Sequential Extraction Processing of High‐Oil Corn

The Sequential Extraction Process (SEP), a process that uses ethanol to fractionate corn into high‐value co‐products when producing fuel ethanol, was evaluated using high‐oil corn (HOC). Oil and protein recoveries, ethanol‐drying capability, and oil and protein properties were compared with those produced from normal soft dent corn (SDC) using SEP. Moisture adsorption capacities (≈24 g of water/kg of corn) and oil recoveries (>95%) were nearly identical for both corn types. However, oil yield from HOC (7.1 g of oil/100 g of corn) was 65% more than that of SDC (4.3 g of oil/100 g of corn). HOC crude oil was less red and contained lower free fatty acid and phosphatide contents than did SDC oil. HOC zein contained higher crude protein content (86% db) than did SDC zein (79% db). The freeze‐dried glutelin‐rich fractions (GRF) from both types of corn contained >90% (db) crude protein, which meet the criteria of protein isolates. SEP GRF protein isolates had >85% protein soluble in water at pH ≥ 7. Both GRF protein isolates from HOC and SDC were heat‐stable, had good emulsifying capacities, and produced highly stable emulsions. They also had substantial foaming capacities, but the foam from HOC GRF protein isolate was significantly more stable than the foam from SDC GRF protein isolate. SEP is a suitable process for recovering oil and protein products from HOC corn when producing fuel ethanol and, if competitively priced, HOC is a preferred feedstock to SDC because of higher yields and qualities of valuable co‐products when using HOC.     

Isolation of Zein Using 100% Ethanol

Traditionally, zein is isolated and recovered from corn gluten meal (GCM) using aqueous alcohol as the solvent. Recovery of zein from this solvent is inconvenient and costly. Zein is insoluble in 100% ethanol at room temperature, but it is soluble at 120°C in ethanol. Absolute ethanol effectively extracted zein from CGM, distillers dried grains (DDG), and ground corn. Zein was extracted from CGM with absolute ethanol in a high‐pressure reactor at 130°C. After extracting at 130°C for 45 min, the solution was pumped out of the extractor and allowed to cool. Upon cooling, the zein precipitated from solution. The precipitate was removed from the solution and air‐dried, resulting in 14% recovery of the starting material. The recovered precipitate had an average protein content of >90% on a dry basis, accounting for ≈20% of the CGM protein and recovered ≈35% of its zein. No differences were seen in the amount of zein extracted from CGM samples that were hand‐collected off the dewatering screen and gently dried, versus commercial CGM samples. The commercial CGM did produce a greater amount of solubles. The extraction procedure also worked at temperatures as low as 90°C. The lower temperature did produce lower yields of extracted zein. The zein extracted at the lower temperatures was less brown, but zein extracted at either temperature was almost fully soluble in traditional zein solvents.     

Quality of Corn Oil Obtained by Sequential Extraction Processing

Sequential extraction processing (SEP) is a new approach to fractionating dried, flaked corn using 95% ethanol. In the original process, corn oil was extracted at 76°C in a countercurrent mode while simultaneously dehydrating the ethanol. This resulted in 20% of the protein (predominantly zein) coextracting with the oil. The process was modified to reduce the amount of coextracted protein. One modification (mSEP1) was to use a blend of 30% hexane and 70% ethanol at 56°C. A second modification (mSEP2) used a longer extraction column (L/D ratio 15) to replace the column with L/D 2 used in the original SEP system. To determine the effect of the modifications on oil quality, the quality of the crude corn oils produced from the modified SEP processes were compared with the quality of oil from the original SEP. To evaluate the quality of the three crude oils produced by SEP with the process typically used in industry, they were compared with the quality of laboratory hexane‐extracted corn oil. The results of the three SEP oils exhibited larger concentrations of fatty acids, phospholipids, and carotenoids, smaller concentrations of triacylglycerols, and darker red color than the hexane‐extracted oil. The oils from the two modified SEP processes contained smaller concentrations of free fatty acids and phospholipids and larger concentrations of triacylglycerols and carotenoids than the original SEP oil. In spite of the improvements to the oil through process modifications, the mSEP1 and mSEP2 oils exhibit greater refining losses than hexane‐extracted oil.     

