Fiber Washing System Enzymatic Hydrolysis Starch Yield
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Solution Overview
Problem
The corn wet milling process faces challenges in increasing the yield of starch and gluten while minimizing fiber content, with existing enzyme technologies not effectively reducing energy expenditure and costs.
Innovation Solution
A fiber washing system optimized for hydrolytic enzymes, utilizing a counter-current washing configuration with multiple screen units and controlled enzyme introduction to enhance starch and gluten separation, and incorporating an incubation space for extended enzyme contact time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional wet milling process is used to increase starch and gluten yield, then fiber content is decreased, but energy expenditure and processing costs increase
Solution Approach 1:
The patent replaces intensive mechanical processing with enzymatic hydrolysis. Hydrolytic enzymes are introduced to break down fiber structure and release bound starch and gluten, substituting mechanical energy-intensive operations with biochemical reactions that occur under milder conditions, thereby reducing overall energy expenditure while maintaining high yield of valuable products
Solution Approach 2:
The patent changes the chemical parameters of the processing system by introducing hydrolytic enzymes and controlling pH and temperature conditions optimal for enzyme activity. This biochemical approach allows for efficient starch and gluten release from fiber without requiring the high mechanical energy input traditionally needed, thus improving productivity while reducing energy consumption
2Productivity
If conventional wet milling process is used to increase starch and gluten yield, then fiber content is decreased, but processing costs increase
Solution Approach 1:
The patent replaces costly mechanical processing operations with enzymatic hydrolysis. The use of hydrolytic enzymes to depolymerize fiber and release bound starch and gluten eliminates the need for intensive mechanical grinding and separation, significantly reducing processing costs while maintaining high productivity of valuable coproducts
Solution Approach 2:
The patent introduces hydrolytic enzymes as intermediary agents that facilitate the breakdown of fiber structure. These enzymes act as mediators between the raw material and the separation process, enabling efficient release of starch and gluten without requiring costly mechanical operations, thus reducing overall processing costs while improving yield
3Productivity
If hydrolytic enzymes are introduced with extended contact time, then starch and gluten yield is improved, but processing time increases
Solution Approach 1:
The patent segments the fiber washing process into multiple stages, with hydrolytic enzymes introduced at specific points in the counter-current washing system. This segmentation allows enzyme treatment to occur during existing process steps rather than requiring a separate extended processing stage, thereby improving starch and gluten yield without proportionally increasing total processing time
Solution Approach 2:
The patent integrates enzyme hydrolysis into the continuous counter-current washing process. The enzymes remain active throughout the washing stages, continuously breaking down fiber and releasing starch and gluten as the material moves through the system. This continuous action maximizes yield enhancement while minimizing additional time requirements, as the enzymatic process occurs parallel to the existing washing operations
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 system improves starch and gluten yield, reduces energy costs, and minimizes fiber content by optimizing enzyme use and contact time, achieving efficient dewatering and anti-foaming effects.
Implementation Method 1
The system is configured for introducing hydrolytic enzymes into the corn kernel mass in the fiber washing process
Implementation Method 2
each screen unit is configured for separating a stream of corn kernel mass and liquid into two fractions
Data Source
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AI summary
The present invention provides to a fiber washing system, optimized for the use of hydrolytic enzymes in the system. Furthermore, the present invention provides to a method for improving starch and gluten yield in a wet milling process, preferably comprising the optimized fiber washing system.