Description
The raw material of this high fructose corn syrup production process is low-fat corn flour. WinTone's corn germ extraction, husk extraction, and low-fat flour production process is a domestically advanced new intelligent semi-dry corn production line. The production line has a germ extraction rate of 9%, a husk extraction rate of 10%, and a low-fat corn flour extraction rate of 81%. The fat content of the low-fat corn flour is controlled within 0.8%, the ash content is controlled within 0.6%, and the starch content of the corn flour is maintained at more than 87%. The physical and chemical indicators meet the requirements of the innovative glucose syrup production process currently developed by our company.
Related finished products
The glucose produced by WinTone's corn glucose syrup production process is light yellow, clear, soft in taste, and free of harmful substances, which is of higher quality than traditional wet products. According to laboratory tests, the concentration of the produced glucose syrup is 27%-71%, the DE value is greater than 98, the DX value is greater than 95, the filtered protein dry grade accounts for 9.5%, the protein content is ≥60%, and the light transmittance is ≥98%.
Technology background
At present, the industry adopts the corn wet soaking process to extract starch and the double enzyme syrup making process to produce starch syrup. This process mainly has the following problems:
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1. Large investment in plant equipment and complex process;
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2. Serious environmental pollution, strong odor, large amount of sewage, and difficulty in project environmental impact assessment approval;
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3. Low grain-to-glucose syrupconversion rate, resulting in large amount of grain waste;
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4. High production and operation costs and high consumption of various energy sources;
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5. Starch glucose syrup contains sulfides and harmful substances produced by microbial metabolism;
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6. Low by-product yield and low cost reduction value.
In order to solve the problems in the above-mentioned industries, our company has joined hands with many industry experts, and after years of research, has innovatively developed a new process for dry separation of corn and defatted corn flour to produce glucose syrup. We have conducted many experiments for this purpose, and have overcome the technical bottlenecks and the difficulties of all process equipment technologies. The technology has been applied to large-scale industrial production and has achieved the expected goals.
Technology Advantages
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Corn ingredient utilization
According to the composition ratio of corn parts, endosperm: germ: husk is 83:9:8, and the effective ingredients are all in the endosperm (81.2% of corn endosperm, 9.5% of germ, and 9.2% of corn husk separated by corn dry separation technology);
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New breakthrough in endosperm yield
A major breakthrough has been made in endosperm yield, all germ has been extracted, and corn husk yield has been reduced;
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Highly effective separation
With the improvement of equipment innovation and photoelectric automatic control level, through steam grain moistening, mechanical crushing, screening, air separation, embryo pressing, gravity separation, color sorting and other advanced process, defatted corn flour, germ, corn husk are successfully and efficiently separated, and the separation effect is better than the wet method;
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Liquefaction and saccharification technology
Innovative and advanced liquefaction and saccharification technologies make defatted corn flour liquefaction and saccharification smooth and filterable, efficiently separate corn gluten powder products and produce high-quality syrup liquid.
New process of glucose syrup production from defatted corn flour
The corn endosperm enters the endosperm powder mixing tank, where acid, dilute alkali and water are added to mix the powder. It is then micronized under the action of special enzymes. The endosperm slurry is then sprayed into the feed tank and, under the action of steam, enters the flash tank, laminar flow tank and plate and frame feed tank in turn. After plate and frame filtration, the corn protein powder product is efficiently separated and high-quality glucose syrup liquid is produced.
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1. Mixing: Mix corn flour into corn flour slurry;
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2. Grinding: breaking up the granules/starch clumps in the corn flour slurry;
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3. Preparation for injection: further prepare corn flour slurry for injection;
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4. Injection: Mix high-temperature steam and corn flour slurry to increase temperature and pressure;
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5. Spray maintenance: maintain the temperature and pressure of corn flour slurry for a period of time;
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6. Flash steaming: reduce the temperature and pressure of corn flour slurry;
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7. Liquefaction maintenance: Maintain the temperature and pressure of the corn flour slurry for a period of time to liquefy it;
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8. Filtration: Filter the liquefied slurry to separate the slurry and solid matter;
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9. Filter residue cleaning: clean the glucose syrup in the filter residue;
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10. Secondary filtration: filter the cleaned residue for a second time;
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11. Filtrate saccharification: saccharify the filtrate into glucose syrup.
The glucose produced by this production line is slightly yellow, clear and transparent, with the unique smell of glucose syrup. Compared with the glucose produced by the wet process, it has a softer sweetness, no odor, and no harmful substances such as sulfide. The grain-to-syrup conversion rate is higher, the by-product yield is higher, and the production and operation costs are reduced.
The corn dry separation and glucose syrup production technology developed by our company is a revolutionary, innovative and groundbreaking technology. It will bring new changes and development opportunities to the corn deep processing industry and open up a new track for the technology of the corn deep processing industry.
Operation cost of producing one ton of glucose (dry syrup production)
| Project |
Name |
Unit consumption |
Price (RMB/ton) |
Cost (RMB) |
Remarks |
| Raw Materials |
Commodity corn |
1.55 |
2300 |
3565 |
|
| Excipients |
Special enzymes |
0.0002 |
60000 |
38.32 |
| Liquefaction enzyme |
0.0002 |
60000 |
Lifrain |
| Glucoamylase |
0.0004 |
35000 |
Food grade enzyme activity≥400,000 |
| acid |
0.001 |
320 |
| Power energy (separation + glucose syrup production) |
water |
2.5 |
1 |
199.4 |
Calculated based on 325 tons of absolute dry syrup per day |
| electricity |
160 |
0.66 |
| steam |
0.55 |
166 |
| Syrup production costs (separation + syrup production) |
Labor cost |
/ |
70 |
150 |
| Depreciation |
/ |
72 |
| Maintenance |
/ |
8 |
| Total |
/ |
/ |
/ |
3952.72 |
|
| By-product cost reduction |
Germ |
0.124 |
4000 |
1468 |
|
| Corn Bran |
0.186 |
1200 |
|
| Corn gluten meal |
0.144 |
5200 |
|
| Cost per ton of glucose |
/ |
/ |
/ |
2484.72 |
|
| Note: Calculated based on 32% glucose concentration. |
This innovative process of WinTone has improved the grain-syrup conversion rate and by-product yield, and reduced the production cost in the syrup production process. According to estimates, the comprehensive cost per ton has been reduced by about 460RMB.
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