Starch and By-Products

ÇEMSAN BUILDS TURN KEY CORN MILLING FACTORIES

CORN PROCESSING INDUSTRY

Commercially corn is one of the most valuable cereal in the world as the main raw material for corn processing industry. According to the statistics total amount of corn grown in the world is about 620million tones and only 10% of which is being used in industry.

The main product of corn processing are natural starch and derivatives of starch like modified starch, dextrins, glucose and fructose. These products are used as raw materials in production of foods like chocolate, confetties, gums, soup, bread, all sweet foods like cakes and pies, ice cream, jam and breweries. Beside these, the demand for starch and sweeteners in textile, paper, chemicals, pharmaceuticals and adhasive industries is also increasing rapidly in all over the world.

By-products of corn processing are also value-added commercial goods in markets. Corn germ, used as main raw material for corn oil production, corn fiber and corn protein consumed mainly in feed industry.

The rapid improvements in processing technologies decreasing losses, leading better separation of products and by-products. Continuous flow processing applications and automation increasing the capacities by using smaller equipments, machines and less labourer. Nowadays, parallel to this processing techniques market researches and feasibility searches indicating that either plants having huge capacities or compact plants near market can be higly profitable.

ÇEMSAN - EXPERIENCED TEAM IN

STARCH AND SWEETENERS FOR MORE THAN 20 YEARS

Çemsan's Engineering Unit is making all projects of all units of Corn Milling Processes one by one or as total plant with process guaranty.

Çemsan is in Corn Wet Milling Industry for more than 20 years. We are supplying many special equipments for this sector like grind mill, germ press, fiber press, dewatering screen, germ separation cyclone unit, germ wash screen, fiber wash screen, conveyor, mixer, agitator, tank, silo, tube drier, flash drier unit, evaporator unit, demineralisation unit, multi cyclone separation unit, reactors, starch conversion unit, filter, vacuum filter, fermentation saccharification tanks, flash cooler unit, isomeric fructose conversion unit, glucose and fructose storage and transfer unit and special projects depending on customer needs.

WHAT WE CAN DO FOR YOU !!!

Çemsan supplies

. Projects and calculations

. Technical Drawings and P&ID's

. Manufacturing and supply of all equipments in process

. Planning

. Installation, piping, steel construction and expertising

. Electricity, cabling and automation plans, supplies and expertising

. Education of staff in terms of all process, QC, QA, planning, reports etc

. Support in preparation of instructions or direct supply

. Commissioning

. Continuous support after start-up, process checks and educations

After installation of process and supply units accordig to the information in projects , the only thing for you to do is to gather the necessary local staff. Çemsan will help you in all ways.

We well knows that these kind of big projects makes people in companies to work together instead of buying and celling to each other.

Çemsan works WITH YOU .

STEEP HOUSE

STEEPING

Steeping unit is the kitchen of wet milling plants where corn is cooked in big bed reaktor type tanks.

Corn kernels are being softened by mill water in Steep Tanks. During this process the soluable minerals and proteins in kernel passes into water while starch and protein matrix softens, bonds between fiber and kernel gets weak. This processes controlled by means of chemicals added to steep water. Typical moisture charactheristics of corn is shown in table 1

After the softening step completed steep water, called as light steep water, LSW, pumped to Steep Water Evaporator while the soft corn transferred to First Grind Mill Dewatering Screen.

Çemsan prepares, installs and runs the projects of Steep House for any corn grinding capacity including the heater, circulation and corn transfer systems, tanks, conveyors.

STEEP EVAPORATORS

In earlier times the corn steep liqueur, CSL, was drained into sewer plants. This was causing environmental problems and huge amount of mass losses. Normally about 6 - 7 % of total mass of corn processed is passing into steepwater. Now, in all over the world light steep water is boiled in Steep Evaporators to produce Heavy Steep Water, HSW, that has high amount of proteins and minerals. This HSW is than added to corn fiber that is increasing the protein content of fiber.

Steep Water Evaporators can be as plate evaporators, co-current circulation evaporators depending on choices.

( Steep Water Bome cizelgesi elden verecegim . Ondan bu araya ilave etmekte fayda var . )

CORN DEWATERING SCREENS

Corn dewatering screens are employed for conditioning of corn mills. These are gravity screens on which either wire type or perforated metal plate type screen susfaces can be used as filtration media.

Dewatering gravity screens are available in all stanrardised sizes for the sector.

GRIND MILLS GERM SEPARATION

After steeping, the softened corn grinded in first and second grind mills to break the kernel and release germ out of corn. In corn milling process special design teeth-disk type de-germination mills are used that Çemsan also manufacture in various dimensions for differant capacities. These mills breaks softened corn into parts while germ remains as whole. Beside germ, fiber is also important in this step, the amount of fine fiber particles after mill should be as less as possible which achieved by design of mill and also by adjusting the process conditions carefully according to instructions supplied by Çemsan.

