Low-Moisture Precooking Corn Flour Process
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Solution Overview
Problem
Current methods for producing pregelatinized and instant corn flours are inefficient in terms of water and energy consumption, and they often result in flours with poor texture and high costs, while also losing valuable nutrients during processing.
Innovation Solution
A continuous low-moisture precooking process using an endoamylase powder as a processing aid to produce pregelatinized and instant corn flours, which involves preconditioning whole corn kernels, milling, low-moisture precooking, and enzymatic treatment to achieve partial gelatinization and protein denaturation, followed by hot-air drying and milling to create uniform and nutrient-rich flours.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional high-moisture precooking methods are used, then complete gelatinization is achieved, but water and energy consumption increase significantly
Solution Approach 1:
The patent changes the moisture parameter from traditional high-moisture conditions to low-moisture conditions (10-20% moisture content), and adjusts temperature and time parameters accordingly (90-110°C for 10-30 minutes) to achieve effective gelatinization with reduced energy and water consumption
Solution Approach 2:
The patent applies partial gelatinization rather than complete gelatinization, treating the corn particles with just enough heat and moisture to achieve the desired functional properties without over-processing, thereby reducing energy and water usage while maintaining product quality
2Manufacturing precision
If traditional precooking methods are used, then starch gelatinization is achieved, but water consumption increases by 40-80%
Solution Approach 1:
The patent fundamentally changes the moisture parameter from traditional high-moisture conditions to low-moisture conditions (10-20% moisture content), achieving starch gelatinization with significantly reduced water consumption while maintaining effective gelatinization
3Manufacturing precision
If extended cooking time is used, then complete gelatinization is achieved, but processing time and energy consumption increase
Solution Approach 1:
The patent changes multiple parameters simultaneously - increasing temperature (90-110°C), reducing moisture (10-20%), and adjusting time (10-30 minutes) - to achieve effective gelatinization faster than traditional methods, thereby reducing processing time while maintaining gelatinization quality
Solution Approach 2:
The patent applies partial gelatinization with optimized time parameters, achieving sufficient gelatinization effect in 10-30 minutes without extending cooking time excessively, balancing gelatinization completeness with processing efficiency
4Productivity
If traditional processing methods are used, then corn flour is produced, but nutrient loss occurs during processing
Solution Approach 1:
The patent uses milder processing parameters (lower moisture 10-20%, controlled temperature 90-110°C, shorter time 10-30 minutes) compared to traditional methods, which reduces nutrient degradation and loss while still achieving effective gelatinization and flour production
Solution Approach 2:
The patent applies partial gelatinization rather than complete gelatinization, which is sufficient for functional properties but less severe than complete gelatinization, thereby preserving more nutrients while achieving the desired gelatinization effect
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 reduces water and energy consumption by 40-80% compared to traditional methods, produces flours with improved nutritional value, and results in flours with enhanced biochemical and phytochemical content, maintaining a higher fat, dietary fiber, and protein composition, while extending shelf-life and improving texture.
Implementation Method 1
enzymatic treatment with an endoamylase powder as a processing aid to produce pregelatinized and instant corn flours
Implementation Method 2
achieve partial gelatinization and protein denaturation
Implementation Method 3
followed by hot-air drying and milling to create uniform and nutrient-rich flours
Implementation Method 4
A continuous low-moisture precooking process using an endoamylase powder as a processing aid
Implementation Method 5
achieve partial gelatinization and protein denaturation
Data Source
Figure 1
AI summary
A bioprocess and apparatus for the continuous production of novel masa and whole-corn flours as cereal-base and functional-food ingredients. The bioprocess includes providing a fine grind fraction of corn kernel; combining the fine grind fraction of corn kernel with at least one endoamylase to produce an enzyme-added fine grind; moist-heat precooking the enzyme-added fine grind to obtain a pre-cooked enzyme-added fine grind; low-moisture conditioning the precooked enzyme-added fine grind to partially hydrolyze starchy endosperm and swell starch and aleurone-bran granules to produce enzymatically conditioned corn kernel particles; and milling the conditioned corn kernel particles to obtain flour comprising a fine grind portion of the conditioned corn kernel particle.