Extraction and solubility characteristics of zein proteins from dry-milled corn

Zein isolation by aqueous ethanol extraction from dry-milled corn produces a mixture of zeins, covalently linked polymers (dimers, tetramers, etc.) and higher-molecular-weight aggregates, some of which were not soluble in aqueous alcohol. The insoluble particles were identified as protein aggregates which form when the extraction solution is heated, particularly under alkaline conditions. The insoluble protein aggregates were not present in zein isolated by the same method from corn gluten meal. Zeins extracted from corn gluten meal and dry-milled corn were fractionated (by differential solubility) to identify differences in their polypeptide compositions. Using polyacrylamide gel electrophoresis, beta- and gamma-zeins were detected in dry-milled corn, but only trace amounts of beta-zein were found in corn gluten meal. Treatment of dry-milled corn with 0.55% lactic acid and 0.2% sulfur dioxide at 50 degrees C for 6 h before ethanol extraction resulted in a 50% increase in zein isolate yield with high solubility (98%). This pre-extraction treatment cleaved disulfide linkages of the beta- and gamma-zeins and significantly reduced insoluble aggregates in zein isolates.     

Solvent Extraction of Zein from Dry‐Milled Corn

Batch extraction of zein from dry‐milled whole corn with ethanol was optimum with 70% ethanol in water, an extraction time of 30–40 min, and temperature of 50°C. High yields (60% of the zein in corn) and high zein contents in the extracted solids (50%) were obtained at a solvent‐to‐solids ratio of 8 mL of 70% ethanol/g of corn. However, zein concentration in the extract was higher at lower ratios. Multiple extraction of the same corn with fresh ethanol resulted in a yield of 85% after four extractions, whereas multiple extractions of fresh corn with the same ethanol resulted in high (15 g/L) zein concentration in the extract. Optimum conditions for batch extraction of zein were 45°C, with 68% ethanol at a solvent‐to‐solids ratio of 7.8 mL/g for an extraction time of 55 min. Column extractions were also best at 50°C and 70% ethanol; a solvent ratio of 1 mL/g resulted in high zein concentrations in the extract (17 g/L) but yields were low (20%).     

Effect of endogenous triacylglycerol hydrolysates on the mechanical properties of Zein films from ground corn

Dry-milled yellow corn and freshly ground food and nonfood grade yellow and white hybrid corn kernels were pretreated in a solution of lactic acid and sodium metabisulfite followed by extraction with 70% ethanol. Zein was precipitated from the extract by reducing the ethanol content of the extract to 40%. Lipid associated with the zein isolates was between 15 and 20% and contained mostly endogenous free fatty acids. The effect of the endogenous free fatty acids on zein isolate films, with and without free fatty acids, was determined by measuring various film properties. Stress-strain measurements indicated 40-200% greater elongation for zein films containing endogenous free fatty acids. Films prepared from zein isolated from preground corn stored for approximately 4 months (27 degrees C, 17% relative humidity) had approximately 3 times greater elongation values than zein films prepared from freshly ground corn.     

Zein Batch Extraction from Dry-Milled Corn: Cereal Disintegration by Dissolving Fluid Shear

Corn particles were extracted in an agitated vessel with a 4:1 mass ratio of 70% ethanol to corn for periods of 1–6 hr at ambient temperature. The extract solution was filtered and centrifuged to remove suspended particles after extraction and then diluted to 40% ethanol to precipitate extracted solute. Measurements of the mass of suspended particles separated by centrifugation indicate that mixing the corn particles with the ethanol dissolves and weakens the protein between cells and between starch granules within cells near the particles' surface. Under the conditions of this study, corn particles release starch granules more rapidly than the protein bodies dissolve, as indicated by analysis of the centrifuged particles. The diffusion coefficient for ethanol solution in corn was estimated and compared with a coefficent derived from a fit of the trend in the rate of release of fine particles from the milled corn. The diffusion coefficient of pure zein in a stagnant 70% ethanol solution was estimated from the measurement of weight loss by a ball of zein. Analysis of the ambient temperature protein extraction rate indicates that 2-mm particles exhibit more convective mass transfer than 20-μm particles.     

