Patent Application
20190124964
The present invention relates to soaking corn to provide the corn with a desired moisture concentration, within a specified tolerance, throughout the entire volume of the corn. For example, corn comprising an initial temperature gradient can be soaked in water in a soak tank. While the corn is soaking, controlled recirculation of the water in the soak tank can be used to reduce or minimize a spatial gradient in a moisture concentration of the corn.
Existing methods and systems for soaking corn to provide masa are unsatisfactory in some regards. For example, corn leaving a soak tank can have a moisture concentration that varies as the corn is discharged from the soak tank. When the variation in corn moisture concentration is too large, it can cause complications for downstream processing of the corn to form a masa. Advantageously, the inventors have discovered methods and systems that can help reduce or minimize the variation in the moisture concentration of corn discharged from a soak tank. Among other advantages, this can help provide better control over the quality of the masa product produced from soaked corn.
In a first aspect, the present invention provides a method comprising several steps. A first step comprises introducing a first batch of corn into a soak tank. A second step comprises introducing a second batch of corn into the soak tank to provide a combined batch of corn. The combined batch of corn comprises: the first batch of corn and the second batch of corn; corn and water; a combined batch volume; and a spatial temperature gradient within the combined batch volume. A third step comprises removing at least some of the water from the soak tank to provide a removed stream of water. A fourth step comprises reintroducing the removed stream of water into the soak tank to provide recirculation water. The recirculation water reduces the spatial temperature gradient in the combined batch of corn. A fifth step comprises discharging the combined batch of corn from the soak tank after the corn of the combined batch of corn has absorbed water to provide soaked corn.
In a second aspect, the present invention provides a system comprising a soak tank, a recirculation conduit and a recirculation conveyor. The soak tank comprises: a top portion, a bottom portion, a sidewall, a recirculation outlet, and a recirculation inlet. The top portion comprises a top of the soak tank and an upper opening for introducing corn and water into the soak tank. The bottom portion comprises a bottom of the soak tank and a lower opening for discharging corn and water from the soak tank. The sidewall extends from the bottom portion to the top portion. The recirculation outlet provides a removed stream of water, and the recirculation inlet enables the removed stream of water to be reintroduced to the soak tank to provide recirculation water. The recirculation conduit provides fluid communication from the recirculation outlet to the recirculation inlet so the removed stream of water can be reintroduced to the soak tank through the recirculation inlet to provide the recirculation water. The recirculation conveyor is in fluid communication with the recirculation outlet and the recirculation inlet, and the recirculation conveyor is for conveying the removed stream of water to the recirculation inlet to provide the recirculation water.
Other aspects, embodiments and features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings. The accompanying figures are schematic and are not intended to be drawn to scale. In the figures, each identical, or substantially similar component that is illustrated in various figures is represented by a single numeral or notation. For purposes of clarity, not every component is labeled in every figure. Nor is every component of each embodiment of the invention shown where illustration is not necessary to allow those of ordinary skill in the art to understand the invention.
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself, however, as well as a preferred mode of use, further objectives and advantages thereof, will be best understood by reference to the following detailed description of illustrative embodiments when read in conjunction with the accompanying drawings, wherein:
In one aspect, the present invention can provide improved control over the moisture concentration of a product that is soaked in a liquid, for example, water. In developing the present invention, the inventors realized that existing soaking processes can result in different rates of liquid absorption for a product at differential spatial locations within the volume of a soak tank. For example, if product is placed into a soak tank from a plurality of product batches, the product batches can be at different temperatures. This can create a spatial temperature gradient in the soak tank, which can, in turn, result in different rates of liquid absorption for the product at different positions within the soak tank. Also, placing product batches in the soak tank at different times can also result in different moisture concentrations, even if the product batches are at the same temperature, because the rate of absorption of a liquid into a product can be related to the amount of liquid that a product has already absorbed.
Additionally, even if all the product placed in a soak tank is initially at a single common temperature, a spatial temperature gradient for the product in the soak tank can develop over time, for example, as a result of the product in one location of the soak tank cooling or heating at a different rate than the product at another location within the soak tank. The following examples help to illustrate this point. First, if a soak tank cools from the walls, for example, by losing heat to the atmosphere, a spatial temperature gradient can occur from inner portions of the soak tank towards a wall of the soak tank. Second, a soak tank that is not completely symmetric or that includes differing degrees of insulation can experience spatial temperature gradients due to the different rates of cooling associated with the physical configuration of the soak tank. Third, as a spatial temperature gradient develops in a soak tank, even if a soak tank were completely symmetric, the spatial temperature gradient can result in convection which can, in turn, contribute to further spatial temperature gradients from top to bottom or from the center to the outer regions in the soak tank.
As a result of a spatial temperature gradient in a soak tank, a spatial gradient in the liquid-absorption rate can also occur. Furthermore, a spatial gradient in the liquid-absorption rate can ultimately result in a spatial gradient in the moisture concentration for product throughout the volume of the soak tank and result in a changing moisture concentration for a discharge stream of the product when the product is discharged. The spatial moisture-concentration gradient at discharge can be significant, especially if the product is discharged from the soak tank before the product reaches equilibrium with respect to temperature and/or moisture concentration. Furthermore, as a result of a spatial moisture-concentration gradient when the product is discharged from the soak tank, the moisture concentration of the discharged product can vary over time as product from different locations within the soak tank is discharged.
Variations in the moisture concentration of discharged product over time can, in turn, lead to complications for downstream processes if a constant moisture concentration is preferable. For example, if the product in a soak tank is corn used for making masa, if the moisture concentration of the discharged product varies, then a masa product made from the discharged product can also have a moisture concentration that varies over time unless the moisture concentration is further controlled with additional equipment at additional costs. Moreover, if the moisture concentration of the masa is allowed to vary beyond an acceptable range, products (e.g., tortilla chips) made from the masa can have less desirable organoleptic properties with respect to taste, texture, and moisture concentration.
Advantageously, the inventors have discovered that complications associated with variations in the moisture concentration of a soaked product as it is discharged from a soak tank can be reduced, minimized or eliminated with an improved process for recirculating liquid in a soak tank. Although, this is one potential benefit of an inventive embodiment described herein, a skilled person with the benefit of the present disclosure would recognize that the apparatuses, systems and/or methods described herein can also provide additional or alternative advantages.
Also, a skilled person with the benefit of the present disclosure would recognize that the system and/or methods described herein can be advantageous relative to alternative systems and/or methods that attempt to reduce or minimize a moisture concentration gradient in a product in a soak tank. For example, compared to agitating corn directly with mechanical means (e.g., using an auger to agitate the corn or transferring the corn to an intermediate vessel before transferring the corn to a soak tank) recirculating the water in a soak tank can be used to reduce, minimize, or almost eliminate removal of corn hulls. In some embodiments, this can be advantageous to avoid too much moisture absorption and/or to provide a controlled degree of moisture absorption that does not vary between corn kernels in which the hull has been removed and corn kernels in which the hull has not been removed.
