Zein Protein Feed Composition from Cold Cook Saccharification
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Solution Overview
Problem
Conventional corn-to-ethanol fermentation processes expose protein feed compositions to high temperatures, resulting in reduced protein content and altered composition properties.
Innovation Solution
A method involving a cold cook saccharification process without cooking, followed by centrifugation and solvent extraction to separate components from the fermentation beer prior to distillation, reducing total heat exposure and enhancing protein content in the resulting protein feed compositions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional cooking and distillation processes are used in corn-to-ethanol fermentation, then ethanol production is achieved, but protein content and quality deteriorate due to high temperature exposure
Solution Approach 1:
The patent applies preliminary action by conducting saccharification before cooking and distillation steps. The fermentation beer is separated and processed into protein feed composition before the high-temperature distillation step that would otherwise expose the protein to damaging temperatures. This sequencing preserves protein content while still achieving ethanol production.
Solution Approach 2:
The patent extracts the protein-containing fermentation beer from the conventional process flow before it undergoes distillation. By taking out the beer component separately for protein extraction and processing, the protein material is removed from the path of high-temperature treatment, thereby preserving its content and quality.
2Quantity of substance
If cold cook saccharification without cooking is used, then protein content is preserved, but the process complexity increases
Solution Approach 1:
The patent changes the temperature parameter of the saccharification process by conducting it without cooking (cold cook saccharification). This parameter change preserves protein content by avoiding high temperatures, while the increased process complexity is managed through integrated process design that combines multiple steps.
Solution Approach 2:
The patent merges multiple process steps including saccharification, fermentation, and protein extraction into an integrated flow. By combining these steps and optimizing their sequence, the overall process complexity is managed while achieving the goal of preserving protein content through avoided cooking.
3Quantity of substance
If fermentation beer is separated prior to distillation, then protein feed composition quality is enhanced, but manufacturing time increases
Solution Approach 1:
The patent performs preliminary separation of the fermentation beer before distillation, extracting the protein-containing stream early in the process. This preliminary action enables subsequent protein recovery operations to proceed independently, enhancing protein content while the overall timeline is managed through parallel processing of ethanol and protein streams.
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 produces protein feed compositions with higher protein content (>40%) and specific nutrient profiles, such as 75% crude protein, <10% crude fat, and <1% residual starch, while minimizing heat exposure, thereby differing from conventional processes.
Implementation Method 1
saccharifying the reduced endosperm using an enzyme composition to form one or more sugars
Implementation Method 2
fermenting the one or more sugars using a yeast to form a beer composition comprising: a liquid fraction comprising ethanol and water
Implementation Method 3
separating the beer composition to separate it into a first composition comprising bulk solids and residual liquid fraction, and a second composition comprising fine solids and a major portion of the liquid fraction
Implementation Method 4
extracting protein comprising zein from the first composition (bulk solids) by adding ethanol to the first composition and allowing the protein to be extracted into the ethanol
Implementation Method 5
at least partially de-solventizing the fourth composition to form a protein feed composition comprising zein
Data Source
AI summary
Protein feed compositions and methods of making the protein feed compositions are disclosed herein. The protein feed compositions may comprise zein and are derived from a starch-based feedstock-to-ethanol fermentation conversion process such as a corn-to-ethanol conversion process. Methods of making the compositions include performing a starch-based feedstock-to-ethanol fermentation process in a manner that reduces the total heat exposure of the components of the protein composition as compared to a similar process which uses a cooking process to saccharify starch and/or a distillation process to separate the fermentation beer into ethanol and whole stillage. The process may include centrifugation of the fermentation beer resulting in a bulk solids mixture, extraction of a protein composition from the resulting bulk solids mixture, and desolventizing the extracted protein composition.