Development of New Method for Extraction of α‐Zein from Corn Gluten Meal Using Different Solvents

A modified procedure for the extraction of α‐zein from corn gluten meal was developed and compared against a commercial extraction method. The modification involved raising the concentration of alcohol in solvent and removing the precipitate by centrifugation. Five organic solvent mixtures were compared using the modified extraction procedure developed along with the reductant sodium bisulfite and NaOH. The modified procedure precipitated most of the non‐α‐zein protein solids by increasing the concentration of alcohol. The supernatant had α‐zein‐rich fraction, resulting in higher yield of α‐zein than the commercial method when cold precipitated. The commercial extraction procedure had a zein yield of 23% and protein purity of 28% using 88% 2‐propanol solvent. The three best solvents, 70% 2‐propanol, 55% 2‐propanol, and 70% ethanol, yielded ≈35% of zein at protein purity of 44% using the modified extraction procedure. Zeins extracted using the novel method were lighter in color than the commercial method. Densitometry scans of SDS‐PAGE of α‐zein‐rich solids showed relatively large quantities of α‐zein with apparent molecular weights of 19,000 and 22,000 Da. The α‐zein‐rich solids also had small amounts of δ‐zein (10,000 Da) because it shares similar solubility properties to α‐zein. A solvent mixture with 70% 2‐propanol, 22.5% glycerol, and 7.5% water extracted significantly less zein (≈33%) compared to all other solvents and had α‐zein bands that differed in appearance and contained little to no δ‐zein.     

An acidic method of zein extraction from DDGS

Zein with a higher intrinsic viscosity and phosphorus content, similar protein content, lower yellowness, and at potentially much lower cost than commercially available zein was obtained from distillers dried grains with solubles (DDGS). A novel extraction method using acidic conditions in the presence of a reducing agent has been used to obtain about 10% aqueous ethanol soluble zein from DDGS. The optimum pH, time, temperature, and amount of reducing agent that can produce zein with high quality and yield have been developed. In addition to the zein, about 17% oil based on the dry weight of DDGS has also been obtained during zein extraction. The zein obtained from this research is expected to be suitable for use as fibers, films, and binders and in paints.     

Improved Isolation of Zein from Corn Gluten Meal Using Acetic Acid and Isolate Characterization as Solvent

An improved means of isolating zein is needed to develop new uses for corn zein. We have measured the yield of zein and evaluated the ability of acetic acid to remove zein from corn gluten meal, distillers dried grains, and ground corn using acetic acid as solvent. Acetic acid removed zein more quickly, at lower temperatures, and in higher yields when compared with alcoholic solvents. After 60 min at 25°C, ≈50% of the zein in corn gluten meal was removed. A step change in yield from 43 to 50% occurs as the extraction temperature is increased from 40 to 55°C after mixing for 30 min at 25% solids. The protein composition of the zein removed from corn gluten meal using acetic acid is very similar to that of commercial zein by SDS‐PAGE. The zein obtained from corn gluten meal using acetic acid had higher amounts of fatty acids and esters according to IR analysis, leading to slightly lower protein content. Films made from zein extracted from corn gluten meal using acetic acid had lower tensile strength (≈60% lower) than films produced from commercial zein. Fibers with very small diameter (0.4–1.6 μm) can be produced by electrospinning using the AcOH solution obtained after corn gluten meal extraction.     