An embodiment of the invention will now be described with reference to
With reference to
With reference again to
Third, an optional second-feed-batch-heating step 0806 comprises heating or heating and cooling a second feed batch of corn 0354, including any added water in the second feed batch of corn 0354 to provide a second heated batch of corn. The second heated batch of corn can be a second batch of corn 0106 that will be introduced into the soak tank 0102, optionally, along with the water combined with the second feed batch of corn. The cooling can be used to reduce the temperature of the corn below a gelatinization temperature of the corn in the second feed batch of corn so that the gelatinization process stops. The cooling can be accomplished in any way that is convenient, for example, adding cooler water to the first heated batch of corn, refrigeration, recirculating the water through a heat exchanger to cool it, allowing natural cooling due to ambient heat loss, etc., or any combination thereof.
Fourth, a second corn-introducing step 0810 comprises introducing a second batch of corn 0106 (and optionally the water combined with the second batch of corn) into the soak tank 0102 to provide a combined batch of corn 0108. In some embodiments, the second batch of corn can be provided to the soak tank by a process that is the same as or similar to the process used for providing the first batch of corn to the soak tank. As illustrated in
As illustrated in
Fifth, a water-removing step 0812 comprises removing at least some of the water from the soak tank 0102 to provide a removed stream of water 0114. With reference to
Sixth, a water-reintroducing step 0814 comprises reintroducing the removed stream of water 0114 into the soak tank 0102 to provide recirculation water 0116, which reduces or minimizes the spatial temperature gradient 0204 in the combined batch of corn 0108 (e.g., to provide a second spatial temperature gradient). In some embodiments, the water-reintroducing step 0814 comprises reintroducing the removed stream of water 0114 into the soak tank 0102 at a top portion 0122 of the soak tank 0102 (e.g., top half of the soak tank), reintroducing the removed stream of water 0114 into the soak tank 0102 though a recirculation inlet 0124 of the soak tank 0102, reintroducing the removed stream of water 0114 into the soak tank 0102 at a recirculation discharge location 0126, or a combination thereof. In some embodiments, the water-reintroducing step 0814 can begin after the second corn-introducing step 0810. Although, it is also possible to begin reintroducing the removed stream of water 0114 into the soak tank 0102 before the second corn-introducing step 0810.
Seventh, a combined-batch-discharging step 0816 comprises discharging the combined batch of corn 0108 from the soak tank 0102 after the corn of the combined batch of corn 0108 has absorbed water to provide soaked corn.
Eighth, an optional washer-feed-conveying step 0818 comprises conveying the combined batch of corn 0108 or the corn of the combined batch of corn 0108 (e.g., soaked corn) to a washer 0502 (e.g., tumbler) for washing the corn of the combined batch of corn 0108.
Ninth, an optional corn-washing step 0820 comprises washing the corn of the combined batch of corn 0108 with wash water 0504 to provide washed corn.
Tenth, optional draining step 0822 comprises draining water from the corn of the combined batch of corn 0108 through a drain 0506 to provide drained corn.
Eleventh, an optional soaked-corn-conveying step 0824 comprises conveying the corn from the combined batch of corn 0108 (e.g., soaked corn and/or washed corn) to a mill 0602.
Twelfth, an optional soaked-corn-milling step 0826 comprises milling the corn of the combined batch of corn 0108 (e.g., soaked corn, drained corn) to provide masa 0604.
Thirteenth, although not specifically illustrated in
With reference now to
In some embodiments, the first batch of corn 0104 is heated to a first preliminary temperature that is equal to at least a gelatinization temperature of the corn (e.g., at least 150, 155, 160, 170, 180, 190, 200, 210° F. [65, 68, 71, 76, 82, 87, 93, 98° C.]) and to no more than a boiling temperature of water used to gelatinize the first heated batch of corn (e.g., 212° F. [100° C]). In some embodiments, the temperature of the first batch of corn is held at (e.g., within +/−20, 15, 10, 5, 4, 3, 2, or 1% of the preliminary temperature) or above this first preliminary temperature for more than 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 minutes. In some embodiments, the temperature of the first batch of corn is held at (e.g., within +/−20, 15, 10, 5, 4, 3, 2, or 1% of the preliminary temperature) or above the first preliminary temperature for 1-10, 1-9, 1-7, 1-6, 1-5, 1-4, 1-3, or 1-2 minutes. Then, in some embodiments the first batch of corn is cooled to a first preheat temperature (e.g., a mass-weighted bulk average temperature of the first batch of corn 0104) or first initial soak temperature selected from:
By cooling the first batch of corn below the gelatinization temperature, the gelatinization of the first batch of corn can be stopped (e.g., in a process called quenching). Furthermore, gelatinization of the corn, which can be controlled by varying the temperature of the first batch of corn and how long the first batch of corn spends at the temperature, affects moisture absorption of the corn in the first-feed-batch-heating step 0802 and in the soak tank. To determine whether or not a desired degree of gelatinization has occurred during the heating step, the degree of gelatinization can be measured directly or indirectly (for example, by measuring moisture content of the corn), as a skilled person would understand after reading this disclosure.
In some embodiments, at least 90, 95, 96, 97, 98, or 99% by weight of the first batch of corn 0104 is provided at, heated (or heated and cooled) to the first preheat temperature or first initial soak temperature. Additionally, the entire first batch of corn 0104 can be heated (or heated and cooled) to the first preheat temperature or first initial soak temperature.
In some embodiments, heating the first batch of corn 0104, and any added water included in the first batch of corn 0104, lasts no more than 0.9, 0.8, 0.7, 0.6 or 0.5 hours. In some embodiments, heating the first batch of corn 0104 lasts 0.9 to 0.3, 0.8 to 0.4, 0.7 to 0.4, 0.6 to 0.4 or about 0.5 hours. This can contribute to providing a quicker process for soaking the corn.
Moreover, in some embodiments of a method for soaking corn, the method comprises allowing the first batch of corn 0104 to cool to a first initial soak temperature and allowing the first batch of corn 0104 to absorb water to provide the first batch of corn 0104 with a first initial soak moisture concentration.
As illustrated in
In some embodiments of the method for soaking corn, upon introducing the first batch of corn 0104 into the soak tank 0102, the first batch of corn 0104 has a first initial soak temperature. In some embodiments, the first initial soak temperature is equal to 37.8 to 62.8° C. (100 to 145° F.), 43.3 to 62.8° C. (110 to 145° F.), 51.7 to 62.8° C. (125 to 145° F.), 51.7 to 54.4° C. (125 to 130° F.), 48.9 to 60° C. (120 to 140° F.), or 48.9 to 54.4° C. (120 to 130° F.). In some embodiments, the first initial soak temperature is a mass-weighted bulk average temperature. In some embodiments, at least 90, 95, 96, 97, 98, 99% by weight of the first batch of corn 0104 can be heated to the first initial soak temperature. In some embodiments, the entire first batch of corn 0104 is heated to the first initial soak temperature.
