Teknologi Pengolahan Pati

PRODUKSI PATI JAGUNG

CORN STARCHES
Dr.rer.nat Lanny Sapei
 Introduction
Corn used in United States for the cultivated
member of the grass family (Gramineae) known as Zea
mays L.
Maize popular name outside United States
Product of domestication in central Mexico beginning
5000-7000 years ago.
Corn has reached its present state of development
through continual mutations, hybridizations,
segregations and selections by random, natural
processes, and by conscious selection.
Popcorn, sweet corn, dent corn, flint corn, flour corn.
 Corn staple food for natives of North and South
America.
Taken to Spain by Columbus Europe. Record:
Seville in 1494.
A mutant waxy maize, first discovered in China.
Commercial processes for corn starch recovery
due to
Availability at relatively low and steady prices
Storability from season to season
Ease of transportation and handling
High starch content
 Process Overview
Wet millingto recover starch, essentially a
method of disrupting the corn kernel in such a
way that the component parts can be separated
in an aqueous medium into relatively pure
fractions.
could achieve a commercially satisfactory yield
and quality of starch.
Dry milling using screening and air classification
for component separation less efficient
fractionation.
Energy saving obtained by dry separation of germ
and fiber and wet processing of only the
endosperm would be useful.
 Structure
Description of the structures and
compositions are helpful in understanding the
process of disruption during wet milling
process.
The corn kernel is a one-seeded fruit classified
as a grain.
The seeds (kernels) mature about 60 days,
harvested when kernel moisture content has
dropped below 30% (wet weight basis).
 The mature corn
kernel is
composed of 4
principles parts
Tip cap, 0.8%
Pericarp, 5.3%
Germ, 11.9%
Endosperm,
82%
 Tip Cap
Attaches the seed to the cob
Composed of insoluble fibrous elements
arranged in a spongy structure well adapted
for rapid water adsorption
Acts as the major pathway for the entrance of
water or other liquids or gases into the kernel
 Pericarp
Smooth, dense, outer covering of the kernel
Referred as hull misnomer, hull is a distinctly
different mophological entity
The pericarps outer layer has a thin coating of
wax-like cutin, beneath which are several layers
of dead, hollow, elongate cells compressed into a
dense tissue. Beneath this layer is a spongy tissue
known as the tube cell and a cross-cell layer
which acts as a natural channel for absorption of
water. Beneath the spongy layer sead
coat/testasemipermeable membrane limiting
passage of large molecules into or out of the
endosperm and germ.
 Endosperm
Beneath the testa first layer of the
endosperm, the aleurone (3% of the weight
kernel), a single layer of highly proteinaceous
cells having thick, tough cell walls
semipermeability. Aleurone together with tip
cap and pericarp grouped as fiber fraction
from wet-milling and in the bran fraction from
dry milling.
In alkali debranning, the aleurone layer is not
removed with the pericarp.
 Endosperm
Mature endosperm is comprised of a large
number of cells, each packed with starch granules
embedded in a continuous matrix of protein; all
the cell contents are surrounded by a cellulosic
cell wall.
Mature endosperm of dent corns contains a
central core of soft or floury endosperm
extending to the crown which shrinks on drying,
causing a dent.
The floury endosperm is surrounded by a glassy-
appearing region known as horny or hard
endosperm.
 Endosperm
The average ratio of floury to horny ratio 1:2
Flour cornvirtually no horny endoperm
Flint corn and popcorn comprised of a small core of
floury endosperm entirely surrounded by horny
endosperm which resists denting when the kernel
dries.
The floury region is characterized by larger cells,
large spherical starch granules and relatively thin
protein matrix easily ruptured during drying
causing air pocket, white opaque appearance and
a porous texture of floury regionease of starch
recovery.
 Endosperm
Horny endosperm thicker protein, shrinks
but do not rupture during drying. The dense
nature of horny endosperm requires adequate
steeping to ensure recovery of starch. It
contains only ~1.5-2.0% higher protein
content and a greater concentration of the
yellow carotenoid pigments than the floury
region.