Recovery and characterization of α-zein from corn fermentation coproducts

Zeins were isolated from corn ethanol coproduct distiller's dried grains (DDG) and fractionated into α- and β γ-rich fractions. The effects of the ethanol production process, such as fermentation type, protease addition, and DDG drying temperature on zein recovery, were evaluated. Yield, purity, and molecular properties of recovered zein fractions were determined and compared with zein isolated from corn gluten meal (CGM). Around 29-34% of the total zein was recovered from DDG, whereas 83% of total zein was recovered from CGM. Process variations of cooked and raw starch hydrolysis and fermentation did not affect the recovery, purity, and molecular profile of the isolated zeins; however, zein isolated from DDG of raw starch fermentation showed superior solubility and film forming characteristics to those from conventional 2-stage cooked fermentation DDG. Protease addition during fermentation also did not affect the zein yield or molecular profile. The high drying temperature of DDG decreased the purity of isolated zein. SDS-PAGE indicated that all the isolated α-zein fractions contained α-zein of high purity (92%) and trace amounts of β and γ-zeins cross-contamination. Circular dichroism (CD) spectra confirmed notable changes in the secondary structure of α-zeins of DDG produced from cooked and raw starch fermentation; however, all the α-zeins isolated from DDG and CGM showed a remarkably high order of α-helix structure. Compared to the α-zein of CGM, the α-zein of DDG showed lower recovery and purity but retained its solubility, structure, and film forming characteristics, indicating the potential of producing functional zein from a low-value coproduct for uses as industrial biobased product.     

REVIEW: Zein Extraction from Corn,Corn Products,and Coproducts and Modifications for Various Applications: A Review

Corn can be fractioned to produce starch, fiber, oil, and protein in relatively pure forms. The corn kernel contains 9–12% protein, but half of this is an industrially useful protein called zein. Dry milled corn (DMC), corn gluten meal (CGM), and distiller's dried grains with solubles (DDGS) are all coproducts from corn that contain zein and are used for zein extraction. Because it is insoluble in water, zein has found uses in many products such as coatings, plastics, textiles, and adhesives. Newer applications are taking advantage of zein's biological properties for supporting growing cells, delivering drugs, producing degradable sutures, and producing biodegradable plastics. This review covers zein characteristics and nomenclature, past and current practices in processing and extraction of zein from corn products and coproducts, and the modifications of zein for various applications.     

Extraction and Film Properties of Kafirin from Coarse Sorghum and Sorghum DDGS by Percolation

The high cost of kafirin and zein restricts their use for bioplastic and food applications. Effective, simple, and rapid kafirin/zein isolation processes are required. Here a percolation‐type aqueous ethanol solvent extraction process from coarse meals (grits) and coarse sorghum distillers dried grains and solubles (DDGS) for kafirin and zein isolation employing a low ratio of extractant to meal (2.5:1) was investigated, which is potentially applicable in the grain bioethanol industry. Postextraction filtration times were more than twice as fast using coarse meals compared with fine flours. Washing the meals prior to extraction to remove starch improved protein preparation purity to 73–85% compared with 68–72% for unwashed meals. Hence, no subsequent filtration or centrifugation step is required to clean up the kafirin/zein solution prior to solvent evaporation. With a single extraction step, kafirin/zein yields were 48% (protein basis) for DDGS and 53–70% for washed sorghum/maize meals. Cast films were used as a model bioplastic system to evaluate extracted kafirin/zein functional properties. DDGS kafirin films had rough surfaces but had the lowest water uptake and in vitro digestibility, owing to heat‐induced disulfide crosslinking during DDGS processing. Extraction by percolation using coarse meal/DDGS has potential to improve kafirin/zein viability.     

