Low Viscosity Corn Syrup via Controlled Saccharide Distribution
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Solution Overview
Problem
Existing low sugar syrups often have high viscosity, making them difficult to pour, mix, and incorporate into final products, resulting in undesirable textures such as hard or brittle consistency.
Innovation Solution
A corn syrup with a saccharide distribution of DP1+DP2 content of 20 wt. % or less and a DP60+ content of 8 wt. % or less, achieved through a method involving liquefaction, saccharification, and processing with specific enzymes to control the saccharide distribution and viscosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If sugar concentration is reduced to meet health and tax requirements, then sweetness and caloric content are improved, but viscosity increases making the syrup hard to pour and mix
Solution Approach 1:
The patent changes the molecular structure parameters of the syrup by controlling the degree of polymerization (DP) distribution. Specifically, it limits DP1+DP2 to 20 wt.% or less and DP60+ to 8 wt.% or less, which fundamentally alters the rheological properties to maintain low viscosity despite low sugar concentration
Solution Approach 2:
The patent creates a composite saccharide structure with a specific distribution of polymerization degrees. By combining different DP fractions in controlled proportions, it achieves a synergistic effect where the syrup maintains both low sugar content and good flow properties that neither component alone could achieve
2Ease of operation
If syrup conversion is increased to reduce viscosity, then pourability is improved, but sugar content increases
Solution Approach 1:
The patent precisely controls the saccharide distribution parameters to achieve the desired balance. By limiting DP1+DP2 to 20 wt.% or less while controlling DP60+ to 8 wt.% or less, it achieves low viscosity without excessive sugar content, resolving the trade-off between conversion level and sugar content
3Quantity of substance
If traditional enzymatic conversion is used to produce low sugar syrup, then sugar content is reduced, but reaction time increases to 40-60 hours
Solution Approach 1:
The patent performs preliminary liquefaction of starch before the main saccharification step. This pre-treatment breaks down the starch structure in advance, making it more susceptible to enzymatic hydrolysis and significantly reducing the overall reaction time from 40-60 hours to a much shorter duration while maintaining low sugar content
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 resulting corn syrup has a viscosity of 2,500 cP or less at 72.5 wt. % solids and 30° C., improving pourability and mixability while maintaining a low sugar content, thus addressing the texture issues in final products.
Implementation Method 1
the polysaccharides are hydrolyzed to shorter monosaccharides, disaccharides and oligosaccharides
Implementation Method 2
alpha amylase enzymes hydrolyze the starch into oligosaccharides
Implementation Method 3
the oligosaccharides are enzymatically hydrolyzed to mono- or disaccharides
Implementation Method 4
maltotetraase and pullulanase for 40-60 hours to obtain a saccharification liquid
Data Source
AI summary
The invention provides a corn syrup, having a saccharide distribution having (i) a DP1+DP2 content of about 20 wt. % or less; and (ii) a DP60+ content of about 8 wt. % or less; relative to the total weight of saccharides. The invention further provides a method for preparing a corn syrup, said method comprising: a) Providing corn starch; b) Subjecting said corn starch to liquefaction to obtain a first hydrolysate; c) Subjecting said first hydrolysate to saccharification to obtain a second hydrolysate; d) Contacting said second hydrolysate with an alpha-amylase to obtain a third hydrolysate; and e) Processing the third hydrolysate to a corn syrup.