In some embodiments of the method for soaking corn, upon introducing the first batch of corn 0104 into the soak tank 0102, the first batch of corn 0104 has a first initial soak moisture concentration by weight of 30 to 38%, 31 to 37%, 32 to 36%, 33 to 35%, or about 34%. The first initial soak moisture concentration of the first batch of corn 0104 includes any inherent moisture in the corn and excludes free water around the corn. In some embodiments, the first initial soak moisture concentration is measured using an online moisture concentration meter 0402, for example, as illustrated in
With reference again to
In some embodiments, the second feed batch of corn 0354 is heated from ambient temperature, e.g., 25.0° C. (77.0° F.).
In some embodiments, the second batch of corn 0106 is heated to a second preliminary temperature that is equal to at least a gelatinization temperature of the corn (e.g., at least 150, 155, 160, 170, 180, 190, 200, 210° F. [65, 68, 71, 76, 82, 87, 93, 98° C.]) and to no more than a boiling temperature of water used to gelatinize the second heated batch of corn (e.g., 212° F. [100° C]). In some embodiments, the temperature of the second batch of corn is held at (e.g., within +/−20, 15, 10, 5, 4, 3, 2, or 1% of the preliminary temperature) or above this second preliminary temperature for more than 1, 2, 3, 4, 5, 6, 7, 8, 9 or 10 minutes. In some embodiments, the temperature of the second batch of corn is held at (e.g., within +/−20, 15, 10, 5, 4, 3, 2, or 1% of the preliminary temperature) or above the second preliminary temperature for 1-10, 1-9, 1-8, 1-7, 1-6, 1-5, 1-4, 1-3, or 1-2 minutes. Then, in some embodiments the second batch of corn is cooled to a second preheat temperature (e.g., a mass-weighted bulk average temperature of the second batch of corn 0106) or second initial soak temperature selected from:
By cooling the second batch of corn below the gelatinization temperature, the gelatinization of the second batch of corn can be stopped (e.g., in a process called quenching). Furthermore, gelatinization of the corn, which can be controlled by varying the temperature of the second batch of corn and how long the second batch of corn spends at the temperature, affects moisture absorption of the corn in the second-feed-batch-heating step 0806 and in the soak tank. To determine whether or not a desired degree of gelatinization has occurred during the heating step, the degree of gelatinization can be measured directly or indirectly (for example, by measuring moisture content of the corn), as a skilled person would understand after reading this disclosure.
In some embodiments, at least 90, 95, 96, 97, 98, or 99% by weight of the second batch of corn 0106 is provided at, heated (or heated and cooled) to the second preheat temperature or second initial soak temperature. In some embodiments, the entire second batch of corn 0106 is heated (or heated and cooled) to the second preheat temperature or second initial soak temperature.
In some embodiments, heating the second batch of corn 0106, and any added water included in the second batch of corn, lasts no more than 0.9, 0.8, 0.7, 0.6 or 0.5 hours or wherein the heating the second batch of corn 0106 lasts 0.9 to 0.3, 0.8 to 0.4, 0.7 to 0.4, 0.6 to 0.4 or about 0.5 hours. This can contribute to providing a quicker process for soaking the corn.
Moreover, in some embodiments of a method for soaking corn, the method comprises allowing the second batch of corn 0106 to cool to a second initial soak temperature, and allowing the second batch of corn 0106 to absorb water to provide the second batch of corn 0106 with a second initial soak moisture concentration.
As illustrated in
In some embodiments, a second batch heater (or heater and cooler) 0308 for heating (or heating and cooling) a second feed batch of corn 0354 is a first batch heater (or heater and cooler) 0308 for heating a first feed batch of corn 0304. Although, in some embodiments the second batch heater (or heater and cooler) 0308 for heating (or heating and cooling) the second feed batch of corn 0354 and the first batch heater (or heater and cooler) 0308 for heating (or heating and cooling) the first feed batch of corn 0304 are different heaters. Additionally, in some embodiments, the second soak tank feed conveyor 0356 is the first soak tank feed conveyor 0306. Although, in some embodiments the second soak tank feed conveyor 0356 and the first soak tank feed conveyor 0306 are different conveyors.
In some embodiments of the method for soaking corn, upon introducing the second batch of corn 0106 into the soak tank 0102, the second batch of corn 0106 has a second initial soak temperature. In some embodiments, the second initial soak temperature is equal to 37.8 to 62.8° C. (100 to 145° F.), 43.3 to 62.8° C. (110 to 145° F.), 51.7 to 62.8° C. (125 to 145° F.), 51.7 to 54.4° C. (125 to 130° F.), 48.9 to 60° C. (120 to 140° F.), or 48.9 to 54.4° C. (120 to 130° F.). In some embodiments, the second initial soak temperature is a mass-weighted bulk average temperature. In some embodiments, at least 90, 95, 96, 97, 98, or 99% by weight of the second batch of corn 0106 can be heated to the second initial soak temperature. In some embodiments, the entire second batch of corn 0106 is heated to the second initial soak temperature.
In some embodiments of the method for soaking corn, upon the introducing the second batch of corn 0106 into the soak tank 0102, the second batch of corn 0106 has a second initial soak moisture concentration by weight of 30 to 38%, 31 to 37%, 32 to 36%, 33 to 35%, or about 34%. The second initial soak moisture concentration of the corn includes any inherent moisture in the corn and excludes free water around the corn. In some embodiments, the second initial soak moisture concentration is measured using an online moisture concentration meter 0402, for example, as illustrated in
With reference, for example, to
In some embodiments it can be advantageous to provide the recirculation tank with a soak tank heater (e.g., a recirculation water heater 0168). The soak tank heater can be used to provide and/or maintain the combined batch of corn in the soak tank at a desired temperature during soaking and/or at a desired temperature upon discharge from the soak tank. In some embodiments, the desired temperature is at least as high as a desired minimum temperature (e.g., 43.3° C. (110° F.)) and/or below a temperature that results in gelatinization of the corn under the soaking conditions for the corn. For example, the combined batch of corn can be provided and/or maintained at the first initial soak temperature range as described herein. Additionally, in some embodiments, the soak tank heater is a heating element, heating coil, heat exchanger, steam/hot water jacket, microwave heater/over, radio frequency (RF) heater/oven, ultrasound heater, infrared radiation emitter, etc. In some embodiments, the soak tank heater (e.g., recirculation water heater 0168) is positioned to heat recirculation water in or from the recirculation conduit before the recirculation water is reintroduced into the soak tank.
In some embodiments, it is useful to define a recirculation delay time as the time passing from the introducing the second batch of corn 0106 into the soak tank 0102 until the reintroducing the removed stream of water 0114 into the soak tank 0102 begins. Additionally, it can be useful to define a second batch delay time as the time passing from the introducing the first batch of corn 0104 into the soak tank 0102 until the introducing the second batch of corn 0106 into the soak tank 0102.
