Corn Syrup Production Line

Description:

The Syrup Production Equipment is designed and manufactured by nanyang sinowin industry to efficiently produce high-quality syrup. The production of the syrup process includes several stages, each optimized for accurate control and automated operation:

1) Starch Milk Adjustment: Starch milk from the starch production workshop enters the starch milk adjustment tank, where the flow rate, DS (dry solids), pH value, and enzyme flow indicators are monitored and automatically adjusted. The adjusted starch milk is then pumped to the liquefaction injector.

2) Liquefaction Injection: The imported liquefaction injector rapidly heats the material using steam injection to reach temperatures of 108-110°C. This instant heating causes the starch milk to gelatinize, reducing its viscosity. After initial enzyme action in the retention column, the starch milk and enzymes are flashed and cooled in the flash evaporator, maintaining the appropriate liquefaction reaction temperature. The liquefaction process takes approximately 90-120 minutes. The resulting liquefied syrup has a DE value of 12-18, clear appearance, and excellent protein flocculation.

3) Saccharification: The liquefied syrup from the flash evaporator passes through a plate heat exchanger to control the temperature precisely before entering the saccharification pH adjustment tank. pH is automatically controlled online, and the proper amount of enzymes is added. Saccharification occurs at temperatures of 55-60°C for a duration of 24-48 hours.

4) Plate and Frame Filtration: After saccharification, the solution is sent to a plate and frame filter press to remove insoluble protein residues and other solid impurities. By using separate plate and frame filters for turbid and clear solutions, the filtration efficiency is improved, and energy consumption is reduced. The resulting sugar residues can be dried and used as animal feed.

5) Membrane Filtration: The glucose saccharification liquid, prefiltered through the plate and frame filter press, enters the membrane filtration system. Under pressure, glucose and water permeate through the membrane surface, forming a dialysate, while larger molecules such as proteins, fats, and pigments are retained, resulting in a concentrated liquid. The concentrated liquid undergoes multiple stages of membrane filtration to form a concentrated syrup, which is then returned for further filtration with the plate and frame filter press. The dialysate proceeds to the next processing step. The equipment utilizes imported spiral-wound membrane cores specifically designed for efficient sugar liquid filtration, with excellent performance, high temperature resistance, and strong anti-pollution ability. The equipment operates continuously with high automation levels, including online automatic cleaning.

6) Ion Exchange: Ion exchange is conducted for decolorization, deodorization, and desalination of the syrup, aiming to enhance the syrup boiling temperature. The glucose ion exchange system adopts a packed bed process with countercurrent feeding and two operational groups, one running while the other is in regeneration standby. The system features high self-control, high operational efficiency, and low regeneration agent consumption. The post-ion exchange syrup is colorless and transparent, with no saltiness, bitterness, odor, or off-flavors; pH value: 4.6-6.0, conductivity ≤50us/cm.

7) DE96 Evaporation: The equipment incorporates a four-effect falling film evaporation system, fully utilizing waste heat generated from the liquefaction and flash evaporation stages to further reduce energy consumption. Key performance advantages include a high concentration ratio, stable post-evaporation material concentration, and the use of a heat pump for evaporation, saving steam. The glucose concentration of the discharged syrup is ≥45%, meeting the requirements for isomerization.

8) Isomerization: Fixed-bed immobilized isomerase enzymes are used to convert glucose to fructose, yielding F42 fructose glucose syrup. Precise control of isomerization parameters such as pH, temperature, and the addition of magnesium sulfate and sodium metabisulfite helps maintain enzyme activity and extend enzyme lifespan.

(9) F42 Fructose Ion Exchange: This equipment is designed to desalinate F42 fructose glucose syrup after isomerization (mainly removing MgSO4 and Na2S2O5 added during isomerization). The device adopts the full bed process, operates in a countercurrent manner, and has two operating groups with one group on standby for regeneration. The system is equipped with sensors, flow meters, and control valve groups, which enable online monitoring and control. With high self-control ability and operational efficiency, the equipment minimizes the consumption of regenerants. The pH value of the syrup after ion exchange is 4.0-5.0, conductivity ≤20us/cm, and light transmittance ≥98%.

(10) F42 Fructose Concentration: After isomerization, the F42 fructose glucose syrup is concentrated to 60% before entering the chromatographic separation section. Our equipment features a multi-effect falling film evaporation system, ensuring a high concentration ratio and stable concentration after evaporation. The adoption of heat pump evaporation saves steam. The concentration of the discharged glucose is ≥60%.

(11) Chromatographic separation: Chromatographic separation is a method that utilizes the different migration velocities of various components in separation resins to separate the mixture components. The separation process of F42 fructose glucose syrup involves the adsorption of fructose molecules by resin ions due to their binding with Ca2+, resulting in a longer retention time. Glucose molecules, on the other hand, have a shorter retention time since they cannot bind with Ca2+. Hence, using water as an eluent can separate fructose with higher purity from F42 fructose glucose syrup. Our chromatographic separation equipment utilizes imported uniform resin particles and the SSMB (sequential simulated moving bed) technology, enabling fully automated operation. It has advantages such as low water consumption and high fructose recovery rate (F≥90%).

(12) F55 Fructose Mixing Bed Ion Exchange: F42 fructose and chromatographically separated F90 fructose are mixed in a mass ratio to produce F55 fructose. The ion exchange resin's adsorption capacity is utilized to further remove pigments, organic salts, and inorganic salts from the fructose, thereby reducing conductivity. After mixing bed ion exchange, the pH value of the syrup is 3.7-4.2, conductivity ≤10us/cm, light transmittance ≥99.5%, color ≤10ICU, and it has no off-flavors. The shelf life of the finished product is ≥12 months.

(13) Deodorization Filtration: Our equipment employs a plate and frame closed filtration machine to remove color and flavors from the F55 fructose syrup obtained after mixing bed ion exchange. It effectively removes organic impurities from the syrup, improving the light transmittance of the final product. Our compact filtration machine is easy to operate, with automatic cake discharging, and requires only a small amount of filter aid, resulting in low filtration costs.

Nanyang sinowin industry supply the syrup production technology to maximize your manufacturing efficiency and satisfy the high-quality syrups production. our syrup production line ensures consistent and reliable results and is suitable for industrial-scale production.please contact and consult sinowin industry for your syrup production engineering now.