Enzymatic Milling Process for Starch Separation
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Solution Overview
Problem
Current processes for producing high-quality starch from crop kernels are inefficient, as they require significant processing time and the use of sulfur dioxide, and do not effectively separate starch from impurities, limiting their suitability for conversion into mono- and oligosaccharides, ethanol, and sweeteners.
Innovation Solution
A process involving soaking and grinding crop kernels followed by treatment with a serine protease of the peptidase family S53, specifically a polypeptide with high sequence identity to certain SEQ IDs, which breaks down protein bonds to enhance starch separation and purity, reducing processing time and eliminating the need for sulfur dioxide.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional wet milling process is used to separate starch from kernel components, then starch can be obtained, but the processing time is long (30 minutes to 48 hours soaking) and sulfur dioxide must be used
Solution Approach 1:
The patent applies preliminary action by using protease enzymes during the soaking step to pre-digest proteins and weaken cell wall structures before mechanical milling. This enzymatic pre-treatment accelerates the breakdown of kernel components, eliminating the need for prolonged soaking (30 minutes to 48 hours) and allowing rapid separation of starch from other kernel components while eliminating sulfur dioxide requirement
Solution Approach 2:
The patent replaces the traditional mechanical/chemical milling system with an enzymatic system. Instead of relying on mechanical grinding and chemical agents like sulfur dioxide for cell wall breakdown and protein denaturation, the invention uses protease enzymes to catalyze the breakdown of proteins and cell wall structures, achieving the same separation effect with shorter processing time and without harmful chemicals
2Manufacturing precision
If traditional wet milling is used, then starch separation is achieved, but starch purity is limited due to protein and other impurities remaining
Solution Approach 1:
The patent applies the extraction principle by using protease enzymes to specifically target and break down protein components during the soaking and milling process. The enzymes extract and degrade proteins from the kernel matrix, separating them from starch granules. This enzymatic extraction of proteins achieves superior starch purity by removing protein impurities that traditional mechanical milling cannot effectively separate
Solution Approach 2:
The patent applies parameter changes by utilizing the specific catalytic properties of protease enzymes to change the molecular structure of proteins during processing. The enzymes convert intact proteins into smaller peptides and amino acids that can be easily separated from starch, fundamentally changing the protein state from a contaminant to a separable component, thereby achieving high starch purity
3Ease of manufacture
If prolonged soaking is used to soften kernels for milling, then kernel structure is broken down, but processing efficiency decreases and chemical agents are required
Solution Approach 1:
The patent replaces the mechanical/chemical softening system with an enzymatic system. Instead of prolonged mechanical soaking and chemical treatment to soften kernels, protease enzymes are used to catalyze the breakdown of cell wall structures and proteins, naturally softening the kernel material. This enzymatic softening achieves the same effect as prolonged soaking but in a fraction of the time without requiring sulfur dioxide or other chemical agents
Solution Approach 2:
The patent applies continuity of useful action by maintaining enzymatic activity throughout the soaking and milling process. The protease enzymes continue to act on kernel components during the entire processing sequence, continuously breaking down proteins and cell walls. This continuous enzymatic action eliminates the need for separate softening and milling stages, improving overall process efficiency while avoiding chemical agents
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 improves starch and gluten yield and quality, reduces processing time, and minimizes the use of chemicals, resulting in a more efficient and environmentally friendly method for producing high-purity starch suitable for conversion into various products.
Implementation Method 1
treating the soaked kernels in the presence of a polypeptide having protease activity, wherein step c) is performed before, simultaneously with or after step b), and said polypeptide is a serine protease of the peptidase family S53
Data Source
AI summary
Provided are processes for treating crop kernels which comprising the steps of a) soaking kernels in water to produce soaked kernels; b) grinding the soaked kernels; c) treating the soaked kernels in the presence of a polypeptide having protease activity.