Corn Syrup Processing Solution

Description

In 2022, WinTone Machinery took the lead in initiating a joint research and development project on semi-dry sugar production technology, collaborating with multiple scientific research institutions and industry experts.
Through the relentless efforts of all participating parties, we have constructed a pilot-scale production line for low-fat corn flour, a pilot-scale production line for sugar manufacturing via the three-enzyme method, a pilot-scale fermentation production line for glucose syrup, and a state-of-the-art physical and chemical index analysis laboratory.
Upholding the principle of scientific rigor, we have fulfilled our vision of achieving breakthroughs in the key links of the industrial chain, promoted the green and sustainable development of the industry, and strived to create greater value for human society.
 

Picture and Video →

Process of Low - Fat Corn - flour

Innovative Technology for Semi-Dry processing Corn Germ and Bran Separation to Produce Low-Fat Corn flour.

This technology integrates the entire process from corn degerming to syrup production, reducing the traditional 12 steps in Syrup making to 7, and lowering total energy consumption by 40%. Glucose conversion rate is increased to 99.2%.

01.Clean up toxins and reduce production volume

The cleaning and separation equipment separates organic impurities from the raw grains and various fungal toxins attached to the surface of the grains, ensuring food safety.

02.Homogeneous degerming and screening section

The double-cone rubbing degerming and screening technology equipment can rub corn into four, six, or eight segments, ensuring that the germ is not damaged and the germ integrity is guaranteed.

03.Optoelectronic technology; graded embryo extraction section

AI optoelectronic technology equipment is used to achieve perfect and effective separation of pure embryo and pure endosperm.

04.Skin selection process

The equipment employs adjustable micro-negative pressure suspension technology to achieve the separation of light and heavy parts of the skin and endosperm grains.

05.Light powder processing section

Graded endosperm is processed using advanced techniques such as fine grinding and separation to obtain high-quality, yellow, low-fat corn flour. All physicochemical properties meet the requirements for Syrup fermentation processes.

06.Auxiliary material purification section

The trace amounts of starch lost in each process section are collected a second time using physical sieving and suspension core extraction technology equipment to improve the yield of low-fat corn flour.

07.Pure germ, pure bran, low-fat corn flour temporary storage or packaging section

The ultimate goal of this process is to produce low-fat corn flour with high purity germ, high purity bran and impurities, and high standard and high yield. This corn flour is produced using an innovative three-enzyme process to ensure the various physicochemical properties of the glucose syrup, creating significant economic value for enterprises in terms of energy saving and efficiency improvement.

08.Product yield

①Low-fat corn flour yield ≥80%, starch content ≥87%, fat content ≤0.85%, ash content ≤0.6%, protein ≥7%.
②The yield of pure corn germ is ≥8%, the starch content is ≤12%, and the fat content is 27-32%.
The yield of pure corn husks is ≤12%, and the starch content is ≤11%.

Energy consumption: ① 65 kWh of electricity per ton of material; ② 20 kg of water per ton of material; ③ 10 kg of steam per ton of material. The overall process cost is only about 90 yuan.

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.

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.

Finished Products of Dry VS Wet Process for Syrup Production.

Finished Product Structure

What finished products can be processed from 1.2 tons of raw corn?

Cost-Benefit Analysis

Project Case