hemicellulose digestion, and pH reduction. This multi-functional system eliminates the need for separate process modifications that would be required if single strains were used, as the complex bacteria collectively address all steeping requirements
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
The use of these bacteria significantly shortens steeping time from 48 hours to 16-30 hours and reduces SO2 concentration from 2000-5000 ppm to 400-1200 ppm, improving starch yield and reducing environmental impact.
Implementation Method 1
the complex bacteria comprises strains capable of producing protease, cellulase and hemicellulase
Implementation Method 2
strains capable of producing protease, cellulase and hemicellulase
Implementation Method 3
strains capable of producing protease, cellulase and hemicellulase
Implementation Method 4
strains capable of producing protease, cellulase and hemicellulase
Implementation Method 5
several microbes with different functions are utilized to ferment and generate functional enzymes
Data Source
AI summary
Provided a complex bacteria for improving the corn steeping effects and usage thereof. The complex bacteria comprises strains capable of producing protease, cellulase and hemicellulase. Using the complex bacteria to steep corn, effects of reducing the addition amount of SO2, shortening the steeping time and improving the starch yield are achieved.