Peroxyacid Sanitizing Solution for Grain Malting Decontamination
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Solution Overview
Problem
Current methods for reducing microbial contamination and mycotoxin production in grains during the malting process are not economically feasible and often produce difficult-to-remove by-products, lacking an effective and environmentally safe solution.
Innovation Solution
A method involving a sanitizing solution with peroxyacid and hydrogen peroxide, applied at specific pH levels and contact times, to reduce microbial counts by at least 90% during the malting process of grains, specifically after steeping, germination, or kilning, using peracetic acid or other peroxyacids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If physical methods (thermal or vibrational cleaning) are used to reduce microbial contamination, then microbial population is inactivated, but the method lacks economic feasibility and may not effectively reduce mycotoxin production
Solution Approach 1:
The patent changes the chemical parameters of the treatment solution by using peroxyacids at controlled concentrations (250-5000 ppm) and pH levels (3-5 or 8-11), which provides effective microbial inactivation and mycotoxin reduction while being economically feasible and environmentally safe
Solution Approach 2:
The patent employs peroxyacids (such as peracetic acid) as strong oxidizing agents to effectively inactivate microorganisms and reduce mycotoxins during malting, achieving reliable decontamination while maintaining economic feasibility and environmental safety
2Reliability
If chemical agents (gaseous ozone, chlorine dioxide, sodium hypochlorite) are used for decontamination, then microbial contamination is reduced, but difficult-to-remove by-products are produced
Solution Approach 1:
The patent converts the potential harm of chemical residues into a benefit by using peroxyacids that decompose into harmless substances (acetic acid and hydrogen peroxide) that are already present in the malting process, eliminating the by-product problem while maintaining effective decontamination
Solution Approach 2:
The patent uses peroxyacids that are consumed during the process and decompose into harmless, easily removable substances, effectively eliminating difficult-to-remove by-products while maintaining reliable microbial contamination reduction
3Reliability
If decontamination procedures are performed prior to steeping, then microbial population is reduced, but the treatment time and process complexity increase
Solution Approach 1:
The patent applies decontamination treatment before steeping to preliminarily reduce microbial population, preventing subsequent mycotoxin production during germination while integrating seamlessly into the existing malting process timeline
Solution Approach 2:
The patent maintains continuous protection against mycotoxin production by applying peroxyacid treatment at strategic points during the malting process, ensuring uninterrupted decontamination effectiveness without adding excessive time or complexity
4Reliability
If high concentrations of antimicrobial agents are used to reduce fungal contamination, then mycotoxin production is reduced, but adverse effects on germination occur
Solution Approach 1:
The patent optimizes the parameters of peroxyacid concentration (250-5000 ppm) and pH (3-5 or 8-11) to achieve effective fungal contamination reduction while minimizing adverse effects on germination, balancing decontamination effectiveness with malt quality preservation
Solution Approach 2:
The patent applies controlled amounts of peroxyacid treatment (250-5000 ppm) that are sufficient to reduce fungal contamination and mycotoxin production but not excessive enough to severely damage germination, achieving partial action that balances effectiveness with safety
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 effectively reduces fungal contamination and mycotoxins, minimizing adverse effects on germination and maintaining malt quality, with peracetic acid showing significant antimicrobial activity across various pH ranges and treatment durations.
Implementation Method 1
contacted with a sanitizing solution comprising a peroxyacid and hydrogen peroxide
Implementation Method 2
hydrogen peroxide
Data Source
AI summary
Compositions and methods can be used to reduce the population of microorganisms present during the processing of grains and seeds. More specifically, microorganism levels are reduced in grains and seeds being malted by contacting the grains and seeds with a sanitizing solution that contains a peroxyacid and hydrogen peroxide.