Nixtamalized Maize Flour Process Eliminates Neyajote Waste
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Solution Overview
Problem
The production of nixtamalized flours generates significant environmental pollution due to the high pH and organic matter content in nejayote, a liquid waste produced during the nixtamalization process, which is not effectively addressed by existing technologies that often result in rigid tortilla products and inefficient use of maize grain components.
Innovation Solution
A process that nixtamalizes maize fractions separately, using semi-humid milling, extrusion of endosperms, and milling-instant dehydration to control cooking efficiency, eliminating the production of nejayote and achieving soft tortilla properties without alkaline effluents, by hydrating only the fine flours, milled fibers, and endosperms with food-grade lime, and completing starch transformations during extrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional nixtamalization process is used with whole grain, then complete nixtamalization is achieved, but rigid tortilla products are produced and nejayote waste is generated
Solution Approach 1:
The maize grain is segmented into different fractions (endosperm, germ, pericarp) before nixtamalization. Each fraction is processed separately through extrusion with controlled cooking parameters, allowing selective gelatinization of starch in endosperm while preserving the functional properties of other components. This segmentation resolves the contradiction by enabling complete nixtamalization of relevant fractions without producing rigid tortillas or nejayote waste.
Solution Approach 2:
Different cooking conditions are applied to different maize fractions based on their specific requirements. The endosperm receives controlled gelatinization treatment for optimal texture, while other fractions are processed to maintain their functional properties. This local quality approach ensures each component contributes optimally to the final product without compromising tortilla softness or generating pollution.
2Productivity
If extrusion of whole grain is used for nixtamalization, then processing efficiency is improved, but rigid flour products are produced
Solution Approach 1:
The grain is divided into fractions before extrusion processing. Only the endosperm fraction undergoes extrusion with controlled cooking to achieve gelatinization, while other fractions are processed separately. This segmentation maintains processing efficiency while preventing the rigidity that would result from extruding whole grain, as the non-endosperm components retain their flexibility-contributing properties.
Solution Approach 2:
The extrusion process parameters (temperature, pressure, moisture content) are precisely controlled during endosperm processing to achieve optimal gelatinization without over-cooking. This parameter control ensures the endosperm contributes to texture while avoiding the rigidity that would result from excessive cooking, thus maintaining tortilla softness despite efficient processing.
3Shape
If fractions are nixtamalized separately, then tortilla softness is improved, but nejayote waste is still generated
Solution Approach 1:
The harmful nejayote liquid waste is extracted and eliminated from the process by using extrusion-based cooking that gelatinizes starch directly within the grain matrix. The process uses controlled moisture and heat during extrusion to achieve nixtamalization effects without generating the alkaline liquid effluent that characterizes traditional methods, thus improving softness without generating pollution.
Solution Approach 2:
The process converts the potential harm of liquid waste generation into a benefit by using controlled moisture during extrusion that is fully incorporated into the food product. The moisture that would otherwise become nejayote waste is instead used to achieve gelatinization and improve texture, transforming a harmful byproduct into a functional ingredient.
4Loss of substance
If traditional milling and nixtamalization are used, then complete grain utilization is achieved, but environmental pollution increases
Solution Approach 1:
The harmful alkaline effluent is extracted and eliminated by replacing traditional nixtamalization with extrusion-based processing. All moisture used during extrusion is incorporated into the food product through gelatinization, eliminating the need for subsequent washing that would generate nejayote waste. This maintains complete grain utilization while removing pollution.
Solution Approach 2:
The process changes the physical and chemical parameters during processing - using controlled moisture, temperature, and pressure during extrusion to achieve gelatinization and nixtamalization effects simultaneously. This parameter control ensures complete utilization of grain components while preventing the generation of alkaline effluent that would require treatment.
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 results in nixtamalized maize flour with improved texture, aroma, and flavor, similar to traditionally nixtamalized doughs, while minimizing environmental impact by eliminating nejayote and alkaline solutions, and optimizing the use of maize grain components, leading to higher flour-dough efficiency and reduced waste.
Implementation Method 1
the extruder, in which heat can be added using electrical resistances and/or water vapor and/or combustion gases if needed. In this manner, doughs are produced and/or semolina and/or precooked flours that possess chemical and nutritional characteristics similar to their traditionally processed counterparts
Implementation Method 2
The aforementioned patent does not use extrusion or milling-instant dehydration, these operations allow control over the cooking and in the flour-dough-tortilla efficiency
Implementation Method 3
hydrating only the fine flours, milled fibers, and endosperms with a calcium hydroxide solution
Data Source
AI summary
The present invention “Production process of nixtamalized maize flour, nixtamalizing the maize fractions separately without producing nejayote”, considers the integration of the processes: Semi-humid milling of the maize (fractionated degerm), extruding of the maize endosperm and milling-instant dehydration of the different nixtamalized and extruded maize fractions, has as novelty the way in which the nixtamalization process is carried out and the objective is to provide a nixtamalized maize flour production system that reduces the residues from the maize grain and completely eliminating nejayote production.