Continuous Enzyme Starch

Conversion (CESC)
Corn Products
International

“A Flexible Alternative in
Size Press and Coating
Application”
Size Press/ Coating Starch
Currently Dominant raw material is corn
based starch

Usage is split between unmodified and

modified starch
Four Main Cooking Methods
• Batch Enzyme
• Continuous Enzyme (CESC)
• Thermally cooked modified starch
Oxidized
Ethylated
Acid Modified
Cationic
• Ammonium Persulfate (A/P) Cookers
CESC - Solutions
Enzymatically Convert Inexpensive
Unmodified Starch To Desired
Viscosity And Solids.

Applications In Coatings

Applications In The Size Press

 Enzymes in Paper Applications
Enz yme F unc t io n

C e l l u o l a s e / He m i c e l l u l a s e In c re a s e p u l p & p a p e r d r a i n a g e

Li g n i n a s e p ulp d e - c o lo riz ing

X y la na s e p ulp b le a c hing e nha nc e m e nt

C e llula s e d e - inking re c y c le d p ulp

Li p a s e p i t c h d i g e s t i o n & re m o v a l

Le v a n h y d r o l a s e s l i m e re m o v a l ( H2 0 re c i r c u l a t o n s y s t e m )

A lp ha - A m y la s e s t a r c h h y d ro l y s i s , v i s c o s i t y c o n t r o l
 Starch Conversion
CH 2 OH
O

OH

0
OH
CH 2 OH CH 2 CH 2 OH

STARCH \ O O

OH OH OH
0 0 0

OH OH OH

Partial Hydrolysis

Complete Hydrolysis
CH 2 OH
O

GLUCOSE HO
OH
OH

OH
Enzyme vs A/P Conversion

A cid C onversion
0 1,4 and 1,6 linkage
0

0 0

E nzym e
1,4 linkage
Enzyme vs A/P Conversion
Enzyme
endo action
specific for 1,4 linkages
less low MW sugars produced
Acid
random action
hydrolyzes both 1,4 and 1,6 linkages
more low MW sugars produced
more linear glucose chains produced
Limitations of Acid Thinning

AP is an acid conversion
Random cleavage of molecules leaves resulting paste that
contains numerous short chain molecules that can retrograde
and precipitate, especially at high solids
Paste color
Conversion requires a caustic addition to stop acid thinning
Limitations of Modified Starches

There are some limitations in using modified starches (oxidized,

ethylated, cationic)
Solids/Viscosity Relationship is set
Limited flexibility
Thin products may have extended molecular weight
distributions
Enzyme Conversion
A Sound Alternative
Maximum flexibility
Complete control of solids/temperature/viscosity relationship
Controlled molecular weight reduction
Excellent paste flow characteristics at high solids
Process of Enzyme Conversion
α-amylase reduces starch chain length systematically at 1-4
linkages (not a random reduction like acid thinning)
Swollen starch subjected to enzyme at 180 to 190 degrees F for
short time; enzyme deactivation with heat necessary after
reaching desired viscosity
CESC Advantages versus
A/P Conversion
Lower operating costs
No pH adjustment needed
Improved paste color reduces loss in paper brightness
Less tendency for amylose precipitation and retrogradation due
to an improved molecular weight distribution
CESC Advantages versus
Modified Starches
Lower cost
Use unmodified starch instead of modified starch
Flexibility
Easily change viscosity and solids for different grades or size
press configurations
Process Overview - Continuous
System consists of two cooking jets and a plug flow thinning tank
Slurry containing enzyme through jet to about 180 -190 deg F
Held in thinning tank for 20 to 30 minutes
Paste pumped through kill jet at 280 deg F
Steam is flashed
Post dilution water can be added

 

Variables Affecting Enzyme
Reaction
Cook & Kill Temperature
Shear from back pressure
Calcium level in starch
pH
Retention Time
Enzyme Dosage
CESC Benefits
Continuous automatic operation
Operator only has to adjust enzyme flow to control viscosity
Operating costs less than AP (less steam, no pH adjustment) and
modified starches (raw material cost)
Uses low cost unmodified starch
Lab Scale Starch Cooking Study
Thermal conversion of ethylated and oxidized starch (approx. 75
fluidity)
Adjust enzyme conversion to match solids and viscosity of
modified starches
Perform tests on three starches - including MW distribution
Modified and Enzyme Converted Starches



 

 
 

1,000 10,000 100,000 1,000,000 10,000,000


 
Molecular Weight vs Enzyme
Dosage

25ppm
75ppm
100ppm
284ppm

100 1000 10000 100000 1000000 10000000


 
Effect of Insufficient Kill
Temperature

240F
280F

100 1000 10000 100000 1000000 10000000



Molecular Weight - Two Cook
Solids

75ppm 24%
75ppm 33%

100 1000 10000 100000 1000000 10000000



Molecular Weight vs Reaction
Time

75 ppm enzyme

20 m inutes
30 m inutes

100 1000 10000 100000 1000000 10000000


 
Summary
Continuous Enzyme Conversion
Sound technology
Proven at quality coated paper producers for metered size
press and coating binder
Provides maximum flexibility
An economical alternative for size press applications
 CESC - New Systems
• Eight Units Operating In North
America
• 15 GPM skid mounted trial CESC
unit for customer evaluations
• Introduction Of Systems To South
America and South Africa
CESC an Attractive
Alternative

Thank You For Your

Time and Attention!