 Endosperm
Just under the aleurone layer is a dense row of
small cells (5% of endosperm) known as
subaleurone or dense peripheral endosperm
containing as much as 28% protein. They
contain very small starch granules and a thick
protein matrix starch isolation and
purification can be difficult.
 Germ
Nutrient mobilization, enzyme secretion
Thick walled cells containing oil droplet
Scutellar epithellium adheres to the
endosperm strong bond that resists many
chemical and physical means of separating the
germ and endosperm prolong steeping is
required.
 Pericarp
As a plastic bag protects the contents
inside by limiting exposure to the external
elements.
Oil sponges (germs)
Marbles (starch)
Glue (gluten meal)
Bags (gluten feed)
The purpose of wet milling is to chemically
loosen the glue and mechanically (primarily by
density) separate the kernel into separate
fractions.
Composition
 Composition
Neutral detergent residue (NDR) which
includes all insoluble, cell wall
polysaccharides.
Acid detergent residues (ADR) measures the
sum of cellulose and lignin (but lignin is
negligible).
About 90% of the kernel NDR fiber content is
in the pericarp and tip cap.
NDR-ADR= hemicellulose (pentoglycan)
 Composition
Endosperm contains > 98% of the total starch;
74% of the kernel protein and 16% of the fat
(only 18% of it are triglycerides).
Germ84% kernel fat (triglycerides), 22%
kernel protein, 82% total ash, 65% sugar.
Germs contais all the phytin phosphorus in
corn probably as a magnesium salt, and a
small, unrecoverable quantity of starch.
 Composition
Yellow cornthe vast majority, white corn
hybridslower yields but enhanced whiteness.
Yellow pigmentis concentrated in the gluten
meal fractionpoultry feed, 1.5x the value of
starch.
Alteration of composition through plant breeding
methods,e.g. higher oil (6-9% of oil (dry basis)).
Genetic change in corn waxy maize hybrids.
Grain Quality
 Wet-milling
The method has been gradually developed
over a period of about 150 years.
Current process technological control and
simplicity compared with those in use as little as
40-50 years ago.
Processes
Grain cleaning
Steeping
Milling and fraction separation
 Grain cleaning
Important step, because the presence of small
pieces of broken kernels can alter the normal
flow of steepwater through the corn mass,
resulting in non-uniform steeping.
Starch granule, eroded from the exposed
endosperm surfaces, are washed into the
steepwater and are gelatinized during
evaporation, resulting in viscous steepwater.
 Grain cleaning
Reciprocating screening removes 50% of
smaller pieces of material when the
equipment is operated at capacity.
US standard size screen: 4.8 mm
Importing countries: 3.2 mm
Aspiration to remove dust and light chaff.
Magnetic separator to recover metal trash
(bolts, tools, scrap iron, etc.)
 Effect of broken and damaged kernels
1. Rate of water sorption was much faster for the
damaged kernels, averaging 8% per hour compared to
5% per hour for intact kernels during the first 4 hour
of steeping
2. Final moisture equilibrium was not affected (in 12 hrs)
3. Rate of solids release into steepwater was much
faster with only 3% total solids after 5 hrs vs 36 hrs for
intact kernel.
4. Higher solids levels (3.8% vs. 3%)
5. Steep water pH increased more rapidly and
maintained a higher level throughout steeping
6. Protein content of the steepwater was almost double
after 12 hrs of steeping 60% higher
 Steeping
Prior to wet milling, the corn must be
softened by a steeping process developed
specifically to produce optimum milling and
separation of corn components.
During steeping, water flow, T, SO2
concentration and pH are maintained.
Corn is normally steeped for 24-40 hrs at a
temperature of 48oC to 52oC.
