Starch Hydrolysate Production via Sift Grinding and Hydrolysis

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Solution Overview

Problem

The processing of pulses for protein production is hindered by the high starch content remaining after extraction, leading to economic viability issues due to excess starch with no market demand, necessitating further processing of starch-containing by-products to increase yield in the value chain.

Innovation Solution

A method involving sift grinding of legumes to separate high-protein and starch-rich fractions, where the starch-rich fraction is hydrolyzed to produce a starch hydrolysate, which can be further processed using microorganisms for various products, including lactic acid, proteins, and biodegradable plastics, while utilizing the protein fraction for fungal mycelium cultivation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If pulses are processed using wet extraction to separate protein and starch, then protein content is improved, but starch remains as an unwanted by-product with no market demand

Engineering Contradiction:
Improveprotein contentVSAvoidstarch by-product
Core Design Contradiction:
Quantity of substanceVSLoss of substance

Solution Approach 1:

The patent converts the harmful effect of excess starch by-product into a beneficial outcome by further processing it through hydrolysis and fermentation. The starch that was previously wasted is transformed into valuable products such as lactic acid, fungal protein mixture, and other marketable compounds, thereby eliminating the loss and creating additional revenue streams.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent applies parameter changes by altering the chemical state of starch through hydrolysis (changing starch into fermentable sugars) and then through fermentation (converting sugars into lactic acid and other products). This series of parameter changes transforms the unwanted starch by-product into high-value chemical and biological products.

Inventive Principle:
Principle #35Parameter changes

2Ease of manufacture

If starch-rich fraction is further processed through hydrolysis and fermentation, then economic viability is improved, but processing complexity increases

Engineering Contradiction:
Improveeconomic viabilityVSAvoidprocessing steps
Core Design Contradiction:
Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent applies multi-functionality by using the same starch-rich fraction as a substrate for multiple different fermentation processes. The hydrolyzed starch can be simultaneously or sequentially used to produce lactic acid, fungal protein mixture, and other valuable compounds, thereby justifying the additional processing steps through multiple product outputs from a single input stream.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent segments the processing into distinct stages: hydrolysis of starch into sugars, followed by separate fermentation pathways for different products. This segmentation allows each process step to be optimized independently and enables flexible production of multiple products from the same starting material, making the complex process more manageable and economically viable.

Inventive Principle:
Principle #1Segmentation

3Productivity

If the protein fraction from starch-rich residue is utilized for fungal cultivation, then value chain yield is improved, but additional processing steps are required

Engineering Contradiction:
Improvevalue chain yieldVSAvoidprocessing steps
Core Design Contradiction:
ProductivityVSDevice complexity

Solution Approach 1:

The patent merges the utilization of both starch and protein fractions from the starch-rich residue into a unified processing scheme. The protein fraction is used as a nitrogen source for fungal cultivation while the starch fraction provides carbon through hydrolysis and fermentation. This merging of resource utilization maximizes the value extracted from the original pulse material and justifies the additional processing steps through comprehensive resource utilization.

Inventive Principle:
Principle #5Merging (Combining)

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 reduces processing costs, effectively utilizes the protein fraction, and produces valuable industrial products, such as protein isolates and lactic acid, enhancing the economic viability of pulse processing by converting excess starch into valuable end products.

Implementation Method 1

The starch-containing fraction is hydrolyzed to a starch hydrolysate

Methodology Applied
Scientific EffectHydrolysis: Hydrolysis

Implementation Method 2

fermentation with microorganisms for the production of lactic acid

Methodology Applied
Scientific EffectFermentation: Fermentation

Data Source

PatentUS20240365832A1Method for processing a starch hydrolysate and starch hydrolysate
Publication Date: 2024.11.07 FOOD OR INTERNATIONAL GMBH
  • US20240365832A1 patent drawing
  • US20240365832A1 patent drawing

AI summary

The invention relates to a method for processing a starch hydrolysate, in which at least one legume species is provided. This is separated into a first fraction and a second fraction by a sift grinding process of the provided at least one legume species. Thereby, the first fraction comprises a higher protein content than the second fraction. In the second fraction, a proportion of the starch contained in the provided at least one legume species is at least 40% by weight. The second fraction is processed to produce a starch hydrolysate which, after hydrolysis, comprises a protein content in the range of 5% to 30% by weight.