Novozymes Creates Novel Enzyme Solution for Cost Reduction in Starch Processing

3 Mar 2014 --- Novozymes has announced the launch of a new alpha-amylase enzyme solution that lowers pH during liquefaction. The solution is designed to break down starch in a way that creates more dextrose when compared to conventional alpha-amylases. The result is higher yields, and chemical, water and energy savings. The combined benefits can enable a starch processor save up to US$1 per metric ton of substrate. Thomas Nilsson, Global Launch Manager for food at Novozymes claims that the launch is “the biggest invention step in the starch enzyme processing business for more than ten years.”

For Nilsson, there are three segments where the most value could be created by using this enzyme solution. “One of the main applications would be for the production of high fructose corn syrup, which is a major application in the US, Europe and to some extent in China. Another application would be crystalline dextrose and the third would be the fermentation of various products based on starch,” Nilsson told FoodIngredientFirst. “I think that from a technical point of view, any starch processor can use our enzyme, but it makes most sense for those customers where we generate the most value to use it as of course they can see the largest savings,” he added.

LpHera is an alpha-amylase that breaks starch down into dextrins, which is a normal step in the conversion process. “Today Novozymes has the standard in the industry for this process with our product Liquozyme Supra. LpHera is a new and better product and is it the only alpha-amylase that drops liquefaction pH and at the same time boosts the formation of dextrose, which makes it very unique,” Nilsson claims.

A simplification of the starch conversion process can lead to cost, sustainability and processing benefits. “Today with conventional alpha-amylases, in order to make them work in the starch processing, you will need to add some caustic to increase your pH and make the enzyme work. Then later on after the liquefaction process, you would need to add some acids; so another set of chemicals,” explains Nilsson. “With LpHera, you don’t need to add as much of either these chemicals, which later have to be removed anyway. This ingredient effectively breaks down a number of conventions, because customers will now see value beyond liquefaction,” he adds.

LpHera brings the liquefaction pH level as low as 4.5-4.8, which means that in some instances customers can reduce their use of pH chemicals by more than 50%. It also prolongs the ion exchange service cycle, which in turn enables more savings on chemicals, water and wastewater.

“We believe that the value potential could be US$1 per metric ton of substrate for a producer of high fructose corn syrup. According to our estimations, with LpHera you might be able to save 2% of the total energy spent just by changing from the liquefaction, and save 4% of the total chemical spent,” says Nilsson. “Those numbers are substantial when you consider that this a mature and optimized industry, where every single cent counts. Chemical, water, waste water and energy pricing trends are all increasing overall,” he adds.

Starch plants vary in size and can process from 0.2 to over 1 million ton of substrate each year, so the impact of using this enzyme can vary greatly too. “The saving potential to our knowledge would be plant specific. Starch processors will need to test it in their specific conditions, to help establish what is the saving potential for them and how much value it can generate,” says Nilsson.

Novozymes have been testing the enzyme for 6 months on an industrial scale and are now ready to roll it out. It is approved in every country globally, except Japan, Russia and France. Just as is the case with other alpha-amylases, there are no other labeling requirements involved.

Novozymes will develop a pipeline of further products linked to this alpha-amylase to help further economize on processing for customers. “With LpHera, we mark the biggest invention step in the starch enzyme processing business for more than ten years. Of course this is not the end of it, but we are continuing to improve conditions for our customers. It is too early to say if it has potential outside of starch. Starch processing is done in many aspects and many industries, but for now we are look at focusing on demonstrating the value beyond liquefaction in the starch industry,” Nilsson concludes.

by Robin Wyers