Abstract: A bioprocess and apparatus for the continuous production of novel masa and whole-corn flours as cereal-base and functional-food ingredients. The bioprocess includes providing a fine grind fraction of corn kernel; combining the fine grind fraction of corn kernel with at least one endoamylase to produce an enzyme-added fine grind; moist-heat precooking the enzyme-added fine grind to obtain a pre-cooked enzyme-added fine grind; low-moisture conditioning the precooked enzyme-added fine grind to partially hydrolyze starchy endosperm and swell starch and aleurone-bran granules to produce enzymatically conditioned corn kernel particles; and_milling the conditioned corn kernel particles to obtain flour comprising a fine grind portion of the conditioned corn kernel particle.

Abstract: A process and apparatus for the continuous production of masa and whole-corn flour for grain-based foods, includes a preconditioning of clean corn, grinding the moisturized corn to produce fine and coarse grind fractions, sieving the fine grind and aspirating from both fractions a light-bran fraction as animal feed, remilling the coarse grind for further bran extraction and admixing the sifted fine grind with lime to produce a limed grind, low-moisture precooking of a stream of limed corn particles in another stream of saturated steam to obtain a partial starch pregelatinization and protein denaturation degree, venting and separating the moist-heated corn particles, conditioning the segregated fine grind to soften and swell the endosperm, germ and bran fractions, hot-air drying the tempered fine grind and stabilizing for extended shelf-life, cooling the dried fine grind with clean air; grinding the agglomerated particles, classifying and separating the fine grind produced from the coarse grind.

Abstract: A process and apparatus improvement for energy and particulate recovery during the production of nixtamalized corn flour, by precooking with a lime solution to effect partial cooking, reduced energy use for pre-cooking and washing by recycling hot water. Next, moisture content is stabilized, and the corn is milled and dried in a super-heated stream of air with reduced energy consumption by recycling waste hot air. Dust trapping is performed on a portion of waste hot air which is reused for preheating combustion air. Wet scrubbing of the remaining waste hot air is performed where heated water is reused and exhaust air vented. Cooling and further drying of the dried-milled particles follows. A fine grind or flour is separated and recovered from the coarse grind which is also aspirated to isolate a hull fraction as corn waste along with particulate collected after entrapping and scrubbing waste hot air. Re-milling and sieving the coarse grind produces a corn flour for tortilla and the like.

Abstract: A process and apparatus improvement for energy and particulate recovery during the production of nixtamalized corn flour, by precooking with a lime solution to effect partial cooking, reduced energy use for pre-cooking and washing by recycling hot water. Next, moisture content is stabilized, and the corn is milled and dried in a super-heated stream of air with reduced energy consumption by recycling waste hot air. Dust trapping is performed on a portion of waste hot air which is reused for preheating combustion air. Wet scrubbing of the remaining waste hot air is performed where heated water is reused and exhaust air vented. Cooling and further drying of the dried-milled particles follows. A fine grind or flour is separated and recovered from the coarse grind which is also aspirated to isolate a hull fraction as corn waste along with particulate collected after entrapping and scrubbing waste hot air. Re-milling and sieving the coarse grind produces a corn flour for tortilla and the like.

Abstract: Precooked and partially-dehulled masa flour for tortilla and the like is produced by pressure pre-cooking in a continuous process with saturated-steam. The precooking effects corn hull hydrolysis and partial cooking with a lime solution, reduced kernel washing and solid loss in wastewater. Next, moisture content is stabilized, and the corn is ground and dried in a super-heated stream of air to produce a partial cooking, cooling and further drying of the dried-ground particles. Separating and recovering yields the fine grind or masa flour from the coarse grind which is segregated to isolate a hull fraction as corn hull waste. Reground coarse grind is sieved to produce further yield of the instant masa flour. The flour is well suited for use in making tortilla and other corn-based snack foods.