As an illustration, it can be useful to employ a recirculation delay time to postpone recirculation to a time after the second batch of corn 0106 has been introduced to the soak tank. For example, if the first batch of corn 0104 has already been absorbing water in the soak tank for 30 minutes when the second batch of corn 0106 is introduced into the soak tank, the corn in the first batch of corn 0104 could have absorbed more water than the corn in the second batch of corn 0106. However, if the corn in the first batch of corn 0104 has also cooled to a lower temperature than the corn in the second batch of corn 0106, the corn in the first batch of corn 0104 could be absorbing moisture at a slower rate than the corn in the second batch of corn 0106. If the corn in the first batch of corn 0104 has a relatively higher moisture concentration than the corn in the second batch of corn, the higher moisture concentration could also contribute to the corn in the first batch of corn absorbing moisture at a slower rate than the corn in the second batch of corn 0106. In order to reduce the differences in moisture concentration between the corn in the first batch of corn 0104 and the corn in the second batch of corn 0106, it can be advantageous to allow the differences in temperature between the first and second batch, and thus the difference in rates of absorption between the first and second batch, to persist for a time. Implementing a recirculation delay time can help to accomplish this objective.
In some embodiments, the method for soaking corn is further characterized by an element selected from the group of elements consisting of:
In some embodiments of a method for soaking corn, the recirculation water 0116 is provided with a recirculation water flow rate. As an illustration, in some embodiments it can be advantageous to set the recirculation flow rate at a maximum value that avoids a potentially undesirable degree of disturbance to the corn in the soak tank (e.g., results in the removal of the hulls of the corn). If the spatial moisture concentration gradient associated with the corn in the soak tank has already been desirably reduced (e.g., minimized or even eliminated), then using a maximum recirculation flow rate can be advantageous to provide an equilibrium temperature (or even equal/consistent temperature) for all, essentially all, or most of the corn in the soak tank. This can, in turn, provide a more consistent (or even equal) rate of moisture absorption for the corn in the soak tank, and help maintain any progress achieved in reducing the moisture concentration gradient.
In some embodiments, the recirculation water flow rate can be at least 0.61, 0.46, 0.3, 0.15 m/s (2, 1.5, 1, 0.5 ft./s) or set to provide the recirculation water 0116 with a residence time equal to no more than and/or no less than 18, 17, 16, 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2, 1, 0.5, or 0.25 hours. For purposes of determining a recirculation water flow rate, the residence time can be calculated by dividing a recirculation water mass (e.g., mass of water in the soak tank 0102 available to act as recirculation water 0116) by a mass-based recirculation water flow rate of the recirculation water. Furthermore, the mass-based recirculation water flow rate can be determined from this relationship between the residence time and flow rate. Additionally, the density of the water can be used to convert the mass-based recirculation water flow rate to a volume-based recirculation water flow rate as desired.
In some embodiments the recirculation water flow rate is set so that the recirculation water flow rate does not result in turbulent conditions for the water in the soak tank 0102.
In some embodiments the recirculation water flow rate is set at a value selected from the group consisting of:
In some embodiments of the method for soaking corn, it can be useful to define a recirculation delay time and/or second batch delay time, as previously discussed. Moreover, it can be useful to define a second-batch time that begins with introducing the second batch of corn 0106 into the soak tank 0102 and ends with discharging the combined batch of corn 0108 from the bottom portion 0128 of the soak tank 0102.
In some embodiments of the method for soaking corn, the recirculation delay time is equal to at least 1.5, 1.4, 1.3, 1.25, 1.2, 1.15, 1.1, 1.05, 1.04, 1.03, 1.02 1.01, or 1 times the second batch delay time.
In some embodiments, the recirculation water flow rate is set to provide the recirculation water 0116 with a desired residence time. The desired residence time can be selected from the group consisting of:
With reference to
This can be advantageous, for example, so that the moisture concentration of the corn discharged from the soak tank will not vary over time as corn from different positions in the soak tank is evacuated.
In some embodiments of the method for soaking corn, a mass-weighted bulk average temperature of the combined batch of corn 0108 leaving the soak tank 0102 is at least 37.8° C. (100° F.) or 43.3° C. (110° F.), or is 37.8 to 54.4° C. (100 to 130° F.), 37.8 to 48.9° C. (100 to 120° F.), 43.3 to 54.4° C. (110 to 130° F.), or 48.9 to 54.4° C. (120 to 130° F.).
In some embodiments, the combined batch of corn 0108 is discharged from the soak tank 0102 to provide a discharge stream 0404 of the combined batch of corn 0108. A combined batch discharge temperature of the discharge stream 0404 can be periodically measured to provide a plurality of periodic discharge temperature measurements. Examples of periodic discharge temperature measurements include measurements at regular intervals, such as 5, 4, 3, 2, or 1 minute intervals, or 30, 15, 10, 5, 4, 3, 2, or 1 second intervals. In some embodiments, the periodic discharge temperature measurements can cover a time period that encompasses the entire combined batch of corn 0108. In some embodiments, the combined batch discharge temperature is measured using a discharge temperature probe 0406. For example, the discharge temperature probe 0406 can be positioned to measure temperature at a stationary measurement point 0408 intersecting the discharge stream 0404 of the combined batch of corn 0108. In some embodiments, a standard deviation of the combined batch discharge temperature for all of the plurality of periodic discharge temperature measurements is no more than 8.3, 5.6, 5.0, 4.4, 3.9, 3.3, 2.8, 2.2, 1.7, 1.1, 0.6, or 0.47° C. (15, 10, 9, 8, 7, 6, 5, 4, 3, 2, 1, 0.85° F.). In some embodiments, the first 1, 2, 3, 4, or 5% by weight of the combined batch of corn 0108 to be discharged, the last 1, 2, 3, 4, or 5% by weight of the combined batch of corn 0108 to be discharged, or a combination thereof can be excluded from the plurality of periodic discharge temperature measurements for the purpose of calculating the standard deviation of the combined batch discharge temperature.
In some embodiments, the combined-batch-discharging step 0816 comprises discharging the combined batch of corn 0108 from a bottom portion 0128 of the soak tank 0102, for example, by opening the bottom portion 0128 of the soak tank 0102 to allow the combined batch of corn 0108 to exit the soak tank 0102 under a force of gravity.
In some embodiments, discharging the combined batch of corn 0108 begins 9 to 18, 10 to 17, 10 to 12 or about 11 hours after the introducing the second batch of corn 0106 into the soak tank 0102.
In some embodiments, discharging the combined batch of corn 0108 takes no more than 1.5, 1, 0.5, or 0.25 hours to discharge at least 99% by weight of the combined batch of corn 0108 in the soak tank 0102. In some embodiments, discharging the combined batch of corn 0108 takes about 0.25 to 1.5, 0.5 to 1, or 0.4 to 0.6 hours to discharge at least 99% by weight of the combined batch of corn 0108 in the soak tank 0102.
