Digestion-Resistant Maltodextrin Filtration Process

Solution Overview

Problem

The existing method for producing digestion-resistant maltodextrin is economically infeasible due to frequent filter press overload and high perlite consumption, leading to reduced filtration rates and increased production costs.

Innovation Solution

Introducing activated carbon after saccharification and before filtration of roasted dextrin to remove fine particles, thereby preventing filter overload and maintaining filtration efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If activated carbon is used in large amounts (5% or more based on total solids) for decoloration, then decoloration effect is improved, but filter press overload occurs and filtration rate decreases

Engineering Contradiction:

Improvedecoloration qualityVSAvoidfiltration rate

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The filtration process is divided into two independent stages: vacuum filtration for removing coarse particles and filter press filtration for removing fine particles. This segmentation allows each filtration stage to handle specific particle sizes, preventing overload and maintaining high filtration rates while still achieving adequate decoloration

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Vacuum filtration is performed as a preliminary action before filter press filtration to remove coarse particles first. This preliminary removal of large particles prevents them from contributing to filter press overload, allowing the filter press to focus on removing fine particles and activated carbon, thereby maintaining high filtration rates throughout the process

Inventive Principle:

Principle #10Preliminary action

2Productivity

If vacuum filtration is omitted or activated carbon amount is reduced to prevent filter overload, then filtration rate is improved, but decoloration becomes insufficient and product quality deteriorates

Engineering Contradiction:

Improvefiltration rateVSAvoiddecoloration quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The filtration process is divided into two independent stages: vacuum filtration for removing coarse particles and filter press filtration for removing fine particles. This segmentation allows each filtration stage to handle specific particle sizes, preventing overload and maintaining high filtration rates while still achieving adequate decoloration

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The amount of activated carbon is optimized to a specific range (1-5% based on total solids) that provides sufficient decoloration effect without causing excessive filter press overload. This parameter optimization balances decoloration quality with filtration rate, resolving the contradiction between the two requirements

Inventive Principle:

Principle #35Parameter changes

3Reliability

If perlite is frequently replaced due to filter press overload, then filtration functionality is maintained, but production costs increase and economic feasibility decreases

Engineering Contradiction:

Improvefiltration functionalityVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The filtration process is divided into two independent stages: vacuum filtration for removing coarse particles and filter press filtration for removing fine particles. This segmentation allows each filtration stage to handle specific particle sizes, preventing overload and maintaining high filtration rates while still achieving adequate decoloration

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Vacuum filtration is performed as a preliminary action before filter press filtration to remove coarse particles first. This preliminary removal of large particles prevents them from contributing to filter press overload, allowing the filter press to focus on removing fine particles and activated carbon, thereby maintaining high filtration rates throughout the process

Inventive Principle:

Principle #10Preliminary action

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 effectively reduces perlite consumption and maintains filtration functionality, enabling efficient and cost-effective production of digestion-resistant maltodextrin with improved filtration rates.

Implementation Method 1

Introducing activated carbon after saccharification of roasted dextrin and before filtration of the saccharified roasted dextrin

Methodology Applied

Scientific EffectAdsorption: Adsorption

Data Source

PatentUS10696752B2Method for preparing digestion-resistant maltodextrin

Publication Date: 2020.06.30 SAMYANG CORP

AI summary

Disclosed herein is a method of preparing digestion-resistant maltodextrin from roasted dextrin. The method includes introducing activated carbon to be reacted with roasted dextrin after saccharification of the roasted dextrin and before filtration of the roasted dextrin.