Factors Affecting Yield and Composition of Zein Extracted from Commercial Corn Gluten Meal

Twelve corn gluten meal samples obtained from six wet-milling plants were processed into zein. Zein was extracted using 88% aqueous isopropyl alcohol at pH 12.5, followed by chilling. Protein recovery ranged from 21.3 to 32.0%, and protein purity ranged from 82.1 to 87.6%. Protein recovery increased as the protein purity increased (r = 0.76) (P < 0.01). One of the major factors influencing extraction yield was protein composition; especially α-zein content, which ranged from 53.4 to 64% of the total protein in the corn gluten meal samples. The intensity of red color of the corn gluten meal was negatively correlated with protein recovery and zein purity (r = -0.66 and -0.72, respectively) (P < 0.02).     

Enzymatic hydrolysis, grease permeation, and water barrier properties of zein isolate coated paper

An inexpensive zein-lipid mixture was isolated from yellow dent, dry-milled corn. Grease permeation through zein isolate applied to brown Kraft paper was found to be independent of loading levels at zein isolate levels above 30 mg/16 in.(2). The data shows that water vapor transmission rates depended on the amount of coating applied. Triacylglycerols were the most abundant lipid in milled corn but were absent in the zein isolate (perhaps due to hydrolysis by lipases). Zein from the paper was hydrolyzed enzymatically and the hydrolysis monitored by SDS-capillary electrophoresis. At an E:S ratio of 1:100 no further increase in the hydrolysate peak occurred after 10 and 30 min for alpha-chymotrypsin and pancreatin 8 x; however, zein and lipid were still present 1 h after hydrolysis by pancreatin 1 x.     

Effect of γ-zein on the rheological behavior of concentrated zein solutions

Zein, the prolamin of corn, is attractive to the food and pharmaceutical industries because of its ability to form edible films. It has also been investigated for its application in encapsulation, as a drug delivery base, and in tissue scaffolding. Zein is actually a mixture of proteins, which can be separated by SDS-PAGE into α-, β-, γ-, and δ-zein. The two major fractions are α-zein, which accounts for 70-85% of the total zein, and γ-zein (10-20%). γ-Zein has a high cysteine content relative to α-zein and is believed to affect zein rheological properties. The aim of this study was to investigate the effect of γ-zein on the often observed phenomena of zein gelation. Gelation affects the structural stability of zein solutions, which affects process design for zein extraction operations and development of applications. The rheological parameters, storage modulus (G') and loss modulus (G″), were measured for zein solutions (27% w/w solids in 70% ethanol). β-Mercaptoethanol (BME) was added to the solvent to investigate the effect of sulfhydryl groups on zein rheology. Modulus data showed that zein samples containing γ-zein had measurable gelation times under experimental conditions, contrary to samples with no γ-zein, where gelation was not detected. Addition of BME decreased the gelation time of samples containing γ-zein. This was attributed to protein unfolding. SEM images of zein microstructure revealed the formation of microspheres for samples with relatively high content of α-zein, whereas γ-zein promoted the formation of networks. Results of this work may be useful to improve understanding of the rheological behavior of zein.     

Thermal Behavior of Zein Sheets Plasticized with Oleic Acid

Zein, extracted from underutilized corn gluten meal may serve as an alternative starting material for fabrication of biodegradable packaging. Zein plasticized with oleic acid may be formed into flexible and water‐resistant sheets. Our objective was to investigate the effect of plasticization on thermal behavior of zein sheets employing differential scanning calorimetry (DSC). Zein sheets were rolled from a resin prepared by dispersing zein and oleic acid in aqueous alcohol followed by the recovery of the formed moldable compound by precipitation with water. Sheets were later replasticized with additional oleic acid to increase ductility. DSC thermograms were used to investigate zein‐oleic acid interactions in zein sheets. DSC endotherms were attributed to melting of free oleic acid or to the dissociation of zein‐oleic acid bonds. Plasticized sheets contained bound and free oleic acid. Further heat‐treatment of plasticized sheets apparently resulted in zein absorption of free oleic acid. However, high temperatures were believed to cause dissociation of some zein‐oleic acid bonds formed during replasticization.     