 Steeping
By the end of steeping process, the kernels
should have:
Absorbed water to about 45% (wet basis)
Release about 6.0-6.5% of their dry substance as
solubles into the steepwater
Absorbed about 0.2-0.4 g of SO2 per kg
Become sufficiently soft to yield when squizzed
between the fingers.
The germ is easily liberated intactand free of
adhering endosperm or pericarp.
When the endosperm is macerated with water,
starch easily separates as a white floc and gluten
is obtained as a yellow floc.
 Steeping
Conventional countercurrent steeping 3
stages with 8-12 hrs for each stage
Stage 1 fermentation phase
Lactobacillus sp lactic acid conc up to 2% in the
steepwater
Near complete hydration of kernels
When the SO2 exceeds a critical level (100-300
ppm) the fermentation stops.
 Steeping
Stage 2 SO2 diffusion stage
Little SO2 diffuses into the kernel because of the
low conc in the steepwater and the SO2 that does
diffuse into the kernel reacts quickly with the
germ and pericarp components before it has a
chance to diffuse into endosperm.
Sufficient SO2 flux to achieve the necessary
reactions leading to starch release in the
endosperm.
 Steeping
Stage 3 SO2 dominated stage
High conc of SO2 (up to 2500 ppm) to provide
enough sulfite to stop the fermentation stage
Since the process is countercurrent, SO2 is
absorbed by the corn and carried by the corn into
subsequent milling operation.
 Steeping
Water works from starch washing to steeps (Fig.
9.6). Use of low hardness water.
Steeps are normally operated as countercurrent
batteries of 6-12 tanks. Process wash water
containing 0.1-0.2% sulfur dioxide is placed on
corn that has been in the steeps longest and,
therefore, has the lowest residual solubles
content. This process water is sequentially moved
from tank to tank (from oldest corn to newest)
while it decreases in SO2 content and increases in
solubles. (see Fig. 9.7)
Each tank or every 2-3 tanks are equipped with a
HE which helps maintain the desired T.
 Steeping problem&advantage
Fine material can plug the screen at the bottom
of the steep tank
Decreases flow through tanks
Build-up of process water thoughout the plant
Chanelling in the steep tanks, resulting in non-uniform
steepingnon uniform starch quality
Each tank operates independent of all other
steep tanks, pump failures or other mechanical
problems do not significantly affect plant
operation as occurs within a conventional system.
Steep capacity can be expanded easily and
discretely, and does not need to be tied with the
old steep tanks.
 Water absorption and solubles
removal
Raw corn entering a steeping battery will start at
14-16% moisture.
The effect of SO2 dissolved in water is to increase
the rate of water diffusion into dent corn kernels.
Increasing the T up to 60oCrate of water
diffusion increases.
After 17 hrs steep at 49oC, the moisture increase
was 25% higher in the SO2 solution than in water
alone.
Mass movement of water into kernel parts is
relatively rapid, but thorough softening is slower ,
takes 12-18 hrs.
 Water absorption and solubles
removal
Absorption of lactic acid into the kernel reduces
the pH in 12 hrs death of all living cells in the
germ. Cell membrane become porous, and soluble
sugars, amino acids, proteins, minerals, and large
assortment of organic molecules required for
growth of living cells leach into the steepwater
(most rapid in the first 12-20 hrs).
One half of solublesfrom germ (11-12% of kernel
weight), remainingfrom endosperm
Increasing fat content from 30-38% to 55-60% in
steeped germ.
No visible increase in volume since the swelling
kernel reorient and fill the irregular voids between
kernels.
 Effect of SO2
First used to prevent growth of putrefactive
organisms. Eventuallyobtained max starch
yield.
Steeping with SO2 over 24 hr period at 50oC
protein matrix gradually swells, becomes
globular, and finally dispersesrelated to the
ease of starch recovery on grinding.
The reaction of bisulfite ion with endosperm
protein is completed in whole kernels in 6-10 hrs.
Both SO2- and HSO3 ions are capable of reducing
disulfide bonds.
pH closer to 4.0-4.5 in commercial steeps with a
solubles level of 1-2% in the steep acid.
