Grain Processing Without pH Adjustment Using Thermostable Phytase
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Solution Overview
Problem
Conventional dry mill ethanol production processes require pH adjustment using alkali or acid, which introduces ions and additional steps, and phytic acid in grains inhibits alpha-amylase activity and reduces starch hydrolysis efficiency, complicating the processing and waste disposal.
Innovation Solution
The use of thermostable phytases, such as BP-110, BP-111, and BP-112, in combination with thermostable alpha-amylases, allows for starch liquefaction without pH adjustment, enhancing enzyme stability and phytic acid removal, thereby simplifying the process and reducing environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pH adjustment using alkali or acid is performed, then enzyme stability is improved, but process complexity and ion contamination increase
Solution Approach 1:
The patent extracts and removes phytic acid from the system using phytase enzyme treatment before starch liquefaction. By eliminating phytic acid, the harmful factor that caused enzyme instability is removed, making pH adjustment unnecessary. This resolves the contradiction by taking out the problematic substance rather than adjusting environmental conditions.
Solution Approach 2:
The patent converts the harmful effect of phytic acid (which inhibited alpha-amylase and required pH adjustment) into a benefit by using phytase to specifically target and remove it. The phytic acid problem becomes the solution pathway - treating with phytase not only removes the inhibitor but also eliminates the need for alkali/acid addition, reducing process complexity and ion contamination.
2Reliability
If pH adjustment is performed, then microbial contamination risk is reduced, but additional processing steps and ion addition are required
Solution Approach 1:
The patent removes phytic acid through phytase treatment, which eliminates the need for pH adjustment steps. By taking out the harmful substance (phytic acid) rather than adjusting pH, the process maintains microbial control while avoiding additional processing steps and ion addition, thus preserving productivity.
Solution Approach 2:
The patent discards phytic acid through enzymatic hydrolysis by phytase, converting it into beneficial phosphates and inositol. This discarding of the harmful component eliminates the need for subsequent pH adjustment steps, maintaining contamination control while improving processing efficiency by reducing step count.
3Stability of the object's composition
If phytic acid is present in grain, then natural grain composition is maintained, but alpha-amylase activity and starch hydrolysis efficiency are reduced
Solution Approach 1:
The patent applies phytase treatment in advance before starch liquefaction to remove phytic acid. This preliminary action eliminates the inhibitor of alpha-amylase activity while maintaining the natural grain composition for other components. By acting first to remove phytic acid, the subsequent starch hydrolysis proceeds with high efficiency without compromising overall grain composition integrity.
Solution Approach 2:
The patent introduces phytase as an intermediary enzyme that selectively targets and removes phytic acid without affecting other grain components. This intermediary action maintains the natural composition of the grain while eliminating the specific harmful element (phytic acid) that inhibited starch hydrolysis efficiency.
4Reliability
If alkali reagents are added for pH adjustment, then enzyme stability is improved, but sodium ion contamination and waste disposal issues increase
Solution Approach 1:
The patent extracts and removes phytic acid using phytase treatment, which eliminates the need for alkali reagent addition. By taking out the root cause of enzyme instability (phytic acid) rather than adding alkali to mask it, the process avoids sodium ion contamination and associated waste disposal problems while maintaining enzyme stability.
Solution Approach 2:
The patent converts the harmful phytic acid into beneficial products through phytase-catalyzed hydrolysis, producing inositol and phosphates that can be utilized by microorganisms. This conversion eliminates the need for alkali addition, thereby preventing sodium ion contamination and waste issues while improving the nutritional value of the fermentation medium.
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 eliminates the need for pH adjustment, increases enzyme stability and activity, and reduces phytic acid content, leading to improved starch liquefaction efficiency and reduced waste disposal issues, while maintaining fermentation quality.
Implementation Method 1
contacting the slurry with a phytase selected from BP-110 (SEQ ID NO: 3), BP-111 (SEQ ID NO: 4), and BP-112 (SEQ ID NO: 5) and an alpha-amylase under primary liquefaction or secondary liquefaction conditions
Implementation Method 2
converting granular starch in whole ground grains into soluble dextrins during primary liquefaction
Implementation Method 3
current commercially-available thermostable alpha amylase enzymes that are used to convert granular starch in whole ground grains into soluble dextrins during primary liquefaction are not stable below pH 5.6 at the elevated temperatures used in the process
Data Source
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AI summary
Described are compositions and methods relating to starch processing without a phytase pretreatment step and without adjustment of the slurry pH adjustment.