Isolation and Characterization of Zein from Corn Distillers' Grains and Related Fractions

Corn distillers' grains with solubles (CDGS), the major coproduct of fermentation of corn to produce ethanol, were extracted with 0.1M NaOH, 0.1% dithiothreitol (DTT), and 0.5% SDS yielding 35% of the total nitrogen and ≈25% of the protein nitrogen. Gel electrophoresis revealed that the extractable proteins contained zein plus other proteins similar to the extractable proteins from corn flour. Although difficult to extract, the proteins isolated from the fermentation coproducts appeared undegraded and apparently survived gelatinization, fermentation, distillation, and drying during the production of ethanol. Extraction of CDGS with 60% ethanol at 60°C yielded 1.5–3.9% of crude zein. When the ethanol contained DTT, yields of crude zein were increased to 3.2–6.6%. Protein contents of the crude zeins were only 37–57%, indicating that lipids and pigments were coextracted with the ethanol. Gel electrophoresis showed that the protein fractions extracted by ethanol contained primarily α-zein whereas the proteins extracted by ethanol + DTT contained α- + β-zein. Further confirmation of the presence of zein in the crude prolamin preparations was obtained by amino acid analyses. The amino acid compositions of the crude zeins paralleled those of commercial zein and α-zein.     

Analysis of zein by matrix-assisted laser desorption/ionization mass spectrometry

Matrix-assisted laser desorption/ionization mass spectrometry (MALDI/MS) was used to analyze the protein composition of corn prolamine (zein). Mass spectra were obtained from commercial zein and zein extracted with aqueous 2-propanol and aqueous ethanol from consumer corn meal. For the commercial zein, three major zein fractions with m/z 26.8k, 24.1k, and 23.4k were clearly seen with two minor fractions (m/z 14.5k and 20.4k) also present. As compared with the results from sodium dodecyl sulfate-polyacrylamide gel electrophoresis (SDS-PAGE), these three fractions were identified as alpha-zeins (24.1k and 23.4k combined as Z19; 26.8k as Z22). When extracted with 55% aqueous 2-propanol, three alpha-zein fractions with m/z 26.8k, 24.1k, and 23.4k were predominant. When extracted with ethanol, extraction temperature had an effect on the final products. When extracted with 75% aqueous ethanol at room temperature, alpha-zein and some 17-18k species were observed, whereas at 60 degrees C, a small amount of delta-zein was also present. Comparison of the MALDI/MS results with SDS-PAGE and gene sequence analysis shows that the MALDI/MS method is superior to SDS-PAGE in having higher resolution and mass accuracy.     

Effect of the corn breaking method on oil distribution between stillage phases of dry-grind corn ethanol production

The majority of fuel ethanol in the United States is produced by using the dry-grind corn ethanol process. The corn oil that is contained in the coproduct, distillers' dried grains with solubles (DDGS), can be recovered for use as a biodiesel feedstock. Oil removal will also improve the feed quality of DDGS. The most economical way to remove oil is considered to be at the centrifugation step for separating thin stillage (liquid) from coarse solids after distilling the ethanol. The more oil there is in the liquid, the more it can be recovered by centrifugation. Therefore, we studied the effects of corn preparation and grinding methods on oil distribution between liquid and solid phases. Grinding the corn to three different particle sizes, flaking, flaking and grinding, and flaking and extruding were used to break up the corn kernel before fermentation, and their effects on oil distribution between the liquid and solid phases were examined by simulating an industrial decanter centrifuge. Total oil contents were measured in the liquid and solids after centrifugation. Dry matter yield and oil partitioning in the thin stillage were highly positively correlated. Flaking slightly reduced bound fat. The flaked and then extruded corn meal released the highest amount of free oil, about 25% compared to 7% for the average of the other treatments. The freed oil from flaking, however, became nonextractable after the flaked corn was ground. Fine grinding alone had little effect on oil partitioning.