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Amorphous insoluble cellulosic fiber and method for making sameRelated Patent Categories: Food Or Edible Material: Processes, Compositions, And Products, Products Per Se, Or Processes Of Preparing Or Treating Compositions Involving Chemical Reaction By Addition, Combining Diverse Food Material, Or Permanent Additive, Plant Material Is Basic Ingredient Other Than Extract, Starch Or ProteinAmorphous insoluble cellulosic fiber and method for making same description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20060286268, Amorphous insoluble cellulosic fiber and method for making same. Brief Patent Description - Full Patent Description - Patent Application Claims
FIELD OF THE INVENTION [0001] The present invention relates to the processing of dietary fiber, including the processing of fiber-containing by-products from the processing of grain, legumes, seeds and other high-fiber plant components and by-products, to produce dietary fiber gel comprising insoluble amorphous cellulosic fiber and aqueous products comprising soluble cellulosic fiber. BACKGROUND OF INVENTION [0002] Methods for processing agricultural grains, the term "grain" to include grains, legumes, seeds and other high-fiber plant components and plant by-products throughout and for the purposes of this application, particularly methods that consume and convert soluble dietary fiber and starches, and reject insoluble dietary fiber, are known. Whole kernels of grain include the following components: the hull, the germ, and the endosperm. Dietary fiber, both soluble and insoluble, is distributed across these various components of the grain kernel. For example, about half of the dietary fiber in corn is in the bran and hull portions of the whole corn. [0003] Dietary fiber is typically separated and removed from the grain during grain processing. Dietary fiber is preferentially removed from the grain when fiber-containing components of the grain kernel are separated during the processing of the whole grain kernel. For example, dietary fiber tends to be concentrated in certain grain components such as the bran. Thus, during grain milling a substantial portion of the dietary fiber can be removed by separating out the bran portion of the grain after grinding. [0004] Dietary fiber rejected with the bran, hulls, and so forth can be further processed in multistage manufacturing processes to produce useful products such as dietary fiber gels. Dietary fiber that is not rejected with the bran, hulls, and so forth stays with the non-bran and non-hull portion of the grain. During further processing to the grain, the remaining dietary fiber is typically rejected as a waste and is often used for animal feed. [0005] Other grain processes feed the whole kernel of grain. Although some of the dietary fiber in grain kernel can be consumed or converted to other desirable products, most of the insoluble dietary fiber is rejected early in the grain process with rejected solids. For example, in the production of masa, corn flour used in the production of arepa, tortillas, chips and other related corn-based products, the whole kernels of corn are pre-cooked or steeped. Corn hulls and other solids that contain insoluble fiber are rejected during this initial masa production step of steeping. Similarly, in the processing of grain to produce alcohol for human consumption and gasohol production, starch is enzymatically depleted from the whole grain kernel. The remaining solid residue, which contains insoluble dietary fiber, is rejected from the process. Generally, the solid residue is filtered off after the enzymatic hydrolysis of starch, and contains protein, lipids, and dietary fiber from all the various grain components such as the hull, the germ, and the endosperm. The depletion of dietary fiber from each of the various grain components can vary depending on the specifics of the grain and its processing. [0006] The fiber-containing residue can be rejected as solids or slurry that contains solids depending on the grain process. In either situation, the solids typically contain soluble and insoluble fiber that potentially can be converted into higher valued products such as dietary fiber gel, adhesives, and so forth. Although the rejected solids from some grain processes can be recovered, typically, the recovered solids are used in relatively low economical value applications such as supplements to animal feeds. Alternatively, the rejected solids may not be suitable for human and animal consumption and must be disposed of in an environmentally safe and typically costly manner, i.e. the grain processor may have to pay to land fill the rejected solids. Although yielding higher valued products from the rejected solids, particularly from the associated insoluble dietary fiber, can improve grain processing economics, the recovery and conversion of rejected solids generally involves multiple complex processing steps and is uneconomical. [0007] Accordingly there is a need for a simple process that can accept grain processing residue and by-products that contain dietary fiber from a variety of grain processes, yet can convert the contained dietary fiber into useful products such as insoluble amorphous cellulose in the form of fiber gel, aqueous products that contain soluble cellulose for use wood adhesive components, and so forth. SUMMARY OF INVENTION [0008] A method for processing grain and agricultural by-products (collectively, "feedstock") that contain insoluble dietary fiber includes an alkaline treatment step under physical conditions that produce a slurry containing amorphous insoluble cellulosic fiber. The physical conditions include at least one stage of shear that physically disrupts the cellular structure of the dietary fiber. The time, temperature, and strength of alkaline treatment can be varied depending on feedstock characteristics and desired end-product characteristics. Likewise, total shear input can be varied to accommodate feedstock characteristics and desired end-product characteristics. BRIEF DESCRIPTION OF THE DRAWINGS [0009] FIG. 1 is a process flow diagram for Corn Bran. [0010] FIG. 2 is a table demonstrating respective compositions of some of the various potential feedstocks. DETAILED DESCRIPTION OF THE INVENTION [0011] The following describes a method for processing of vegetable material, grain and agricultural residues and by-products of grain processing that contain insoluble dietary fiber. Preferred feedstocks are vegetable material comprising high percentages of cellulose. The method includes at least one step of alkaline pre-treatment of the feedstock under physical conditions, including shear, that disrupt morphological structures containing