Maltodextrin Enzyme Processing for Low-Viscosity High-Solids Solutions
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Solution Overview
Problem
Existing maltodextrin solutions have high viscosity, short shelf-life, and poor processing characteristics due to high water activity and microbiological growth, making them difficult to handle and store.
Innovation Solution
A process involving liquefaction and saccharification steps to produce maltodextrins with a dextrose equivalent between 17.0 and 19.9, using acid or enzyme hydrolysis, and subsequent enzymatic treatment with alpha-amylase and pullulanase to achieve desired polysaccharide distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high solids content solutions are used, then maltodextrin powder production efficiency is improved, but viscosity becomes excessively high making processing difficult
Solution Approach 1:
The patent changes the molecular weight distribution parameters of maltodextrin by controlling the hydrolysis process to produce a specific degree of polymerization distribution. This parameter change reduces viscosity at high solids content while maintaining production efficiency
Solution Approach 2:
The patent creates a composite molecular weight distribution profile combining different polysaccharide chain lengths (DP1-DP10+), where the specific ratio of these components works together to achieve low viscosity at high concentrations, enabling both high productivity and ease of processing
2Ease of operation
If high water activity is present, then maltodextrin solution is easier to process, but shelf-life decreases due to microbiological growth
Solution Approach 1:
The patent changes the molecular structure parameters of maltodextrin to produce a specific degree of polymerization distribution that inherently reduces water activity. This structural parameter change allows the product to maintain both processability and extended shelf-life without compromising either property
3Ease of operation
If more water is used in production, then processing is easier, but energy consumption and production time increase
Solution Approach 1:
The patent changes the maltodextrin molecular weight distribution parameters to achieve low viscosity at high solids content. This parameter change enables concentration of the solution with minimal water, reducing the energy and time required for subsequent evaporation and drying operations while maintaining ease of processing
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 resulting maltodextrin solutions have reduced viscosity, improved shelf-life, and better processing characteristics, allowing for easier handling and reduced water usage, energy consumption, and production time.
Implementation Method 1
applying a liquefaction step comprising adding either an acid or an enzyme to an aqueous starch mixture in sufficient amount to hydrolyze the starch to form a mixture comprising polysaccharides
Implementation Method 2
applying a saccharification step comprising adding an alpha-amylase and a pullulanase to hydrolyze the polysaccharides in the mixture to obtain maltodextrin
Data Source
AI summary
This specification discloses process for obtaining maltodextrin having DE between 17 and 19.9 and the maltodextrins obtained from the process. The disclosed maltodextrins can be provided as a powder or in shelf stable liquid form. The disclose maltodextrins have a polysaccharide profile similar to those observed for prior art maltodextrins, but make maltodextrin solutions having a high solids content, but reduced viscosity compared to prior art maltodextrins, on equivalent solids-in-solution basis. The process combines adds an alpha-amylase and a pullulanase enzyme to a polysaccharide mixture during a saccharification step. The disclosed maltodextrins make solutions at 50° C. and greater than 65% on a solids dry solids basis having a viscosity between 5,000 and 12,000 cP and having a water activity of less than 0.80.