Corn Syrup Production Line

Description 

　　WinTone mainly produces the original, refined and deep processed food engineering equipment for corn, grains, food, health care, biological fermentation food. Our corn deep processing field is in manufacturing and install the high fructose corn syrup production plant, glucose syrup processing plant, maltose syrup processing plant etc. WinTone's corn syrup is made from low-fat flour of corn/maize and contains varying amounts of sugars: glucose, maltose and higher oligosaccharides, depending on the grade.Corn syrup is widely used in the manufacture of a variety of candy products. It can be processed into high-fructose corn syrup (HFCS) by using the enzyme D-xylose isomerase to convert a large proportion of its glucose into sweeter fructose.

　　Technical background

　　At present, the industry uses corn wet soaking process to extract starch and double enzyme syrup manufacturing process to make starch syrup. This process mainly has the following problems:

　　1. Large investment in plant equipment and complex process;

　　2. Serious environmental pollution, strong odor, large amount of sewage, and difficulty in project environmental impact assessment approval;

　　3. Low grain-to-sugar conversion rate, resulting in a large amount of food waste;

　　4. High production and operation costs, high energy consumption;

　　5. Starch syrup contains sulfides and harmful substances produced by microbial metabolism;

　　6. Low by-product yield and low cost reduction value.

　　In order to solve the above-mentioned industry problems, our company has joined forces with many industry experts. After years of research, we have innovatively developed a new process of corn dry separation and defatted corn flour syrup manufacturing, and have conducted many experiments for this purpose. We have overcome the technical bottleneck and opened up the difficulties of all process equipment and technology, and applied it to large-scale industrial production, achieving the expected goals.

PROCESS OVERVIEW

　　The raw material of this syrup manufacturing process is low-fat corn flour. WinTone's corn germ extraction, husk extraction and low-fat flour production process is a domestically advanced new semi-dry corn intelligent 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 syrup manufacturing process currently developed by our company.

　　New process flow of syrup manufacturing

　　1. Low-fat corn flour processing: low-fat corn endosperm powder is produced through the corn degerm flour production line;

　　2. Slurry preparation: low-fat corn endosperm powder is mixed with acid, dilute alkali and water, special enzymes are added, and micronization is carried out;

　　3. Grinding and filtration: the micronized slurry is lightly ground by a colloid mill, and then high-pressure sprayed, and then treated by a flash tank and a laminar flow tank, and 60% pure corn protein powder is filtered and separated to obtain a clear filtrate;

　　4. Saccharifying enzyme, decolorization and evaporation: the filtrate is adjusted under certain temperature and pH conditions, and the syrup is obtained by the action of saccharifying enzyme, and the colorless concentrated glucose syrup and maltose syrup are obtained by decolorization, ion exchange and evaporation.

　　The glucose produced by WinTone low-fat corn syrup manufacturing process is slightly yellow and clear in color, soft in taste, and free of harmful substances, which is better 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 transmittance is ≥98%.

FEATURE

• Low-fat flour processing with dry method

  With reduced fat content, it streamlines the production process and enhances the quality of the final corn syrup.

• Low environmental impact

  The reduced need for water and energy consumption during production not only cuts down on operational costs but also aligns with sustainable manufacturing practices.

• Saving energy and water

  Our low-fat corn flour bypasses many of these complex and resource-intensive steps. It directly enters the liquefaction stage,leading to a faster conversion into glucose syrup.

• Automation and monitoring systems

  Real-time tracking of the production process to maintain the quality and safety of the corn syrup.

EQUIPMENT DISPLAY

FINISHED PRODUCTS