Corn SOD Extraction Using Rotary Hydrolysis and Starch Separation
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Solution Overview
Problem
Existing methods for extracting superoxide dismutase (SOD) from corn face issues such as high starch content causing viscosity, low enzyme yield, and environmental pollution due to chemical disinfectants, hindering large-scale production and product quality.
Innovation Solution
A method involving enzymatic hydrolysis on a rotary screen with a drum immersed in the hydrolysis liquid, combined with real-time monitoring and image analysis to optimize starch removal, ensuring efficient enzymatic contact and dynamic control of starch concentration, followed by centrifugal separation and post-treatment to produce high-purity SOD.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If corn is used as raw material for SOD extraction, then accessibility and availability are improved, but high starch content causes viscosity that hinders enzymatic hydrolysis efficiency
Solution Approach 1:
The patent applies preliminary action by implementing a germination process before enzymatic hydrolysis. The corn undergoes controlled germination in a germination chamber where temperature, humidity, and oxygen conditions are optimized to promote sprout growth. This preliminary germination breaks down starch into simpler carbohydrates, reducing the viscosity problem that would otherwise hinder subsequent enzymatic hydrolysis efficiency
Solution Approach 2:
The patent applies parameter changes by systematically optimizing multiple process parameters: germination temperature (25-35°C), pH levels during hydrolysis (5.0-6.0), enzyme dosage, and germination time. These parameter adjustments transform the high-starch corn material into a more hydrolysis-friendly state, converting the adverse effect of high starch content into a beneficial process feature
2Reliability
If chemical disinfectants are used in the preparation process, then sterilization effectiveness is improved, but residues are left causing environmental pollution and affecting product quality
Solution Approach 1:
The patent converts the harmful effect of chemical disinfectants into a beneficial natural process by using biological disinfection through controlled germination. The germination process itself creates a biological environment that naturally suppresses pathogens while producing beneficial enzymes and carbohydrates. This transforms the need for chemical sterilization into a self-regulating biological system that eliminates chemical residues
Solution Approach 2:
The patent introduces an intermediary biological system (germinating corn with controlled microbiota) that mediates between the need for sterilization and the avoidance of chemical residues. The germination chamber creates a controlled ecosystem where beneficial microorganisms outcompete pathogens, providing natural disinfection without chemical contamination
3Reliability
If freeze drying is used for product drying, then enzyme activity preservation is improved, but production cost increases
Solution Approach 1:
The patent applies parameter changes by optimizing drying parameters to achieve a balance between enzyme activity preservation and cost reduction. Instead of using expensive freeze drying, the patent employs spray drying or vacuum drying at controlled temperatures (40-60°C) with optimized drying time and humidity parameters. These parameter adjustments maintain sufficient enzyme activity while dramatically reducing production costs for large-scale manufacturing
4Ease of operation
If germination is performed in a confined chamber, then control over germination conditions is improved, but bacterial biofilm formation causes putrefaction and reduces germination rate
Solution Approach 1:
The patent applies dynamics by making the germination chamber environment dynamically adjustable rather than static. The system continuously monitors and adjusts temperature, humidity, oxygen concentration, and air circulation based on real-time germination progress. This dynamic control prevents stagnant conditions that lead to biofilm formation while maintaining the benefits of controlled germination
Solution Approach 2:
The patent applies periodic action through cyclic air circulation, periodic humidity adjustment, and intermittent agitation of the corn material in the germination chamber. These periodic actions prevent stagnant microenvironments where bacterial biofilms could form, while maintaining overall controlled germination conditions. The system cycles between different parameter states to optimize both control and prevent putrefaction
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 significantly improves enzymatic hydrolysis efficiency, reduces production costs, and ensures stable SOD quality, facilitating large-scale production while minimizing environmental impact and resource waste.
Implementation Method 1
enzymatic hydrolysis on a rotary screen with a drum immersed in the hydrolysis liquid
Implementation Method 2
centrifugal separation and post-treatment to produce high-purity SOD
Implementation Method 3
pulverizing sprouted corn to 80-120 mesh, into the pulverized sprouted corn, adding a pH=7.8, 0.05 mol/L phosphate-buffered saline at a ratio of 1:2-4, and mixing uniformly and grinding to obtain a corn slurry, followed by ultrasonic cell disruption
Data Source
AI summary
Provided are preparation method for corn superoxide dismutase, including: S1. corn pre-treatment; S2. enzymatic hydrolysis: S21. transferring corn slurry into rotary screen, and immersing lower half of drum into enzymatic hydrolysis mixed liquid; starting rotary screen, to enable corn material to tumble inside drum while remaining immersed in enzymatic hydrolysis mixed liquid; S22. extracting enzymatic hydrolysis mixed liquid at fixed intervals to undergo centrifugal separation, to remove starch granules and other impurities; S23. pouring centrifuged clear liquid back into rotary screen, and performing enzymatic hydrolysis cyclically; S24. uniformly stirring corn slurry having undergone enzymatic hydrolysis and filtering, collecting filtrate; and S3. extraction and post-treatment.