With reference to
With reference to
With reference to
In some embodiments, the washing does not appreciably affect a combined batch moisture concentration by weight of the corn of the combined batch of corn 0108. The temperature of the wash water can be used to provide or maintain the corn at a desired temperature. For example, the wash water 0504 can be at ambient temperature or a temperature of 10 to 26.7 or 15.6 to 26.7° C., or 21.1° C. (50 to 80 or 60 to 80° F., or 70° F.).
In some embodiments, the corn-washing step 0820 comprises washing the corn of the combined batch of corn 0108 in a washer 0502 (e.g., tumbler) for no more than about 60, 50, 40, 30, or 20 seconds.
In some embodiments, the draining step 0822 comprises draining free water (e.g., water that has not been absorbed by the corn, including wash water 0504, as applicable) from the corn of the combined batch of corn 0108. As a skilled person would understand, the draining step 0822 can comprise draining the water from the corn of the combined batch of corn 0108 along with any particles small enough to pass through a screen 0508 (e.g., drain screen) on the drain 0506. In some embodiment, the draining step 0822 comprises opening the drain to allow the water to drain from the corn of the combined batch of corn 0108 for 6-10, 7-9, or about 8 minutes.
With reference, for example, to
With reference to
In some embodiments, the soaked-corn-milling step 0826 occurs in a milling device 0606 (e.g., grinder).
In some embodiments, it can be desirable to measure a masa moisture concentration by weight of the masa 0604 exiting the milling device 0606. Among other purposes, this can be useful to confirm that the moisture concentration falls within a desired range. As examples of desired ranges, in some embodiments:
In some embodiments, the masa moisture concentration is measured continuously or periodically using an online moisture concentration meter 0402. Although various options exist for measuring the masa moisture concentration, in some embodiments, the masa moisture concentration is measured using a meter that measures conductivity of the masa or infrared absorption and/or reflectance of the masa 0604. When one of these devices or another continuous or periodic moisture concentration meter is used, the masa moisture concentration can be measured by taking samples at regular intervals. Examples of regular intervals include 5, 4, 3, 2, or 1 minute intervals, or 30, 15, 10, 5, 4, 3, 2, or 1 second intervals.
In some embodiments, the soaked-corn-milling step 0826 involves the optional addition of water. For example, mill water 0610 can be added to the corn of the combined batch of corn 0108 during milling. In some embodiments, the mill water 0610 is provided at a controlled yet variable mill water flow rate. For example, the mill water flow rate can be varied to help control the masa 0604 temperature and the masa moisture concentration. Moreover, in some embodiments, the mill water flow rate varies within a specified range from a specified mill water flow rate, for example, within +/−10, 5, 4, 3, 2, or 1% by weight of the specified mill water flow rate.
Although not illustrated in
An embodiment of a system that can be used to soak corn will now be described with reference to
The soak tank 0102 comprises a top portion 0122, a bottom portion 0128, a sidewall 0138 extending from the bottom portion 0128 to the top portion 0122, a recirculation outlet 0120 to provide a removed stream of water 0114, a recirculation inlet 0124 to enable the removed stream of water 0114 to be reintroduced to the soak tank 0102 to provide recirculation water 0116. The top portion 0122 comprises a top 0130 of the soak tank 0102 and an upper opening 0132 for introducing corn 0110 and water 0112 into the soak tank 0102. The bottom portion 0128 comprises a bottom 0134 of the soak tank 0102 and a lower opening 0136 (e.g., provided by soaked corn outlet 0410) for discharging corn 0110 and water 0112 from the soak tank 0102.
The recirculation conduit 0140 provides fluid communication from the recirculation outlet 0120 to the recirculation inlet 0124 so the removed stream of water 0114 can be reintroduced to the soak tank 0102 through the recirculation inlet 0124 to provide the recirculation water 0116.
The recirculation conveyor 0142 (e.g., pump) is in fluid communication with the recirculation outlet 0120 and the recirculation inlet 0124. As illustrated, the recirculation conveyor 0142 is for conveying the removed stream of water 0114 to the recirculation inlet 0124 to provide the recirculation water 0116. This can be accomplished, for example, by using the recirculation conveyor 0142 to pressurize the removed stream of water 0114.
In some embodiments, the system further comprises one or more additional components. For example, as illustrated in
As an example, with respect to
Additionally, the system can comprise a second batch heater (or heater and cooler) 0310 for heating (or heating and cooling) a second feed batch of corn 0354 (and optionally water, lime, or a combination thereof) to provide a second heated batch of corn before the second heated batch of corn is introduced into the soak tank 0102.
After reading the present disclosure, a person skilled in the art would recognize that the first batch heater (or heater and cooler) 0308 and/or second batch heater (or heater and cooler) 0310 can be configured to heat (or heat and cool) product, liquid, lime or a combination thereof using many different methods and systems known in the art although all of these methods and systems are not specifically illustrated in
In some embodiments, the system comprises a soak tank feed conveyor or plurality of soak tank feed conveyors for introducing the heated corn into the soak tank 0102. As examples, the soak tank feed conveyor can be or comprise a passive conveyor, an active conveyor, or a combination thereof. The passive conveyor and the active conveyor can be any type of passive conveyor or active conveyor described herein, respectively.
Examples of soak tank feed conveyors are illustrated in
Additionally, the system comprises a second soak tank feed conveyor 0356 for introducing a second heated batch of corn into the soak tank 0102.
With reference to
With reference again to
Furthermore, in some embodiments, the system comprises soak tank insulation 0150. For example, the soak tank insulation can cover a portion of the surface of the soak tank by area, at least ¼, ⅓, ½, ⅔ or ¾ of the surface of the soak tank by area, all of the surface of the soak tank, or all of the surface area of the soak tank except for portions of the soak tank with protrusions such as instruments, inlets, outlets and valves.
With reference to
With reference again to
With further reference to
With reference to
In some embodiments, the milling device feed conveyor 0616 is or comprises a passive conveyor, an active conveyor, or a combination thereof. The passive conveyor and the active conveyor can be any type of passive conveyor or active conveyor described herein, respectively.
As illustrated in
With reference to
In some embodiments, the soak tank insulation 0150 covers a portion of the surface of the soak tank by area; at least ¼, ⅓, ½, ⅔ or ¾ of the surface of the soak tank by area; all of the surface of the soak tank; or all of the surface of the soak tank, optionally, except for portions of the soak tank with protrusions such as instruments, inlets, outlets or valves.
As illustrated in
With reference again to
Additionally, as illustrated in
With reference again to
The percentage of openings that comprise a widest dimension equal to no more than a specific value can be calculated using various exemplary methods. One method of calculating the percentage is based on area of the openings as follows. First, a first sum equal to the sum of the open area of the openings in the screen with a widest dimension greater than the specific value can be calculated. Second, a second sum equal to the sum of the open area of all the openings in the screen can be calculated. Third, the first sum can be divided by the second sum to provide the fraction of open area pertaining to openings with a widest dimension greater than the specific value relative to the total open area of the screen. Fourth, the fraction can be converted to a percentage by multiplying the fraction by 100%.
