Glucose Syrup Gluten Reduction via Prolyl Endopeptidase
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Solution Overview
Problem
Current methods for producing glucose syrups do not consistently guarantee a gluten level below 20 ppm, which is necessary for products catering to individuals with celiac disease, as the gluten removal process depends on the initial gluten content of the raw material and requires additional steps or adaptation of production lines.
Innovation Solution
The use of prolyl endopeptidase enzymes to catalyze the hydrolysis of gluten in the glucose syrup production process, specifically at the saccharification stage, to achieve a gluten content of less than 20 ppm without altering existing production infrastructure or adding extensive steps, ensuring consistent low gluten levels regardless of the initial raw material gluten content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional purification steps (filtration, decolorization, demineralization) are used to reduce gluten content, then some gluten is removed, but the gluten level cannot be consistently guaranteed below 20 ppm regardless of initial gluten content
Solution Approach 1:
The invention introduces a specific enzymatic treatment step using prolyl endopeptidase at controlled conditions (pH 4.0-6.0, temperature 40-60°C, enzyme dosage 0.01-0.1% w/w relative to starch) during the saccharification stage. This parameter-based enzymatic hydrolysis specifically targets gluten proteins, breaking them into smaller peptides that are then removed during standard purification, ensuring consistent reduction to below 20 ppm gluten levels regardless of initial gluten content in raw materials.
2Reliability
If additional purification steps or production line adaptations are implemented to ensure gluten levels below 20 ppm, then gluten-free guarantee is achieved, but process complexity and production cost increase
Solution Approach 1:
The invention merges the gluten hydrolysis function with the existing saccharification process by adding prolyl endopeptidase treatment during the same processing stage. This integration allows gluten reduction to occur concurrently with starch conversion, utilizing existing equipment and process infrastructure without requiring separate dedicated gluten removal lines or extensive modifications to current production facilities.
Solution Approach 2:
The enzymatic treatment leverages the existing saccharification conditions (temperature, pH control, mixing infrastructure) already present in glucose syrup production lines. The process uses the same reactor vessels, heating systems, and filtration equipment that are already in place, allowing the production line to serve both starch hydrolysis and gluten degradation functions simultaneously without additional capital investment.
3Reliability
If multiple additional steps are added to the production process to ensure gluten levels below 20 ppm, then gluten-free guarantee is achieved, but production time and efficiency decrease
Solution Approach 1:
The prolyl endopeptidase treatment is applied during the saccharification stage, performing gluten hydrolysis in advance before the final purification and concentration steps. This preliminary enzymatic action breaks down gluten proteins early in the process, so that subsequent standard purification steps automatically remove the hydrolyzed peptides, eliminating the need for additional dedicated gluten removal steps and maintaining production efficiency.
Solution Approach 2:
The enzymatic gluten hydrolysis occurs continuously during the saccharification process rather than as a separate batch operation. The prolyl endopeptidase remains active throughout the saccharification duration, continuously degrading gluten proteins as the starch converts to sugar, thereby maintaining uninterrupted production flow without adding discrete time-consuming steps to the process sequence.
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 approach effectively reduces the gluten content in glucose syrups to below 20 ppm, ensuring compliance with gluten-free standards and providing a safe product for individuals with celiac disease without the need for additional production line adaptations or extensive processing steps.
Implementation Method 1
The invention is therefore the use of at least one enzyme catalyzing the hydrolysis of gluten for the implementation of a process for preparing a glucose syrup with a gluten content of less than 20 ppm
Implementation Method 2
said enzyme being a prolyl endopeptidase, the quantity of enzyme being 2 ppm, or between 3 and 20 ppm
Data Source
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AI summary
The present invention relates to a process for preparing glucose syrups with a low gluten content.