Resistant Dextrin Composition With Two-Stage Dextrinization Control
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Solution Overview
Problem
Existing methods for preparing resistant dextrin suffer from issues such as bitterness, deliquescence, and poor flowability, limiting their application in high-grade food and healthcare products.
Innovation Solution
A two-stage dextrinization process using hydrochloric acid at specific concentrations and temperatures, followed by enzyme-free catalytic reactions, including gelatinization, acidic hydrolysis, and multi-stage purification with activated carbon and ion exchange, to produce resistant dextrin with controlled DP1, DP2, and DP3 contents and high dietary fiber content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional single-stage acid hydrolysis method is used to prepare resistant dextrin, then the production process is simple, but the product has bitterness, deliquescence, and poor flowability
Solution Approach 1:
The patent divides the dextrinization process into two distinct stages: first stage acid hydrolysis (100-150°C, 1-3h) to break down starch, followed by second stage dextrinization (140-180°C, 30-60min) to form the final product. This segmentation allows optimization of each stage independently, preventing excessive hydrolysis that causes bitterness while ensuring complete dextrinization for good flowability.
Solution Approach 2:
The patent optimizes specific process parameters including acid concentration (0.1-1.0% HCl), temperature ranges for each stage, and reaction times. By precisely controlling these parameters, the method achieves complete conversion of starch to dextrin with minimal side reactions, eliminating bitterness and improving flowability while maintaining production efficiency.
2Object-generated harmful factors
If multi-stage purification process is used to improve product quality, then the product taste and flowability are improved, but the production cost increases and process complexity increases
Solution Approach 1:
The patent combines multiple purification operations (filtration, centrifugation, decolorization, drying) into an integrated multi-stage purification process. By merging these steps into a coordinated sequence with optimized parameters, the method achieves high product quality while avoiding the need for separate complex equipment for each purification step, thus controlling process complexity.
Solution Approach 2:
The patent employs a systematic purification approach where impurities are selectively removed at different stages: coarse impurities removed by filtration, fine particles by centrifugation, and colored substances by decolorization. This staged removal efficiently eliminates bitterness-causing substances while recovering valuable dextrin product, improving taste without excessive complexity.
3Productivity
If acid concentration and temperature are increased to improve reaction efficiency, then the production speed increases, but side reactions increase causing product degradation
Solution Approach 1:
The patent segments the thermal processing into two stages with different temperature and time parameters. The first stage uses moderate temperature (100-150°C) for extended time (1-3h) to ensure complete hydrolysis without excessive side reactions. The second stage uses higher temperature (140-180°C) for shorter time (30-60min) to complete dextrinization. This segmentation maintains high productivity while controlling product degradation.
Solution Approach 2:
The patent optimizes the relationship between acid concentration, temperature, and time parameters for each stage. By using moderate acid concentrations (0.1-1.0% HCl) combined with optimized temperature-time profiles, the method achieves high reaction efficiency while minimizing side reactions that cause product degradation, maintaining manufacturing precision.
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 results in a resistant dextrin with improved taste, flowability, and solubility, suitable for high-grade food and healthcare products, with reduced production costs and simplified purification.
Implementation Method 1
adding hydrochloric acid solution into starch according to mass percent of 0.1-0.5% and uniformly stirring the mixture to obtain a reaction material; increasing temperature of the reaction material obtained in step (1) to 80-120°C, performing reaction for 2-4h at normal pressure
Implementation Method 2
increasing temperature to 140-200°C and performing gelatinization reaction for 15-30min at normal pressure to obtain a dextrin crude material
Implementation Method 3
performing pyrolytic reaction under a high-temperature condition by using starch after acidic treatment as a raw material
Implementation Method 4
performing discoloration, ion exchange, concentration, purification and drying to the hydrolysate obtained in step (3) to obtain the resistant dextrin
Implementation Method 5
performing discoloration, ion exchange, concentration, purification and drying to the hydrolysate obtained in step (3)
Data Source
AI summary
A resistant dextrin and prepration method therefor. According to the resistant dextrin, the molar content of DP1 is smaller than or equal to 1%, the molar content of DP2 is less than or equal to 4.5%, the molar content of DP3 is less than or equal to 7.0%, the average degree of polymerization is 6-12, the pH value is 3.0-6.0, and the molar content of dietary fibers is more than or equal to 85%. According to the preparation method of the resistant dextrin, starch is used the raw material, a dextrinization reaction is divided into two stages for the first time, and the degree of polymerization of the polymerization reaction is powerfully guaranteed; meanwhile, generation of side reactions is reduced, and the subsequent treatment difficulty of purification is greatly reduced.