Maltodetxtrin production line(Glucose, Maltose and Maltodetxtrin production line)

DESCRIPTION

Use different kinds of refined starch, such as corn starch, wheat starch or cassava as raw material to produce glucose or malt dextrin by the methods of acid hydrolysis or enzyme hydrolysis.

Acid hydrolysis is to produce some colorful material or non-fermentable sugar easily, because of adverse effect, in practice this method is stopped. We provide plants with enzyme hydrolysis to produce glucose or malt dextrin.

Theoretically, when DE value is less than 20%, i.e., reducing sugar contents is less than 20%, it is called as malt dextrin. But in daily use, the separation is not very clear.

Process description

ⅰ. Liquefaction

Glucose amylase used for saccharifying is kind of exoenzyme, hydrolysis from substrate molecules non-reducing end. In order to increase the chance of maltogenic amylase, speed up the reaction of saccharifying, it is necessary use а-amylase make the macromolecular glucose hydrolyze into maltodextrin and compound sugar. But the crystalline structure of starch particles has strong resistance of the enzyme. For example, the speed proportion between bacterial a-amylase hydrolyze starch particles and the hydrolyze starch is 1:2000. Because of this, it doesn't allow amylase directly act on starch, starch milk needs to be heated first, then the starch hydrate and expand, past and destroy their crystalline structure.

(ⅰ). Gelatinization and aging

If the starch milk is heated into a certain temperature, the starch particles begin to expand and polarized cross would disappear. With the temperature becoming higher, starch particles continue to expand to several times bigger or scores times bigger of the original volume.As particles expanding, the crystalline structure would disappear; then the particles contact each other because of the expanding volume, finally, it becomes gelatinous liquid. Even the stir stops, the starch would no longer deposit, this phenomenon is known as gelatinization. Generated sticky liquid is known as starch paste, and the temperature in the progress is the gelatinization temperature.

Starch aging is actually the progress that the gelatinized starch intermolecular hydrogen bond has been broken and rearranged to form a new hydrogen bonding process is a complex crystallization process.

(ⅱ). Liquefaction

Liquefaction has many methods, and factories can choose the best from these according to their own production condition, generally, the most ideal way is jet liquefaction. When the vapor pressure ≥0.8Mpa, you can choose the high pressure steam jet liquefaction process; when steam pressure ≤0.5Mpa, you can choose low pressure jet liquefaction. The jet liquefaction process is divided into the once-enzyme-adding technology and twice-enzyme-adding technology.

If generated glucose and fructose syrup product, take potato as raw materials to do enzyme process. Take corn&wheat starch, if the starch quality is good(protein ≤0.3%), you may add enzyme once, which is easy and can save steam; and liquid with light color applies to one kind enzyme. If the starch of corn or wheat is in poor quality(protein >0.6-1.0%), adding this kind of starch would age starch and generate insoluble starch granules. So there should be high protein in the raw material and adding enzyme two times to make the material completely liquefied.

ⅱ. Scarifying

When the liquefaction is finished, quickly adjust the solution's PH to 4.2~4.5, at the same time cooling down to 60ºC, then add scarifying enzyme, keep the temperature 60 ºC. Keep stirring to prevent uneven scarifying, add anhydrous alcohol and make them react fully, then inspect them, if finding that there's no maltodextrin, adjust the PH value to 4.8-5.0, and heat the solution to 80ºC, keep the temperature at 20 minutes, and then filter. Store the liquid in filtered solution into the storage tank, keep above 60ºC temperature for further use.

ⅲ. Filtering

After starch saccharifying, DE could be up to 98% (varies as per the configuration and customer's requirements), but the starch hydrolyzed, it also takes insoluble impurities and ashes, fat, protein and so on, meanwhile in the procedure of hydrolysis, add some impurities, if we add acid, may bring inorganic salt, add enzyme, bring protein, in the procedure of decomposition, generate amylose and oligose, generated 5-HMF in the secondary reaction and other colorful materials and so on, they need to be refined, so to improve the quality of glucose and quality of finished products. Therefore after saccharifying, it is necessary to make filtration. After inspection with anhydrous alcohol and find that there’s no maltodextrin, stop Saccharifying, adjust PH4.2~4.5 to 4.8~5.0, and heat up to 80ºC, keep for 20 minutes, then start filtering. There’re different kinds of filtering ways: plate and frame pressing filter, rotary vacuum drum filter, membrane filter, and centrifuge etc. Balancing the operation cost, investment, and quality of product, we normally use plate and frame pressing filter.

ⅳ. Decoloring

Decoloring the saccharified liquid of enzyme method is normally to adjust the PH around 4.8, The enzyme is kind of protein itself, the solution's PH is close to the protein isoelectric point, there is many suspended substances, many factories first use drum filter, which is made by diatomite pre-coating, or add used active carbon filter to remove the protein, fat and impurities, then do decoloring. The color of the saccharified liquid with enzyme method is light, we normally use twice decoloring with active carbon, and then do Iron Exchange (IX). Or sometimes not use active carbon for decoloring, but drum filter directly and then go for Iron Exchange.

Changzhou Yibu Drying Equipment Co., Ltd. is a leading manufacturer of drying, mixing, and granulating equipment in China, a specially-designated enterprise of China Association for Pharmaceutical Equipment (CAPE) and China General Machinery Industry Association (CGMA) Drying Equipment Branch. The factory covers an area of over 50,000 m2, has fixed assets of CNY 35 million, with more than 180 sets of special processing equipment and strong technical force. The company owns the provincial famous trademark of "YIBU", and has passed the ISO9001 & ISO14001 certifications.
The founder, Mr Zha Guocai has devoted more than 30 years in R&D, production and business of drying equipment. He holds the post of Deputy Director-General of China General Machinery Industry Association (CGMA) Drying Equipment Branch for a long time. The company pays great attention to science and technology innovation, has collaborated with Medicine Design Institutes in Shanghai, Wuhan, Chongqing and other places, Shenyang Chemical Research Institute, Qinghua University, Shanghai Jiaotong University, Dalian University of Technology, etc. The company launched 3-5 new products to the market every year. In 1998, YIBU established "China Research Center of Drying and Granulating" with the approval of relevant state department, and cooperated with pharmaceutical, chemical and food industries to research and develop new technologies related to drying, granulating and mixing, etc. The factory also has a variety of test prototypes in the laboratory for customers' trials.
The company sold equipment to USA, Mexico, Columbia, Guatemala, Brazil, Peru, Australia, New Zealand, Ghana, Russia, Cyprus, Greece, Iran, Indonesia, Philippines, Korea, Japan, Taiwan, Hong Kong and other countries.