insoluble dietary fiber. A bleaching step can be performed to enhance visual qualities of any product of the disclosed process. [0012] A flowchart depicting a method for processing of grain, agricultural residues and by-products that contain insoluble dietary fiber is shown in FIG. 1. Generally, the feed to the process is fiber-containing agriculturally derived materials; however, other fiber sources such as raw grain and so forth can also be processed by the method. Without specifically limiting the list, the typical sources for agriculturally derived high fiber material are grains such as wheat, barley, oats, sorghum, soy, corn, malt, legumes, seeds and so forth, as well as byproducts and products of the processing of these materials. Examples of these processes include wet and dry milling, distillation, brewing, soy extraction, grain milling, fruit and vegetable processing, and nut processing. High cellulose bearing materials are the preferred feedstock. Although not intended to limit the list of feedstocks, the table in FIG. 2 lists preferred feedstock materials according to their respective crude fiber concentrations. [0013] Generally, agricultural grains are made up of a hull, germ, and endosperm. Depending on the specific grain these components contain various amounts of fiber, both soluble and insoluble. Grain and its components can be processed in myriad ways so as to produce a wide variety of products, by-products, and residues that contain dietary fiber that can be fed to the process. For example, bran and hulls recovered during the milling of whole grain kernels can be fed to the process. The process is not limited to bran and hulls; the whole grain kernel can also be processed. When processing whole grain and the individual components of the whole grain, however, the feedstock is normally finely ground to a nominal diameter of about 0.1 mm to 1.0 mm. [0014] Other agricultural grain derived feedstocks include by-products and residue from a variety of manufacturing processes. For example, the residue rejected during the initial steeping of whole corn in the production of masa can be further processed by the method of this invention. Another example of a feedstock to the method includes starch-depleted grains from alcohol production. Generally, the various manufacturing processes deplete some of the fiber contained in the various components of the grain kernel. Although fiber residue from almost any grain manufacturing process grain can be processed by the method, the desirability of a specific feedstock can depend on the relative amount of fiber remaining in the feedstock. In addition, the residue and by-products from a number of grain manufacturing processes can be a slurry that contains solids. Although the slurry can be feedstock for a process of the invention, it can be a desirable alternative to recover solids from such a slurry and feed the recovered solids to the process. [0015] Structurally, the fiber that is fed to the process of this invention is substantially morphologically intact. Although the cellular structure of the feedstock fiber is substantially intact, some manufacturing processes can contribute to a weakening of the cellular structure. Any weakening of cellular structure can contribute to improved process efficiency. [0016] The method includes a pre-treatment step that substantially disrupts the cellular structures of the fiber contained in the feed to the process. The specific conditions required to disrupt morphological structure of the fiber can vary depending on the type of feedstock, including conditions of any prior manufacturing if any, and any feedstock conditioning. Feedstocks comprising difficult to process fiber, i.e. stronger fiber such as oat, flax, pea hull and soy hull, can be processed under high-shear conditions. Feedstocks comprising weaker fiber and feedstocks comprising partially degraded fiber can be processed under lower-shear conditions. Preferably, the feed is contacted with alkali at an elevated temperature and sheared to produce a slurry. Of particular importance in evaluating feedstocks is the ratio of available insoluble cellulosic fiber to interfering substances, for example lignin, tannin, polyphenol and bound organic acids. [0017] Alternatively, the feedstock can be contacted with alkali for a predetermined amount of time prior to shearing. For high fat feedstocks, extrusion and simultaneous Critical Carbon Dioxide Extraction of fat, oil and phytosterols during the pre-treatment step can be advantageous. Following the pre-treatment step, insoluble fiber is separated from the slurry, isolated, and recovered as a gel product. Additionally, aqueous soluble fiber, as well as protein and ash, can be separated from the slurry, isolated, and recovered as a component for adhesive products. [0018] The fiber in the feedstock comes from vegetation and as a result comprises cellulose. Fiber has a complex and varied chemical structure that depends on the nature and the source of the fiber. The disruption of the cellular structures during application of the method involves the chemical and mechanical breakage of chemical bonds upon which cellular structure depends. Thus, the ease or difficulty in disrupting cellular structure depends upon the nature and source of the fiber being processed. For example, the disruption of the cellular structure found in wheat bran can be expected to be different than morphological disruption of corn bran. When grain manufacturing is involved, for example grain steeping, the fiber can be expected to be in a weakened state such that disruption of the cellular structure can be easier than for grain components, such as bran, that have not been steeped and therefore can require application of more extreme shearing force, higher temperatures and higher pH values. [0019] Optionally, feedstocks and particularly feedstocks comprising tough fiber can be fed to the pre-treatment step through a high-shear extruder operating at 250 psi to 1500 psi. It is advantageous to co-extrude the feedstock with alkali. Ideally, processing temperature can be maintained within the range of 100 degrees C. to 230 degrees C. during the extrusion. Extrusion pressure is generated by compression. Carbon dioxide gas can be introduced to the extruder, and can attain a critical liquid state in situ under the high pressure of extrusion. Liquid carbon dioxide is an excellent fat solvent that can act to remove fat from the feedstock during extrusion. The fat can be recovered, and is a desirable by-product because it contains a valuable anti-oxidant, namely phytosterol. Continue reading about Amorphous insoluble cellulosic fiber and method for making same... 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