Corn Steeping with Thermostable Alpha-Amylase
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Solution Overview
Problem
Current grain processing methods, such as wet milling and dry grind milling, are inefficient in extracting maximum value from corn kernels with minimal capital investment, often resulting in low-value animal feed products and requiring extensive energy consumption and additional processing steps.
Innovation Solution
A high temperature steeping process using thermostable α-amylase to release soluble starch hydrolysates from intact corn kernels, which inactivates endogenous enzymes and allows for the production of protein and oil-enhanced, starch-depleted residuals suitable for high-quality animal feed or food-grade products, with optional additional enzyme treatments and mechanical processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional wet milling or dry grind milling is used to process corn kernels, then starch and other components can be extracted, but capital investment and processing complexity increase significantly
Solution Approach 1:
The patent extracts only the necessary function (starch hydrolysis) from the complex milling process by using a simple steeping tank with thermostable alpha-amylase, eliminating the need for complex mechanical fractionation equipment while still achieving starch extraction and hydrolysis
Solution Approach 2:
The patent changes the temperature parameter to above starch gelatinization temperature (typically 60-100°C) and uses thermostable alpha-amylase to enable starch hydrolysis during steeping, transforming the conventional low-temperature steeping process into a high-temperature enzymatic hydrolysis process that simplifies equipment requirements
2Quantity of substance
If conventional steeping is used to soften corn kernels for starch release, then starch granules can be released, but endogenous enzymes cause uncontrolled hydrolysis and protein degradation
Solution Approach 1:
The patent raises the steeping temperature above the gelatinization temperature of starch (60-100°C), which inactivates endogenous proteases and carbohydrate hydrolyzing enzymes in the corn kernels, preventing uncontrolled hydrolysis and protein degradation while still enabling starch release
Solution Approach 2:
The patent introduces thermostable alpha-amylase as an intermediary enzyme that performs controlled starch hydrolysis at high temperatures, replacing the uncontrolled action of endogenous enzymes and enabling reliable starch extraction while preserving protein integrity
3Ease of manufacture
If high temperature steeping with thermostable alpha-amylase is used, then energy consumption and capital investment are reduced, but the process requires maintaining temperature above gelatinization point
Solution Approach 1:
The patent uses thermostable alpha-amylase as a mediator that enables starch hydrolysis at high temperatures without being denatured, allowing the process to maintain temperature above gelatinization point (60-100°C) to inactivate endogenous enzymes while achieving controlled starch hydrolysis, thereby simplifying equipment and reducing capital investment
4Quantity of substance
If conventional milling processes are used to produce animal feed residuals, then starch-depleted residuals are obtained, but the residuals are low-value and require extensive processing
Solution Approach 1:
The patent changes the temperature parameter to above gelatinization temperature during steeping, which not only enables starch hydrolysis by inactivating endogenous enzymes but also preserves protein integrity and enhances residual quality, transforming low-value starch-depleted feed into high-value protein-enriched animal feed without requiring extensive additional processing
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 reduces energy consumption and capital investment while producing higher-quality residuals that can be used for various valuable products, including animal feed, specialty syrups, and biochemicals, with improved protein integrity and reduced uncontrolled hydrolysis.
Implementation Method 1
steeping is performed in the presence of an exogenous thermostable α-amylase that produces soluble starch hydrolysates or hydrolysed starch syrups from starch present in the corn kernels
Implementation Method 2
the steeping temperature causes inactivation of endogenous corn proteases and carbohydrate hydrolyzing enzymes present in the corn kernels
Implementation Method 3
steeping is performed at a temperature at or above the gelatinization temperature of starch in the corn kernels
Data Source
AI summary
Described is a process for releasing soluble starch hydrolysates or hydrolysed starch syrup from substantially intact corn kernels during high temperature steeping at a temperature at or above the gelatinization temperature of starch in the corn kernels, and the recovery of protein and oil-enhanced, carbohydrate-depleted residuals that are ideally suited for use as high quality animal feed or other food-grade products.