Germ, that has lower specific gravity than other components, is separated by hydrocyclones specially designed for liquid phase. Typically separation occured in 2 steps and each step has 2 serial groups. New technology manifolded germ cyclones maintains good seperation. Hardened stainless steel or special plastic germ separation cyclones available, both has longer lifetime. Germ has higher price than other by products in markets so the efficiency of separation is important. Efficiency is directly related with design and processing conditions.

Typical efficincies in our systems are in table--

Corn quality is no1 US corn for wet milling process.

GERM WASH GERM DEWATERING

Typically, germ is washed in 3 step germ wash screens to separate the starch remaining in the fluid from germ cyclones. Wire or perforated types can be used for germwash to prepare the germ for germ dewatering press. These compact gravity screens are easy to use and needs no maintenance. Germ press drops the moisture of germ for less steam consumption in germ drier. For different capacities Çemsan producing dewatering presses and their spare parts like special tubular screens, screw of press and others.

3rd GRIND MILLS

Third grind mills are used for breaking the starch and protein blocks binded on fiber particles that were primarily broken in degermination mills. In some applications horizontal centifugal force type mills and in some applications special design vertical corn mills are prefered.

The mills and their consumables are all available in differant sizes. Çemsan supplies equipments and service.

FIBER WASH SCREENS

Starch recovery is the main goal of Wet Mill Processes. For this aim fiber wash system has great importance in terms of efficencies. In multiple stage forced flow fiber wash screens the starch sticked on fiber and the free starch in fluid washed by process water. There are many Çeman's 120 DSM Fiber Wash Screen housings equipped with standart wire type tilted screens with size starting from 50 microns working in many plants in this sector. Depending on capacities wide and narrow screens are available.

STARCH SEPARATION & GLUTEN THICKENERS

Separators are the heart of the wet milling process. In the first step starch is separated primarily from suspension containing starch protein and water. This is called as primary separation and the centrifuge separator employed for this action is called as Primary Separator.

At the second step the the excess water mixed with gluten removed by centrifuge separator to prepare heavy gluten for vacuum filtration. Gluten thickeners are very important for the factory since they are producing process water that is the carrier fluid for all factory.

For higher capacity corn starc processes additional separators are installed, like Mill Stream Thickeners, MST Separators and Clarifier Separators. MST is used to share the load on Primary Separator and Gluten Separators by separating the excess water coming from the mills ad fiber wash pool tank. Clarifier Centrifuge Separators are used to increase the boume of over flow coming from starch hydrowash systems. For smaller sized plants it more profitable, in terms of fixed and operational costs, to use single primary separation and gluten thickener units.

We, as Çemsan, are giving majority on using the best quality and well known separators in all of our projects. We are always keep in close contacts with these suppliers to follow the changes and to be able to help our partners as soon as possible in the proper way. Çemsan arranges education and regular control programs for processing, maintenance and spare parts for you.

STARCH WASHING

Starch hydrowash is a set of mini cyclonettes used for washing the starch slurry by clean water to remove the protein remining in starch solution after primary separation. There are many small cyclonettes used in multistage washing system. Typically 11-13 steps employed to achieve the desired protein levels.

Typical starch quality parameters can be seen in table ---

Table -- Typical charaktheristics of Starch Slurry

Boume vs dry substance can be seen in table ---

For all capacities starch wash systems are available. There are compact pre-configured starch hydrowash units that is easy to install. You may connect four pipes and electricity to pumps, than start process tests. There are also full compact systems including filters, cooler and main electricity board that only thing you have to do is to connect 4 SS and 2 CS pipes and main electricity cable.

DRIERS

Usually corn germ gluten, fiber and corn steep liqueur, CSL, are dried in Rotary Tube Drier.

These systems are running with circulation conveying and mixing systems to prevent roundish lump formation and also to prevent the product to stick over the heating coils of drier. Çemsan's rotary tube driers, various types of conveyors and mixers are in use for more than 20 years in this sector in many corn milling plants. We are also manufacturing aspiration and dust collection system includig dust cyclones.

STARCH DEWATERING & STARCH DRIERS

Dewatering systems saves money, efficiency of your system directly influencing the manufacturing costs.

Before drying the starch the excess water in the starch slurry is removed to drop moisture typically to 35 % by means of Rotary Drum Vacuum Filters or Basket Centrifuges. Çemsan prepares the projects, makes choices, supply, installation and comissioning of whole starch dewatering unit suitable for your capacity and needs.

Starch driers are fire and explosion exproved flash drier units. Dewatered starch is dried in starch drier. Çemsan has own designed Starch Flash Driers in various capacities starting from 20 tones per day up to 200-250 tones per day starch production. We may also supply each item separately, like stainless steel conveyors, vortex cyclones, kicker mills, steam hot box with heater cassettes, all suitable for starch applications and for other flash drier applications.

MODIFIED STARCH