Water- and energy-saving systems and methods for producing lime-cooked masa are described. Such methods generally include adding water to maize kernel in a first predetermined proportion, the maize kernel having endosperm, germ, pericarp, and tip cap components. Using a first conditioner, the maize kernel is conditioned for a first predetermined amount of time to cause moisture absorption to within a first predetermined range. The maize kernel is limed. The maize kernel is cooked, using a cooker, in an environment of steam. After the maize kernel is cooked, water is added to the maize kernel in a second predetermined proportion and, using a second conditioner, the maize kernel is conditioned for a second predetermined amount of time to cause moisture absorption to within a second predetermined range. The maize kernel is milled using one or more mills.

Water- and energy-saving systems and methods for producing lime-cooked masa are described. Such methods generally include adding water to maize kernel in a first predetermined proportion, the maize kernel having endosperm, germ, pericarp, and tip cap components. Using a first conditioner, the maize kernel is conditioned for a first predetermined amount of time to cause moisture absorption to within a first predetermined range. The maize kernel is limed. The maize kernel is cooked, using a cooker, in an environment of steam. After the maize kernel is cooked, water is added to the maize kernel in a second predetermined proportion and, using a second conditioner, the maize kernel is conditioned for a second predetermined amount of time to cause moisture absorption to within a second predetermined range. The maize kernel is milled using one or more mills.

The Invention relates to a process for the milling of vegetable-based material, in particular plants like seeds, to produce dehulled or/and fractionate flour that includes a Material Bed Compression milling of the vegetable-based material. A first air classification of the milled material is performed to obtain a first fine fraction on one side and a first coarse fraction on the other side. A first post-treatment to the first fine fraction is then performed to obtain separate flour. The first coarse fraction is then recycled to the milling step.

The Invention relates to a process for the milling of vegetable-based material, in particular plants like seeds, to produce dehulled or/and fractionate flour that includes a Material Bed Compression milling of the vegetable-based material. A first air classification of the milled material is performed to obtain a first fine fraction on one side and a first coarse fraction on the other side. A first post-treatment to the first fine fraction is then performed to obtain separate flour. The first coarse fraction is then recycled to the milling step.

A process for converting spent grain into flour by drying and milling is disclosed. The process includes the steps of introducing a quantity of wet spent grain into a container for removing moisture by the action of gravity. After the gravity drying, the wet spent grain is transferred to a press to mechanically remove additional moisture. The wet spent grain is placed in a fluid bed processor where the grain additional moisture is removed through heating and fluidization. Some embodiments may include a dust collection system in connection with the fluid bed processor, wherein the dust collection system incorporates a separator for separating the grains. Once dried, the dry spent grain is introduced into a mill to be ground into the proper flour consistency. The resulting flour product can then be used for a variety of foodstuff applications.

A process for converting spent grain into flour by drying and milling is disclosed. The process includes the steps of introducing a quantity of wet spent grain into a container for removing moisture by the action of gravity. After the gravity drying, the wet spent grain is transferred to a press to mechanically remove additional moisture. The wet spent grain is placed in a fluid bed processor where the grain additional moisture is removed through heating and fluidization. Some embodiments may include a dust collection system in connection with the fluid bed processor, wherein the dust collection system incorporates a separator for separating the grains. Once dried, the dry spent grain is introduced into a mill to be ground into the proper flour consistency. The resulting flour product can then be used for a variety of foodstuff applications.

Methods for inoculating a grain suitable for use in testing methods of reducing bacterial load are disclosed. Also disclosed are methods of reducing bacterial load on a grain by using elevated temperature and an organic acid. Also disclosed are methods of tempering a grain at an elevated temperature and reduced time as compared to standard tempering methods.

An electromechanical nixtamalization system comprises a vertical cylindrical reactor formed by an inside container with an insulating layer, an end in the shape of a truncated cone, in which the material inlet and outlet reactor cover is provided. A reactor resistor is arranged inside the reactor and can be removed from the reactor through a resistor cover to which it is attached by one of the ends thereof, the cover being accessible from the outside through the wider end of the reactor, which is exactly opposite to the end in the shape of a truncated cone in which the material inlet and outlet is located. The reactor rotates in an oscillating manner about a horizontal rotation shaft attached to a base or structure along with bearings. A compressor introduces pressure through a pressure inlet valve located inside the reactor and a water tank located above the reactor is in communication with a lime container and in turn feeds the reactor through a valve. The gasses generated inside the reactor are used to heat the water reservoir.

An electromechanical nixtamalization system comprises a vertical cylindrical reactor formed by an inside container with an insulating layer, an end in the shape of a truncated cone, in which the material inlet and outlet reactor cover is provided. A reactor resistor is arranged inside the reactor and can be removed from the reactor through a resistor cover to which it is attached by one of the ends thereof, the cover being accessible from the outside through the wider end of the reactor, which is exactly opposite to the end in the shape of a truncated cone in which the material inlet and outlet is located. The reactor rotates in an oscillating manner about a horizontal rotation shaft attached to a base or structure along with bearings. A compressor introduces pressure through a pressure inlet valve located inside the reactor and a water tank located above the reactor is in communication with a lime container and in turn feeds the reactor through a valve. The gasses generated inside the reactor are used to heat the water reservoir.

A method of reducing the asparagine content of whole grain flour for the production of baked goods includes treating whole grains by tempering the whole grains in an aqueous solution of an asparagine-reducing composition to concentrate and localize asparaginase activity in the bran and germ of the whole grains. In one approach, the asparagine-reducing composition may comprise an asparaginase enzyme. In another approach, the asparagine-reducing composition may comprise a yeast strain capable of degrading asparagine. The tempering treatment with the asparagine-reducing composition reduces asparagine in the whole grains by at least about 25%, resulting in a whole grain flour having an asparagine content of no more than about 250 ppm. Also described are baked goods having a reduced asparagine and acrylamide content comprising a whole grain flour obtained by treating whole grains with an asparagine-reducing composition during tempering.