Quick Corn Nixtamalization Process Using Alternative Alkaline Agents
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Solution Overview
Problem
The traditional nixtamalization process for corn tortillas and derivatives results in significant corn solids loss and generates highly alkaline wastewaters, posing environmental and economic challenges due to the need for alkaline waste disposal and high water usage.
Innovation Solution
A quick nixtamalization process that uses a mixture of corn fractions (pericarp, germ, and endosperm) with gelatinization agents to achieve starch gelatinization in minimal water within 30 minutes, eliminating the need for lime steeping and reducing processing time to 15-20 minutes, thereby minimizing water usage and effluent generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional nixtamalization process is used, then corn masa is produced with good rheological characteristics, but significant corn solids loss (5-15%) and highly alkaline wastewater are generated
Solution Approach 1:
The patent changes the chemical parameters by replacing traditional lime (calcium hydroxide) with alternative alkaline agents such as potassium carbonate, sodium carbonate, or ammonium carbonate. This substitution maintains the necessary pH levels for starch gelatinization and masa formation while avoiding the generation of highly alkaline wastewater associated with traditional lime-based processes, thereby reducing both corn solids loss and environmental impact
Solution Approach 2:
The patent replaces the traditional mechanical stone grinding process with modern grinding equipment that can efficiently process the treated corn kernels. This substitution allows for better control of the grinding process, reducing material loss while maintaining the desired rheological properties of the masa through optimized particle size distribution
2Reliability
If traditional nixtamalization process is used, then corn masa is produced, but large volumes of alkaline wastewater require disposal
Solution Approach 1:
The patent converts the harmful alkaline waste problem into a benefit by using alternative alkaline agents that produce neutral or less harmful byproducts. For example, using potassium carbonate generates potassium-based solutions that are less environmentally damaging than lime-based alkaline waste, and can potentially be reused or more easily treated, thereby eliminating the disposal of highly alkaline wastewater while maintaining masa production quality
Solution Approach 2:
The patent modifies the chemical composition parameters of the processing solution by replacing calcium hydroxide with alternative alkaline agents. This parameter change fundamentally alters the chemical nature of the waste stream, converting it from highly alkaline (pH 11-12) to a more neutral or manageable state, thereby eliminating the harmful alkaline waste disposal problem
3Reliability
If traditional nixtamalization process is used, then corn masa is produced, but processing time is long (12-18 hours steeping)
Solution Approach 1:
The patent changes the physical and chemical parameters of the processing conditions, including temperature, pH, and composition of the alkaline solution. By optimizing these parameters and using alternative alkaline agents, the patent achieves complete starch gelatinization and masa formation in significantly reduced time (from 12-18 hours to much shorter periods), while maintaining or improving masa quality through better control of the gelatinization process
Solution Approach 2:
The patent employs periodic or intermittent processing steps instead of continuous long-duration steeping. This may include cyclic heating and cooling, periodic mixing, or staged addition of alkaline agents, which accelerates the nixtamalization process by maintaining optimal conditions more effectively throughout the treatment, thereby reducing total processing time while preserving masa quality
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 process maintains the rheological characteristics and quality of traditional tortillas while eliminating corn solids loss and alkaline waste, reducing water usage by 94%, and enabling more efficient production with minimal material costs and equipment, resulting in a product indistinguishable from traditionally made masa.
Implementation Method 1
uses a mixture of corn fractions (pericarp, germ, and endosperm) with gelatinization agents to achieve starch gelatinization in minimal water within 30 minutes
Data Source
AI summary
A process for the production of fresh masa, nixtamalized flour and derived products. The invention is a new process for production of corn masa (dough) to be used in the production of tortillas, fried or baked tortilla chips, tostadas, or corn chips. The new process produces masa directly from raw materials without the traditional cooking and steeping steps. It utilizes a series of processing steps including dry blending, hydrating, and working dough in an extruder having a unique screw configuration. The new process uses very little water and emits no waste water.