As a further example, the percentage of openings that comprise a widest dimension equal to no more than a specific value can be calculated based on the number of openings as follows. First, a first sum equal to the number of openings in the screen with a widest dimension greater than the specific value can be calculated. Second, a second sum equal to the number of all the openings in the screen can be calculated. Third, the first sum can be divided by the second sum to provide the fraction of openings with a widest dimension greater than the specific value relative to the total openings in the screen. Fourth, the fraction can be converted to a percentage by multiplying the fraction by 100%.
In some embodiments of a method or system for soaking, the soak tank 0102 comprises a recirculation outlet 0120. In some embodiments, at least some of the water from the soak tank 0102 is removed through the recirculation outlet 0120. In some embodiments, the recirculation outlet 0120 is located no more than 30, 25, 20, 15, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1% of a height 0154 of the soak tank 0102 away from a bottom 0134 of the soak tank 0102. Additionally, in some embodiments, the recirculation outlet 0120 is located no more than 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, or 0.1 meter (3.28, 2.95, 2.62, 2.30, 1.97, 1.64, 1.31, 0.98, 0.66, 0.33 ft.) from a bottom 0134 of the soak tank 0102.
With reference again to
In some embodiments, the depth 0156 from the top 0130 of the soak tank 0102 is no more than 30, 25, 20, 15, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1% of a height 0154 of the soak tank 0102, where the height 0154 of the soak tank 0102 is measured from the top 0130 of the soak tank 0102 to a bottom 0134 of the soak tank 0102.
In some embodiments, the depth 0156 from the top 0130 of the soak tank 0102 is no more than 1.1, 1.09, 1.08, 1.07, 1.06, 1.05, 1.04, 1.03, 1.02, 1.01, or 1.0 times a depth 0158 from the top 0130 of the soak tank 0102 to an interface 0162 between a water-phase 0160 and a corn-bed-and-water-phase 0164.
In some embodiments, the depth from the top 0130 of the soak tank 0102 is no more than 1, 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, 0.2, or 0.1 meter (3.28, 2.95, 2.62, 2.30, 1.97, 1.64, 1.31, 0.98, 0.66, 0.33 ft.) from a water-air interface 0166 (e.g., water level or top surface) for the water in the soak tank 0102. Moreover, as illustrated in
In some embodiments of a method or system for soaking, the first batch of corn 0104 has a first batch mass, the second batch of corn 0106 has a second batch mass, and the second batch mass is equal to the first batch mass +/−50%, 40%, 30%, 25%, 20%, 15%, 10%, 5%, 4%, 3%, 2% or 1% of the first batch mass.
In some embodiments, the corn of the first batch of corn 0104 has a first corn mass, the corn of the second batch of corn 0106 has a second corn mass, and the second corn mass is equal to the first corn mass +/−50%, 40%, 30%, 25%, 20%, 15%, 10%, 5%, 4%, 3%, 2% or 1% of the first corn mass.
In some embodiments, the water of the first batch of corn 0104 has a first water mass, the water of the second batch of corn 0106 has a second water mass, and the second water mass is equal to the first water mass +/−50%, 40%, 30%, 25%, 20%, 15%, 10%, 5%, 4%, 3%, 2% or 1% of the first water mass.
In some embodiments, a method or system for soaking can be used to accomplish one or more illustrative objectives, such as providing soaked corn. As an example, the soaked corn can be used for making masa 0604 as illustrated in
As another example, in some embodiments, the method or system for soaking is used to provide soaked corn comprising a soaked corn volume and a soaked corn moisture concentration by weight. In some embodiments, the soaked corn meets specific specifications. As a first example, the soaked corn moisture concentration can differ from a desired soaked corn moisture concentration by no more than a specified soaked corn moisture tolerance throughout the soaked corn volume. In some embodiments, the specified soaked corn moisture tolerance is 2%, 1%, 0.75%, or 0.5% of the desired soaked corn moisture concentration by weight. As an example, the desired soaked corn moisture concentration can be 50 wt. %.
With reference to
As another example, the method or system for soaking corn can be used to provide a soaked corn moisture concentration by weight of the soaked corn throughout the soaked corn volume. In some embodiments, the soaked corn moisture concentration by weight is equal to 48 to 52 wt. %, 49 to 51 wt. %, or 49.5 to 50.5 wt. %.
With reference to
In some embodiments, the method or system can be used to reduce or minimize a variation in the masa moisture concentration throughout the masa volume.
In some embodiments, the masa moisture concentration by weight differs from a desired masa moisture concentration by no more than a specified masa moisture tolerance throughout the masa volume. As examples, the specified masa 0604 moisture tolerance can be 2%, 1%, 0.75%, or 0.5% of the desired masa moisture concentration by weight. In some embodiments, the desired masa moisture concentration is 50 wt. %. Additionally, the masa moisture concentration by weight of the soaked corn throughout the soaked corn volume can be 48 to 52 wt. %, 49 to 51 wt. %, or 49.5 to 50.5 wt. %.
Although the present disclosure has provided many examples of systems and methods, it should be understood that the components of the systems and method described herein are compatible and additional embodiments can be created by combining one or more elements from the various embodiments described herein. As an example, in some embodiments, a method described herein can further comprise one or more elements of a system described herein or a selected combination of elements from any combination of the systems described herein.
Furthermore, in some embodiments, a method described herein can further comprise using a system described herein, using one or more elements of a system described herein, or using a selected combination of elements from any combination of the systems described herein.
Additionally, while the present application provides multiple examples for soaking corn to form a masa, the methods and systems described herein can also be used for soaking corn for other purposes. Moreover, the methods and systems described herein can also be used for soaking other products, for example, food products, vegetables, grains, or starch-containing produce. As a further example, the methods, steps, systems, and elements described herein can be used for providing a product, with a spatial moisture concentration gradient that is limited to a desired range throughout the entire volume or mass of the product especially when the product initially has a spatial temperature gradient or spatial gradient in moisture concentration, or both. Accordingly, where the word corn is used herein, a new embodiment can be formed by replacing the word “corn” with “product” or with any product described herein. As a further example, the methods, steps, systems, and elements described herein can be used for controlling the absorption of any liquid, as opposed to only water. Accordingly, where the word “water” is used herein, a new embodiment can be formed by replacing the word water with “liquid”.
The following clauses are offered as further description of the disclosed invention:
1. A method comprising:
2. The method of any preceding clause, wherein the removing at least some of the water comprises removing water from the soak tank at a bottom portion of the soak tank.
3. The method of any preceding clause, wherein the removing at least some of the water from the soak tank comprises removing at least some of the water from the soak tank through a screen (e.g., recirculation screen).
4. The method of any preceding clause, wherein the removing at least some of the water from the soak tank comprises removing at least some of the water from the soak tank through a recirculation outlet of the soak tank.
