Zein Purification via Size-Exclusion Chromatography
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Solution Overview
Problem
Current methods for producing zein from corn face challenges in achieving high purity and yield simultaneously, often resulting in zein that is not devoid of xanthophylls and requires harsh processing conditions, which limits its applications and profitability in the dry-grind ethanol process.
Innovation Solution
A method involving the extraction of zein and xanthophylls from corn using aqueous ethanol followed by size-exclusion chromatography, which separates impurities and produces substantially purified zein and xanthophylls in a single step, utilizing a size-exclusion resin with a suitable molecular weight exclusion limit to avoid conformational changes in the products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional purification methods are used to increase zein purity, then purity is improved, but yield is reduced and production cost increases
Solution Approach 1:
The patent changes the purification parameter from multiple sequential steps to a single chromatography step, achieving both high purity (90%+) and high yield (80%+) by optimizing the chromatographic conditions and resin selection
Solution Approach 2:
The patent extracts and removes impurities (xanthophylls, lipids, proteins) from the zein solution through a single chromatography step, separating them based on their different affinities for the chromatography medium, thereby obtaining pure zein with high yield
2Manufacturing precision
If harsh processing conditions are used to purify zein, then purity is improved, but the natural conformation of zein is changed, limiting its applications
Solution Approach 1:
The patent changes the processing conditions from harsh (high pH, high temperature, strong solvents) to benign (neutral pH, ambient temperature, mild solvents), maintaining zein's natural conformation while achieving high purity through optimized chromatography
Solution Approach 2:
The patent uses a chromatography medium as an intermediary substance that selectively interacts with impurities while leaving zein unchanged, allowing purification without altering zein's natural structure or conformation
3Manufacturing precision
If multiple purification steps are used to remove xanthophylls and impurities, then purity is improved, but process complexity and production cost increase
Solution Approach 1:
The patent merges multiple purification functions (removal of xanthophylls, lipids, and other proteins) into a single chromatography step, achieving comprehensive purification in one operation rather than requiring multiple sequential steps
Solution Approach 2:
The patent uses a single chromatography step that performs multiple purification functions simultaneously, making the process universal and efficient, thereby reducing both process complexity and production cost while achieving high purity
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 achieves high purity and yield of zein and xanthophylls, providing a cost-effective and benign process that maintains the natural conformation of zein, enhancing its value and applicability, while also producing a valuable coproduct with potential health benefits.
Implementation Method 1
the resulting extract is purified in a single size-exclusion chromatography step to separate impurities and produce substantially purified zein
Implementation Method 2
utilizing a size-exclusion resin with a suitable molecular weight exclusion limit to avoid conformational changes in the products
Implementation Method 3
The zein and/or xanthophylls are first extracted from corn using aqueous ethanol
Data Source
AI summary
Methods and systems for obtaining zein and/or xanthophylls in highly pure form. Zein is first extracted from corn using aqueous ethanol. Suspended corn solids are separated, and the resulting extract is purified in a single size-exclusion chromatography step to separate impurities and produce substantially purified zein. The chromatography step may simultaneously produce substantially purified xanthophylls.