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 for the continuous production of pregelatinized corn flours for dairy-based and cereal-based foods, includes an acid precooking with a sodium metabisulfite, or sodium hydrogen sulfite or sodium sulfite solution as a food processing aid for partial hydrolysis of insoluble fiber, starch and protein, along with a controlled pregelatinization and denaturation, kernel washing, stabilizing moisture content for grinding, milling and drying preconditioned kernel to produce a partial gelatinization, cooling and drying the dry-ground particle, separation and recovery of the ultrafine grind from the coarser grind while the latter is further aspirated to remove a light corn bran and further reground to produce bran flour, remilling and sieving the isolated coarser grind to obtain fine corn flour for cereal-based foods, and admixing only fine flour with lime to produce a masa flour. An ultrafine corn flour is used as an aid or adjuvant flour for dairy-based foods.

Abstract: Precooked and partially debranned corn flour is continuously produced by an enzymatic precooking using a commercial endoxylanase and endoamylase blend as a processing aid. The low-temperature and near neutral-pH precooking with an endoxylanase and endoamylase solution effects a partial hydrolysis of bran and starchy cell-walls with a controlled gelatinization and reduced conditioning and corn solid loss in wastewater. Moisture content is then stabilized after washing, followed by milling and drying at a high temperature for a short time to produce a partial gelatinization in the ground kernel, cooling and further drying the dried-milled particle.

Abstract: Precooked and partially-debranned corn flour is continuously produced by an enzymatic precooking using a commercial blend of xylanase, endoamylase and endoprotease as a processing aid. The low-temperature and neutral-pH precooking with an endoenzyme solution effected a partial bran hydrolysis while avoiding excessive pregelatinization, reduced washing and corn solid loss in wastewater. Moisture content is then stabilized, followed by milling and drying at a high-temperature and short-time to produce a controlled gelatinization and denaturation in the ground kernel, cooling and further drying the dried-ground particle. A fine particle size or flour is separated and recovered from the coarser particle which is also segregated to isolate a partially hydrolysed bran fraction for integral flour or animal feed diet, remilling and sieving the coarser particle to produce an instant corn flour for snack, and admixing the fine particle with lime to obtain a masa flour for tortilla and other corn foods.

Abstract: Corn masa dough texture and tortilla flexibility are improved by adding to the nixtamalized corn flour, an enzyme blend comprising commercial hemicellulase and/or cellulase. The enzyme preparation has a positive effect on dough texture and improvement in tortilla elasticity and ductility during commercial storage. The combination of the enzyme blend and the method for dough and tortilla preparation can enhance conventional additives to delay corn tortilla hardening during storage.

Abstract: Precooked and partially debranned corn flour is continuously produced by an enzymatic precooking using a commercial endoxylanase and endoamylase blend as a processing aid. The low-temperature and near neutral-pH precooking with an endoxylanase and endoamylase solution effects a partial hydrolysis of bran and starchy cell-walls with a controlled gelatinization and reduced conditioning and corn solid loss in wastewater. Moisture content is then stabilized after washing, followed by milling and drying at a high temperature for a short time to produce a partial gelatinization in the ground kernel, cooling and further drying the dried-milled particle.

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-debranned corn flour is continuously produced by an enzymatic precooking using a commercial xylanase as a processing aid. The low-temperature and near neutral-pH precooking with a xylanase effected a partial bran hydrolysis while avoiding excessive pregelatinization, reduced washing, and corn solid loss in wastewater. Moisture content is then stabilized, followed by milling and drying at a high-temperature and short-time to produce a controlled gelatinization in the ground kernel, cooling and further drying the dried-ground particle. A fine particle size or flour is separated and recovered from the coarser particle which is also segregated to partially isolate a bran fraction for animal feed or integral flour, remilling and sieving the coarser particle to produce an instant corn flour for arepa, and admixing the fine particle with lime to obtain a masa flour for tortilla and other snack foods.

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: Corn masa dough texture and tortilla flexibility are improved by adding to the nixtamalized corn flour, an enzyme blend comprising commercial hemicellulase and/or cellulase. The enzyme preparation has a positive effect on dough texture and improvement in tortilla elasticity and ductility during commercial storage. The combination of the enzyme blend and the method for dough and tortilla preparation can enhance conventional additives to delay corn tortilla hardening during storage.

Abstract: Corn masa dough texture and tortilla flexibility are improved by adding to the nixtamalized corn flour, an enzyme blend comprising commercial hemicellulase and/or cellulase. The enzyme preparation has a positive effect on dough texture and improvement in tortilla elasticity and ductility during commercial storage. The combination of the enzyme blend and the method for dough and tortilla preparation can enhance conventional additives to delay corn tortilla hardening during storage.

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.

Abstract: Precooked and dehulled corn flour for arepa and tortilla is produced in a continuous process. First, the whole cleaned kernel is wetted and crushed to obtain two fractions. The fine fraction only is air-dried and sieved, while segregating both fractions through aspirations to isolate a floury-grit and hull fraction, incorporating the isolated fractions for animal feed by-product, and further producing an endosperm-germ fraction. The endosperm-germ fraction is conditioned and precooked fraction, cooled, air-dried and stabilized as to moisture content in the flaked material. It is then ground to particulate form, separating and collecting fine particles from coarse particles which are further processed, subjecting only the fine particles to centrifugation to yield an integral arepa flour, and, if desired, admixing the fine flour with lime to make a masa flour.

Abstract: Precooked and partially-dehulled corn flour is produced using an acid-cooking in a continuous process, by acid-precooking to effect corn hull hydrolysis with sodium metabisulfite or sodium hydrogen sulfite or sodium sulfite, with reduced kernel washing and solid loss. Moisture content is then stabilized, followed by grinding and drying in a super-heated stream of air, cooling and further drying the dried-ground particle. A fine grind or flour is separated and recovered from the coarse grind which is also segregated to isolate a hull fraction as corn hull waste, regrinding and sieving the coarse grind to produce an instant corn flour for arepa, and admixing the fine grind with lime to obtain a masa flour for tortilla and the like.