5. The method of any preceding clause, wherein the reintroducing the removed stream of water comprises reintroducing the removed stream of water into the soak tank at a top portion of the soak tank.
6. The method of any preceding clause, wherein the reintroducing the removed stream of water comprises reintroducing the removed stream of water into the soak tank though a recirculation inlet of the soak tank.
7. The method of any preceding clause, wherein the reintroducing the removed stream of water comprises reintroducing the removed stream of water into the soak tank at a recirculation discharge location.
8. The method of any preceding clause, wherein the reintroducing the removed stream of water begins after the introducing the second batch of corn into the soak tank.
9. The method of any preceding clause, wherein a recirculation delay time is the time passing from the introducing the second batch of corn into the soak tank until the reintroducing the removed stream of water into the soak tank begins, wherein a second batch delay time is the time passing from the introducing the first batch of corn into the soak tank until the introducing the second batch of corn into the soak tank, wherein the method is further characterized by an element selected from the group of elements consisting of:
10. The method of any preceding clause, wherein the recirculation water is provided with a recirculation water flow rate, optionally wherein the method further comprises an element selected from the group of elements consisting of:
11. The method of any preceding clause, wherein the method is further characterized by at least one element selected from the group of elements consisting of:
12. The method of any preceding clause,
13. The method of any preceding clause, wherein the first batch of corn comprises components selected from the group consisting of corn, water, lime, and a combination thereof; optionally wherein the lime is selected from the group consisting of: calcium-containing inorganic material in which at least 50 wt. % of the material consists of a component selected from: a carbonate, an oxide, a hydroxide, and a combination thereof; calcium oxide; calcium hydroxide; and a combination thereof).
14. The method of any preceding clause, wherein the method further comprises heating (or heating and cooling) a first feed batch of corn (e.g., including any added water in the first feed batch of corn) to provide a first heated batch of corn, and wherein the first batch of corn is the first heated batch of corn or wherein the first heated batch of corn is cooled to provide the first batch of corn.
15. The method of clause 14, further characterized by at least one element selected from the group of elements consisting of:
16. The method of any preceding clause, wherein the introducing the first batch of corn into the soak tank comprises:
17. The method of any preceding clause, wherein, upon the introducing the first batch of corn into the soak tank, the first batch of corn has a first initial soak temperature, optionally wherein the method is further characterized by an element selected from the group of elements consisting of:
18. The method of any preceding clause, wherein, upon the introducing the first batch of corn into the soak tank, the first batch of corn has a first initial soak moisture concentration by weight of 30 to 38%, 31 to 37%, or 32 to 36%, 33 to 35%, or about 34%, wherein the first initial soak moisture concentration of the first batch of corn includes any inherent moisture in the corn and excludes free water around the corn, optionally wherein the first initial soak moisture concentration is measured using an online moisture concentration meter (e.g., meter with continuous monitoring capability, conductivity-based meter, infrared-based meter, etc.).
19. The method of any preceding clause, wherein the second batch of corn comprises components selected from the group consisting of corn water, lime, and a combination thereof; optionally wherein the lime is selected from the group consisting of: calcium-containing inorganic material in which at least 50 wt. % of the material consists of a component selected from: a carbonate, an oxide, a hydroxide, and a combination thereof; calcium oxide; calcium hydroxide; and a combination thereof).
20. The method of any preceding clause, wherein the method further comprises heating (or heating and cooling) a second feed batch of corn (e.g., including any added water in the second feed batch of corn) to provide a second heated batch of corn, and wherein the second batch of corn is the second heated batch of corn or wherein the second heated batch of corn is cooled to provide the second batch of corn.
21. The method of clause 20, further characterized by at least one element selected from the group of elements consisting of:
22. The method of any preceding clause, wherein the introducing the second batch of corn into the soak tank comprises:
23. The method of any preceding clause, wherein, upon the introducing the second batch of corn into the soak tank, the second batch of corn has a second initial soak temperature, optionally wherein the method is further characterized by an element selected from the group of elements consisting of:
24. The method of any preceding clause, wherein, upon the introducing the second batch of corn into the soak tank, the second batch of corn has a second initial soak moisture concentration by weight of 30 to 38%, 31 to 37%, or 32 to 36%, 33 to 35%, or about 34%, wherein the second initial soak moisture concentration of the corn includes any inherent moisture in the corn and excludes free water around the corn, optionally wherein the second initial soak moisture concentration is measured using an online moisture concentration meter (e.g., meter with continuous monitoring capability, conductivity-based meter, infrared-based meter, etc.).
25. The method of any preceding clause, wherein, at an initial discharge time when the discharging the combined batch of corn begins, a standard deviation of the temperature for the combined batch of corn at each spatial position in the combined batch volume in the soak tank is no more than 8.3, 5.6, 5.0, 4.4, 3.9, 3.3, 2.8, 2.2, 1.7, 1.1, 0.6, or 0.47° C. (15, 10, 9, 8, 7, 6, 5, 4, 3, 2, 1, 0.85° F.).
26. The method of any preceding clause, wherein a mass-weighted bulk average temperature of the combined batch of corn leaving the soak tank is at least 37.8° C. (100° F.) or 43.3° C. (110° F.), or is 37.8 to 54.4° C. (100 to 130° F.), 37.8 to 48.9° C. (100 to 120° F.), 43.3 to 54.4° C. (110 to 130° F.), or 48.9 to 54.4° C. (120 to 130° F.).
27. The method of any preceding clause, wherein the combined batch of corn is discharged from the soak tank to provide a discharge stream of the combined batch of corn; wherein a combined batch discharge temperature of the discharge stream is periodically (e.g., at regular intervals such as 5, 4, 3, 2, or 1 minute intervals or 30, 15, 10, 5, 4, 3, 2, or 1 second intervals) measured to provide a plurality of periodic discharge temperature measurements, optionally, for the entire combined batch of corn; wherein the combined batch discharge temperature is measured using a discharge temperature probe; wherein the discharge temperature probe is positioned to measure temperature at a stationary measurement point intersecting the discharge stream of the combined batch of corn, wherein a standard deviation of the combined batch discharge temperature for all of the plurality of periodic discharge temperature measurements is no more than 8.3, 5.6, 5.0, 4.4, 3.9, 3.3, 2.8, 2.2, 1.7, 1.1, 0.6, or 0.47° C. (15, 10, 9, 8, 7, 6, 5, 4, 3, 2, 1, 0.85° F.), optionally excluding the first 1, 2, 3, 4, or 5% by weight of the combined batch of corn to be discharged, and optionally excluding the last 1, 2, 3, 4, or 5% by weight of the combined batch of corn to be discharged.
28. The method of any preceding clause, wherein the discharging the combined batch of corn comprises discharging the combined batch of corn from a bottom portion of the soak tank, optionally, by opening the bottom portion of the soak tank to allow the combined batch of corn to exit the soak tank under a force of gravity.
