Crystalline Trehalose Dihydrate Production via Enzymatic Conversion
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Solution Overview
Problem
Conventional processes for producing high-purity particulate compositions containing crystalline trehalose dihydrate from starch face challenges in achieving high yield and purity, with existing methods resulting in trehalose content around 85% and yield of 40% against starch, which are not economically viable for industrial scale production due to the use of expensive materials and inefficient fractionation steps.
Innovation Solution
The process involves using enzymes derived from microorganisms of the genus Arthrobacter, specifically α-glycosyltrehalose-forming and trehalose-releasing enzymes, in combination with natural or recombinant CGTase from Paenibacillus, to increase trehalose content to over 86% without column chromatography, followed by controlled cooling to enhance production yield and crystallinity, resulting in a high-purity particulate composition with trehalose content of 98% or more.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional enzymatic processes are used to produce trehalose from starch, then the production process can be simplified, but the trehalose content remains around 85% and yield is only 40% against starch
Solution Approach 1:
The patent optimizes enzymatic reaction parameters including temperature, pH, enzyme ratios, and reaction time to maximize trehalose content. By carefully controlling these parameters, the process achieves over 86% trehalose content in the saccharide solution, which then yields 98% pure crystalline trehalose dihydrate after crystallization, resolving the contradiction between process simplicity and manufacturing precision.
2Manufacturing precision
If column chromatography fractionation is used to increase trehalose purity, then the purity can be improved, but the process complexity and cost increase significantly
Solution Approach 1:
The patent extracts and removes unwanted saccharides from the reaction mixture through selective enzymatic degradation and crystallization processes. By using specific enzymes to convert unwanted sugars and optimizing crystallization conditions, the process achieves 98% pure trehalose dihydrate without requiring complex column chromatography, thus resolving the contradiction between purity and process complexity.
Solution Approach 2:
The patent replaces expensive and complex column chromatography systems with simpler, more economical enzymatic treatment and crystallization steps. The use of readily available enzymes and standard crystallization equipment reduces both device complexity and operational costs while maintaining high purity output.
3Manufacturing precision
If expensive materials and inefficient fractionation steps are used, then high purity can be achieved, but the economic viability for industrial scale production is compromised
Solution Approach 1:
The patent optimizes reaction conditions including temperature, pH, enzyme concentrations, and reaction time to maximize trehalose yield and purity simultaneously. These parameter optimizations enable the process to achieve 98% pure trehalose dihydrate with over 40% yield against starch using cost-effective materials and methods, ensuring economic viability for industrial production.
Solution Approach 2:
The patent employs cost-effective enzymes and eliminates the need for expensive column chromatography equipment. By using readily available enzymatic reagents and standard crystallization processes, the method achieves high purity trehalose production at lower operational costs, improving economic viability for industrial scale production.
4Manufacturing precision
If the trehalose content in the saccharide solution is increased to over 86%, then the crystallizability is satisfied without column chromatography, but the yield against starch must be improved to be economically viable
Solution Approach 1:
The patent optimizes enzymatic reaction parameters including temperature, pH, enzyme ratios, and reaction time to simultaneously achieve over 86% trehalose content in the saccharide solution and improve yield against starch to over 40%. This dual optimization ensures both excellent crystallizability and economic viability for industrial production.
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 significantly improves the production yield of crystalline trehalose dihydrate to over 40% against starch, achieving high purity and crystallinity, making the process more economically viable and efficient for industrial production while maintaining the quality of the final product.
Implementation Method 1
allowing, together with a starch debranching enzyme and CGTase, an α-glycosyltrehalose-forming enzyme and a trehalose-releasing enzyme which are derived from a microorganism of the genus Arthrobacter to act on liquefied starch
Implementation Method 2
precipitating crystalline trehalose dihydrate from the saccharide solution
Data Source
AI summary
A process for enabling the production of a particulate composition containing crystalline trehalose dihydrate is provided. Including allowing an α-glycosyltrehalose-forming enzyme to act on liquefied starch derived from a microorganism of the genus Arthrobacter and a trehalose-releasing enzyme derived from a microorganism of the genus Arthrobacter along with a starch debranching enzyme and a cyclomaltodextrin glucanotransferase; allowing glucoamylase to act on the resulting mixture to obtain a saccharide solution containing α,α-trehalose; precipitating crystalline α,α-trehalose dihydrate from the above saccharide solution; collecting the precipitated crystalline α,α-trehalose dihydrate by a centrifuge; and ageing and drying the collected crystals. Cyclomaltodextrin glucanotransferase derived from a microorganism of the genus Paenibacillus or a mutant enzyme thereof is used to increase the α,α-trehalose content in the saccharide solution to over 86.0% by weight, on a dry solid basis, without passing through a fractionation step by column chromatography.