 Role of Lactic acid bacteria
A process water pH of 4.0-5.0 generally is most
favorable for optimum separation of
components, especially the starch-gluten
separation.
The effectiveness of SO2 in preventing the growth
of undesirable m.o is also operative in that pH
range.
Higher pHmineral scale in HE surfaces.
Lactic acid bacteria also affect hydrolysis of high
MW, soluble proteins. They produce stable
foamsdeposited as gelatinous precipitates on
the HE surfaces of evaporator.
Lactic acid increase starch yield (~4%), affect
starch quality.
MILLING AND FRACTION SEPARATION
MILLING AND FRACTION SEPARATION
Samples steeped with 0.2% SO2 and 0.55% lactic
acid for 24 hrs at 52oC
 Germ separation
After steeping, the grain is coarsely ground or pulped with water
in an attrition mill in preparation for degermination.
The bulk of the germ is freed in the first pass, but a second pass is
usually provided after free germ has been removed.
Germ cells that are cut or disrupted lose oil, absorbed by gluten
and cannot be recovered.
Over half of starch and gluten is also freed in this first milling step.
Separation of oil rich germ and the heavier kernel component
based on density difference liquid cyclone/hydrocyclone.
The germ is washed to remove occluded starch.
The free starch and protein are separated from the unmilled
endosperm and fiber by screening. The slurry of starch and gluten is
called prime mill starch, because it derives mainly from the floury
endosperm. Prime mill starch is lower in protein than whole starch.
Pulped corn adjusted to 7-8o Baume (12-14% dry solids) with suspended starch is forced
into the tube under pressure. The heavier endosperm and fiber particles pass out the bottom of
the tube at a dry solids concentration of 20-24%, while the lighter germ is drawn off the top of
the vortex.
Secondary milling and Fiber separation
The underflow from the germ cyclone containing starch,
fiber, and pieces of horny endosperm, is more thoroughly
milled to recover the maximum yield of starch.
An impact type mill known as Entoleter mill is preferred.
Starch and gluten released by milling must be separated
from fiber. difference between the fine particle sizes of
starch granules and gluten particles, and the larger
endosperm and pericarp particles. A few dense pieces of
horny endosperm that are not disrupted in milling alwasys
remain. fine nylon screens; wedge bar screening.
Typically, finished fiber contains 15-20% starch. The fiber is
further processed blended with concentrated steep liquor ,
and with corn cleanings, spent (defatted) germ flakes and
starch hydrolyzate residuedried CORN GLUTEN FEED
(18-22% protein)
 Starch-Gluten Separation
The defibered mixture of starch and protein,
known as mill starch, carries 5-8% insoluble
protein content.
The low density of hydrated gluten particles (1.1
g/cm3) as compared with starch (1.5 g/cm3)
permits their ready separation by settling or
centrifugation.
Operation of hydroclone system will normally
produce gluten of 70% protein (dry weight basis)
and starch of 0.33% protein (dry weight basis).
 Starch Processing
1. Dried directly and sold as unmodified corn
starch
2. Modified by chemical or physical treatment in a
way that preserves the granule structure, then
rewashed to removed residual reactants, and
dried
3. Gelatinized and dried
4. Chemically or physically modified and then dried
5. Hydrolyzed either completely or partially
 The products
Starch
Sweeteners
Ethanol
Corn oil
Feed products
Total co-product volume amounts to about one-third of the total mill
output.
Corn gluten feed (18-22% protein) is composed of fiber (pericarp and
cellular fiber), steep liquor and screenings, plus corn germ residue.
Corn gluten meal (60% w.b. protein overflow stream from the first
starch separation step dried to 11% moisture content.
Corn germ meal (21% protein)
Corn starch molasses (from dextrose crystallisation)
Corn bran (10% protein)
 TASK
Principle of hydrocyclone
Summary of Alternative Fractionation
Procedures (BeMiller, p. 427-429)
Group of 3-4 persons