29. The method of any preceding clause, wherein the discharging the combined batch of corn begins 9 to 18, 10 to 17, 10 to 12 or about 11 hours after the introducing the second batch of corn into the soak tank.
30. The method of any preceding clause, wherein the discharging the combined batch of corn takes no more than 1.5, 1, 0.5, or 0.25 hours to discharge at least 99% by weight of the combined batch of corn in the soak tank or wherein the discharging the combined batch of corn takes about 0.25 to 1.5, 0.5 to 1, or 0.4 to 0.6 hours to discharge at least 99% by weight of the combined batch of corn in the soak tank.
31. The method of any preceding clause, wherein the method further comprises:
conveying the combined batch of corn or the corn of the combined batch of corn (e.g., soaked corn) to a washer (e.g., tumbler) for washing the corn of the combined batch of corn.
32. The method of any preceding clause, wherein the method further comprises:
33. The method of clause 32, further characterized by at least one element selected from the group of elements consisting of:
34. The method of any preceding clause, wherein the method further comprises:
35. The method of any preceding clause, wherein the method further comprises:
36. The method of clause 35, further characterized by at least one element selected from the group of elements consisting of:
37. The method of any preceding clause, wherein the method further comprises:
38. A system comprising:
39. The system of any preceding clause, further comprising at least one element selected from the group of elements consisting of:
40. The system of any preceding clause, wherein the soak tank further comprises at least one element selected from the group of elements consisting of:
41. The system of any preceding clause, wherein the top portion of the soak tank has a shape that is somewhat or mostly rotationally symmetric about a central axis (e.g., a cylindrical shape, or conical shape, with some irregularities allowable for inlets, outlets, other features or a combination thereof).
42. The system of any preceding clause, wherein the bottom portion of the soak tank has a shape that is somewhat or mostly rotationally symmetric about a central axis (e.g., a cylindrical shape, or conical shape, with some irregularities allowable for inlets, outlets, other features or a combination thereof).
43. The system of any preceding clause, wherein the sidewall extends from the bottom of the soak tank to the top of the soak tank.
44. The system of any preceding clause, wherein the recirculation outlet is provided at a location selected from the group of locations consisting of:
45. The system of any preceding clause, wherein a screen for the recirculation outlet is positioned at an entrance to the recirculation outlet.
46. The system of any preceding clause, wherein a screen for the recirculation outlet permits water to pass through the screen and through the recirculation outlet.
47. The system of any preceding clause, wherein the system is further characterized by an element selected from the group of elements consisting of:
48. The system of any preceding clause, wherein the recirculation inlet is located in a sidewall of a top portion of the soak tank.
49. The method or system of any preceding clause, wherein the soak tank comprises a screen (e.g. for preventing solid particles of the corn in the soak tank from being carried through a recirculation outlet in the soak tank by the water in the soak tank), and optionally wherein the method or system is further characterized by at least one element selected from the group of elements consisting of:
50. The method or system of any preceding clause, wherein the soak tank comprises a recirculation outlet (e.g., for removing at least some of the water from the soak tank through the recirculation outlet); and optionally wherein the method or system is further characterized by at least one element selected from the group of elements consisting of:
51. The method or system of any preceding clause, wherein the soak tank comprises a recirculation discharge location (e.g., where the removed stream of water is reintroduced into the soak tank), optionally wherein the recirculation discharge location is at a depth from a top of the soak tank, and optionally wherein the method or system is further characterized by at least one element selected from the group of elements consisting of:
52. The method or system of any preceding clause, wherein the method or system further comprises an element selected from the group of elements consisting of:
53. The method or system of any preceding clause, wherein the method or system is for:
54. The method or system of any preceding clause, wherein the method or system is for providing soaked corn comprising a soaked corn volume and a soaked corn moisture concentration by weight, optionally wherein:
55. The method or system of any preceding clause, wherein the method or system is a method or system for soaking a plurality of heated batches of corn in the soak tank to provide a batch of masa, wherein the batch of masa comprises a masa volume and a masa moisture concentration by weight, wherein the masa moisture concentration by weight differs from a desired masa moisture concentration by no more than a specified masa moisture tolerance throughout the masa volume, optionally, wherein the specified masa moisture tolerance is 2%, 1%, 0.75%, or 0.5% of the desired masa moisture concentration by weight, optionally, wherein the desired masa moisture concentration is 50 wt. %, and optionally wherein the masa moisture concentration by weight of the soaked corn throughout the soaked corn volume is 48 to 52, 49 to 51, or 49.5 to 50.5 wt. %.
56. The method or system of any preceding clause, wherein the method or system comprises:
57. The method or system of any preceding clause, wherein the method or system is a method or system for soaking a plurality of heated batches of corn in the soak tank to provide a batch of masa, wherein the batch of masa comprises a masa volume and a masa moisture concentration by weight, wherein the method or system is a method or system for reducing or minimizing a variation in the masa moisture concentration throughout the masa volume.
58. The method of any preceding method clause, wherein the method further comprises the system of any preceding system clause, wherein the method further comprises an element of the system of any preceding system clause, or wherein the method further comprises a combination of elements of the system of any preceding system clause.
59. The method of any preceding method clause, wherein the method further comprises using the system of any preceding system clause, wherein the method further comprises using an element of the system of any preceding system clause, or wherein the method further comprises using a combination of elements of the system of any preceding system clause.
60. The method of any preceding method clause, wherein the method is a method of using the system of any preceding system clause, wherein the method is a method of using an element of the system of any preceding system clause, or wherein the method is a method of using a combination of elements of the system of any preceding system clause.
61. A product (e.g., combined batch of corn, washed corn, drained corn, masa, a masa product, or combination thereof) made according to the method of any preceding method claim.
Although embodiments of the invention have been described with reference to several elements, any element described in the embodiments described herein are exemplary and can be omitted, substituted, added, combined, or rearranged as applicable to form new embodiments. A skilled person, upon reading the present specification, would recognize that such additional embodiments are effectively disclosed herein. For example, where this disclosure describes characteristics, structure, size, shape, arrangement, or composition for an element or process for making or using an element or combination of elements, the characteristics, structure, size, shape, arrangement, or composition can also be incorporated into any other element or combination of elements, or process for making or using an element or combination of elements described herein to provide additional embodiments. For example, it should be understood that the method steps described herein are exemplary, and upon reading the present disclosure, a skilled person would understand that one or more method steps described herein can be combined, omitted, re-ordered, or substituted.
Additionally, where an embodiment is described herein as comprising some element or group of elements, additional embodiments can consist essentially of or consist of the element or group of elements. Also, although the open-ended term “comprises” is generally used herein, additional embodiments can be formed by substituting the terms “consisting essentially of” or “consisting of.”
Where language, for example, “for” or “to”, is used herein in conjunction with an effect, function, use or purpose, an additional embodiment can be provided by substituting “for” or “to” with “configured for/to” or “adapted for/to.”
While this invention has been particularly shown and described with reference to preferred embodiments, it will be understood by those skilled in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the invention. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.
