Maize Protein Extraction for Gluten-Free Dough Structure
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Solution Overview
Problem
Current gluten-free bakery products and pasta lack the structural and sensory qualities of traditional wheat-based products due to the inability of maize proteins, such as zein, to form visco-elastic doughs at room temperature, and require numerous additives to achieve acceptable texture and taste, making them unpalatable and costly.
Innovation Solution
A method for extracting maize proteins, specifically zein and glutelin, from white maize using an aqueous isopropanol solution without reducing or purifying agents, followed by a controlled pH extraction process, to produce a protein mixture that can replace wheat gluten in bakery products and pasta, maintaining the quality and structure of traditional wheat-based items without additives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If maize proteins (zein) are used to produce gluten-free bakery products, then the products are suitable for coeliac patients, but the products lack structural quality and visco-elastic properties
Solution Approach 1:
The patent combines multiple maize protein fractions (zein and glutelin) in specific proportions to create a composite protein material that exhibits visco-elastic properties similar to wheat gluten, thereby achieving both coeliac suitability and structural quality
Solution Approach 2:
The patent modifies the extraction parameters (pH, temperature, solvent composition) to optimize the recovery of specific protein fractions with desired functional properties, transforming the protein mixture into a dough-forming material
2Productivity
If reducing agents are used to extract and purify zein, then the extraction efficiency is improved, but the extracted zein lacks ability to form visco-elastic structures
Solution Approach 1:
The patent changes the extraction conditions by avoiding reducing agents and controlling pH and temperature parameters to preserve the disulphide bonds and molecular weight of glutelin polymers, enabling visco-elastic structure formation while maintaining extraction efficiency
Solution Approach 2:
The patent selectively extracts specific protein fractions (zein and glutelin) from maize using controlled extraction conditions, separating them from other components while preserving their functional properties
3Ease of operation
If numerous additives are used to achieve acceptable texture and taste in gluten-free products, then the sensory quality is improved, but the production cost increases and the products become less natural
Solution Approach 1:
The patent enables the maize protein mixture to self-form visco-elastic dough structures through controlled extraction and processing, eliminating the need for external additives like xanthan gum or hydrocolloids that are typically required in gluten-free formulations
4Adaptability or versatility
If commercial zein is used in gluten-free products, then the products are gluten-free, but the products acquire unwanted colors and odors
Solution Approach 1:
The patent controls extraction parameters (pH, temperature, solvent composition) to prevent degradation and oxidation of the protein fractions, maintaining their natural color and odor properties while achieving the desired functional characteristics
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 method enables the production of gluten-free bakery products and pasta with rheological characteristics similar to traditional wheat products, including elasticity, strength, and stability, while being economically viable and free from unwanted colors and odors, thus addressing the limitations of existing gluten-free formulations.
Implementation Method 1
extracting from white maize and/or its by-products... protein fractions comprising zein and glutelin, using an aqueous solution based on an alcohol
Data Source
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AI summary
A method for the production of maize proteins comprises a step of extracting protein fractions comprising zeins and rich in glutelins from white maize and/or its sub-derivatives, such as for example flour, CGM (Corn Gluten Meal) or other, using an aqueous solution of alcohol in the absence of a reducing and purification agent. The present invention also concerns the formulation of recipes for the preparation of bakery gluten-free products and pasta with said proteins extracted