High Temperature Steeping of High Amylose Corn for Starch TDF
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Solution Overview
Problem
Current methods for increasing total dietary fiber (TDF) content in starch products often require costly secondary processing such as heating, acid treatment, or enzyme treatments, which are not economically viable for large-scale production.
Innovation Solution
A process involving steeping high amylose corn kernels at temperatures from 71° C to 93° C for 24 to 72 hours followed by conventional wet milling, which increases the TDF content of the extracted starch to 33% to 45% without additional chemical modifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional wet milling at low temperature (40-55°C) is used, then starch recovery is maintained, but TDF content remains low (20-25%)
Solution Approach 1:
The patent changes the temperature parameter from conventional 40-55°C to high temperature range of 71-93°C during the steeping process. This parameter change transforms the starch structure to increase TDF content to 33-45% while maintaining a simple single-stage process without additional chemical modifications or secondary processing steps
2Quantity of substance
If heat-moisture treatment or acid hydrolysis is applied to increase TDF content, then TDF content exceeds 60%, but process complexity and production cost increase significantly
Solution Approach 1:
The patent achieves high TDF content (33-45%) by changing only the temperature parameter during steeping to 71-93°C, eliminating the need for costly secondary processes such as heat-moisture treatment, acid hydrolysis, or enzyme treatments that would be required by conventional methods to achieve similar TDF levels
Solution Approach 2:
The patent performs the TDF enhancement action during the initial steeping process itself, before starch extraction. By pre-treating the corn kernels at high temperature during steeping, the starch naturally develops high TDF content, eliminating the need for subsequent secondary processing steps
3Quantity of substance
If steeping time is extended to 72 hours at conventional temperature, then starch separation is improved, but TDF content remains low and energy consumption increases
Solution Approach 1:
The patent increases the temperature parameter to 71-93°C during steeping, which accelerates the biochemical processes that increase TDF content. This allows achieving high TDF content (33-45%) in 24-72 hours at high temperature, which would require much longer times at conventional temperatures, thereby reducing overall energy consumption
Solution Approach 2:
The patent implements a two-stage steeping process with periodic temperature adjustment: first stage at 71-76°C for 14-26 hours, then second stage at 76-88°C for 14-26 hours. This periodic temperature variation optimizes both TDF development and energy efficiency
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 method provides a cost-effective and simple way to produce starch with high TDF content, maintaining the quality and recovery of the starch, and exhibits desirable thermal properties like delayed melting and reduced viscosity, making it suitable for nutritional and industrial applications.
Implementation Method 1
Singh et al., 'Effect of Soak Time, Soak Temperature, and Lactic Acid on Germ Recovery Parameters', Cereal Chem. 73(6):716-720, 1996, reported steeping yellow dent corn at 75° C. in an experimental wet-milling process and stated, 'effects of starch gelatinization could be observed'
Data Source
AI summary
The application relates to a process comprising: a) steeping high amylose corn kernels at a temperature from about 71° C. to about 93° C. for a time from about 24 hours to about 72 hours; b) subjecting the high-temperature steep corn kernels to conventional wet milling; c) recovering starch with a total dietary fiber (TDF) content from about 33% to about 45% (w/w); and d) wherein the recovered starch has not been chemically modified.