Description
Glucose syrup is a kind of starch sugar crystal made by hydrolysis and isomerization of plant starch. It is an important sweetener,Colorless viscous liquid, good fluidity at room temperature, odorless.
The low-fat corn flour is the raw material for the low-fat corn flour to glucose process. WinTone's technology of corn germ extraction, husk extraction, and low-fat flour production is a domestically advanced new intelligent semi-dry corn production line. The production line features a germ purification rate at 9%, a husk purification rate at 10%, and a low-fat corn flour extraction rate at 81%. For the low-fat corn flour, the fat content is controlled within 0.8%, the ash content is limited within 0.6%, and the starch content of the corn flour is mainained above 87%. This physical and chemical index complies with the requirements of the innovative syrup manufacturing process developed by our company.
Degermed corn grits
Low-fat corn flour
Corn germ
Corn hulls & impurities
Degermed white wine
Corn germ oil
Glucose syrup & maltose syrup
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Wow, turns out corn germ can do these things!→
The raw material of corn germ, which is of high nutritional value, has been subjected to in-depth processing, thereby enhancing its comprehensive value.
Firstly, the germ oil extracted from the corn germ obtained by dry extraction method has superior taste and quality compared to that extracted from the corn germ obtained by wet extraction method where it is soaked in sulfurous water by corn starch enterprises.
Secondly, the pressed corn germ cake can be further processed to produce high-protein beverages.
This not only extends the industrial chain of corn processing but also fully exploits the economic value of corn and germ raw materials and improves the comprehensive benefits of corn processing enterprises.
Original germ
Corn germ oil
Corn germ cake
High protein drink
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. Laboratory tests have determined that the concentration of the produced glucose syrup ranges from 27% to 71%. The DE value is greater than 98, and the DX value exceeds 95. The dry grade of filtered protein accounts for 9.5%. The protein content is no less than 60%, and the light transmittance is not less than 98%.
Dry Process VS Wet Process for Syrup Production
At present, the industry adopts the corn wet soaking process to extract starch and the double enzyme syrup making process to produce starch syrup. The dry corn separation we developed has more obvious advantages than traditional wet separation products.
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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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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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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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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.
Finished Products of Dry VS Wet Process for Syrup Production.
| Finished Product Yields Between Dry VS Wet Separation |
| Items |
Available starch |
Corn Gluten Meal |
Oil |
Spray corn husk |
Germ meal |
Corn Syrup |
| Semi-dry |
717kg |
95 kg |
28.6 kg |
90 kg |
70 kg |
/ |
| Wet |
690 kg |
55 kg |
28 kg |
125 kg |
40 kg |
45 kg |
| Dry Corn Syrup VS Wet Corn Syrup Production |
| Type performance |
Defatted corn flour |
Corn starch （milk） |
| Source |
Corn is degermed,
peeled and crushed to 40 mesh,
ready for direct consumption |
Corn wet soaking,
food raw materials |
| Ingredients |
Starch powder＞88%
fat＜0.8% Protein 7-8%
Total bacteria count＜100/g or not detected |
Starch＞98% protein ＜0.4% fat＜0.1%
Total bacteria count＜10000/g
Starch milk is 2-5 times
higher than starch |
| Toxin |
None |
None |
| Polysaccharides |
A little |
None |
| Anti-nutritional factors |
None |
None |
| Microbial metabolites |
None |
Yes |
| Sulfur dioxide |
None |
＜40ppm |
| Acidity（Ph value） |
stable 6.0-6.2 |
Unstable 4.5-6.0 |
| Natural fermentation blank test |
Sour smell 24 hours |
Sour smell 32 hours |
Glycation experiment
（Liquefaction liquid plus
saccharifying enzyme
DE value＞98、DX value＞96） |
36-40 hours |
44-48 hours |
| Appearance of glucose |
Slightly yellow, clear and transparent,
with the unique smell of glucose syrup,
soft sweet taste, no peculiar smell |
Light yellow, clear and transparent,
with the unique smell of glucose syrup,
accompanied by sour or sulfur taste |
Finished Product Structure
What finished products can be processed from 1.2 tons of raw corn?
Cost-Benefit Analysis
| 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.
New process of glucose syrup production
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.
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