Corn Protein Retention Using High-Concentration Ethanol Extraction
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Solution Overview
Problem
Corn protein extraction processes face challenges such as high protein loss, fouling of surfaces, and undesirable physical behavior due to excess water, leading to reduced yield and increased costs in producing food-grade corn protein concentrates.
Innovation Solution
A method involving the use of an ethanol-water solvent with at least 85 wt % ethanol, combined with heat treatment and hydrogen peroxide, to minimize water content and operate at lower temperatures during extraction, effectively reducing protein loss and improving yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional extraction methods are used, then extraction process is simple, but protein loss is high (greater than 25% of total corn protein)
Solution Approach 1:
The patent applies parameter changes by modifying the solvent composition to use high-concentration ethanol (at least 85 wt%) instead of conventional aqueous solvents, and by controlling extraction temperature (25-40°C) to optimize protein recovery. These parameter changes reduce protein loss to less than 25% of total corn protein while maintaining a relatively simple extraction process.
Solution Approach 2:
The patent implements preliminary action by pre-treating the corn gluten material with heat treatment (heating to 60-80°C for 10-30 minutes) and/or hydrogen peroxide treatment (0.5-5% H2O2 for 5-30 minutes) before extraction. This pre-treatment modifies the protein structure to improve subsequent extraction efficiency and reduce protein loss.
2Object-affected harmful factors
If excess water is present during extraction, then solvent cost is reduced, but fouling of surfaces and undesirable physical behavior occur
Solution Approach 1:
The patent applies parameter changes by严格控制 the water content in the extraction solvent to maintain at least 85 wt% ethanol concentration. This high ethanol concentration prevents surface fouling and undesirable physical behavior while minimizing solvent volume requirements, thereby reducing both water content and solvent cost.
3Productivity
If higher temperatures are used during extraction, then extraction speed increases, but protein loss increases
Solution Approach 1:
The patent applies parameter changes by optimizing the extraction temperature to a moderate range of 25-40°C, which balances extraction speed with protein recovery efficiency. This temperature range provides sufficient kinetic energy for effective extraction while preventing excessive protein denaturation and loss that would occur at higher temperatures.
Solution Approach 2:
The patent implements preliminary action by pre-heating the corn gluten material to 60-80°C for 10-30 minutes before the actual extraction process. This pre-heating step activates the protein structure for better extraction without subjecting it to prolonged high-temperature exposure that would cause protein loss during the extraction itself.
4Quantity of substance
If conventional solvents are used, then extraction cost is low, but protein yield is reduced
Solution Approach 1:
The patent applies parameter changes by using high-concentration ethanol (at least 85 wt%) as the extraction solvent, which significantly improves protein yield to greater than 70% of total corn protein. While ethanol is more expensive than conventional aqueous solvents, the high protein recovery rate and reduced protein loss compensate for the increased solvent cost, improving overall process economics.
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 method achieves a corn protein yield loss of less than 25% and enhances the overall corn protein yield index, resulting in a high-protein, low-cost, and functionally suitable corn protein concentrate for food and animal consumption.
Implementation Method 1
washing the corn gluten material to remove non-protein components with an ethanol-water solvent comprising at least 85 wt % ethanol
Implementation Method 2
A method involving the use of an ethanol-water solvent with at least 85 wt % ethanol, combined with heat treatment and hydrogen peroxide
Implementation Method 3
A method involving the use of an ethanol-water solvent with at least 85 wt % ethanol, combined with heat treatment and hydrogen peroxide
Data Source
AI summary
Described herein is a method of maintaining corn protein yield during extraction, comprising obtaining a corn gluten material, washing the corn gluten material to remove non-protein components with an ethanol-water solvent comprising at least 85 wt % ethanol to obtain a corn protein concentrate product, wherein the loss of corn protein content during extraction is less than 25% of total corn protein.