Equipment and Systems for Corn Wet Milling

Increase efficiency Better sanitation Reliable product quality from Dorr-Oliver, EIMCO, Krebs and Pneumapress 60+ years of experience

2 Corn Wet Milling Process Flowsheet .

uses standard pumps and has simple instrumentation. quick reversible and totally enclosed design. three stages of DSM screens are used. and Fiber Washing Dewatering and Germ Washing Economical corn wet milling practice requires dewatering of the supply stream ahead of the degerminating mills. Space needed is minimal since units are compact and handle high throughputs. Benefits of Gravity-Fed DSM Screens No maintenance necessary as screen media is rugged stainless steel and there are no moving parts. System’s multi-stage countercurrent flow design assures maximum starch yield. The system consists of six stages of 120 DSM screens. double and triple width configurations for maximum flexibility in system design. engineered feed system distributes feed flow across screen surface with high velocity for highly effective separation. Gravity-Fed DSM Screen Benefits of Pressure-Fed 120 DSM Screens Close tolerance. No fumes and spillage as screens are totally enclosed. For germ washing. Pressure-Fed DSM Screen Gravity-Fed DSM® Screens Dewatering and germ washing are done more effectively with Dorr-Oliver DSM screens. Germ Washing.Dewatering. The DSM screen’s precisely selected screen media and its proven reliability are unmatched by equipment using fragile textiles or thin etched screens. Screens available in single. The DSM screens for these applications are gravity fed over a weir. Also the separated germ must be washed to get a high purity germ product free of starch. High capacity compact design drastically curtails space needed for fiber washing operations. Long service life due to no moving parts. wedge wire screen surface. 3 . A single stage screen is used for dewatering. Requires little operator attention because system is designed for small sumps. it is necessary to wash the free starch from the fiber during processing. while keeping any fiber in the final product to an absolute minimum. The extremely fine separations are possible only with our highly polished wedge wire screen surfaces with openings as fine as 50 microns. with the starch reporting to the undersize. Operation is trouble free due to non-blinding. Fiber Washing To get maximum starch recovery. Pressure-Fed 120 DSM® Screens Most plants accomplish this very economically today with the Dorr-Oliver Fiber Washing System. The pressure fed screens are arranged for countercurrent washing of the fiber. Cascade mounting arrangement of three screens also makes effective use of available space. The wash water flows countercurrently and removes the starch quite efficiently as the germ moves forward from stage to stage. however.

Lightweight construction and shipment as a complete factory assembled package means low cost installation. Specially sized DorrClone cyclones and engineered flow distributions are specifically designed for the magma/ germ separation. Benefits of Starch Washing Hydrocyclones Easy operation because simplified control system uses self regulation of intermediate stages. Totally enclosed design assures clean and fume-free operating area.Germ Separation and Starch Washing Systems Germ Separation After the corn kernels are steeped for softening. These high capacity units incorporate advanced flow channeling with superior materials and layout to save money in installed cost and operating power. Hydrocyclone Starch Washing System A typical Dorr-Clone or Hydrocyclone Starch Washing System consists of batteries of 10 mm cyclones in completely unitized and enclosed housings. high quality starch required in today’s highly demanding marketplace. They have to be removed before a top quality starch can be made. Improved sanitation since system is completely closed and pressurized Low maintenance. The latest in starch washing technology incorporates recently developed highefficiency 10mm cyclones for the Starch Washing System. they are cracked open to release the germ. The germ contains the valuable corn oil. The multistage systems provide easy and precise control of the process. which saves on space. This system has given processors a new standard of process control and sanitation. Capital cost is less because of the system’s compactness. Because of the high centrifugal forces employed. overflow wash water stream. and easy expandability when additional capacity is needed. Easy maintenance and quick replacement of individual cyclone units because of the quick opening couplings. This method serves to eliminate any adverse effects of traces of corn oil in later processing steps. The centrifugal forces needed to make the separation are derived from energy supplied by pumps. The high rotational velocities in the individual cyclones cause the starch to concentrate in the underflow while the suspended gluten follows the . most plants today use Dorr-Oliver’s compact manifolded two-stage Germ Separation System. The germ is separated from the heavier density mixture of starch. Germ Separation DorrClone System Starch washing The starch slurry from the primary separation contains some insoluble protein and much of the solubles. resulting in the uniform. Rapid response to process changes through single instrument control. hulls and fiber essentially by “floating” the germ segments free of the other substances under closely controlled conditions. arranged for efficient countercurrent washing. Modular system design allows easy expansion when production demands dictate. Modern plants are using Dorr-Oliver Starch Washing Systems for this important task. Benefits of Germ Separation DorrClones Maximum germ oil recovery (very low loss of the valuable process fraction). Varying plant capacities can be handled. germ is separated instantly. Starch Washing Hydrocyclone System Manifolded DorrClone Systems To accomplish this critical separation most efficiently. The only moving parts are in the standard centrifugal pumps. The first pass makes a selective separation for optimum purity and the second pass increases germ recovery by capturing any germ that may have been bypassed in the first stage.

Benefits of E-Belt Drum Filters No more blinding problems and greatly improved washing and cloth tracking with the revolutionary swivel roll concept that doesn’t require filter cloth rubber edges. Delivers high rates of filtration and high hydraulic capacity for cake dryness enhancement. Hi Hydraulic capacity Food design for cleaning and sanitation Innovative cloth alignment design Low installation costs and clean working environment due to compact design.Gluten Dewatering Gluten Dewatering Before the gluten moves on to drying it is good practice to dewater the gluten slurry from the gluten thickener. No operator attention required. Its reliable filtration enhances product recovery minimizing protein loss. This is usually accomplished economically on a rotary drum filter with belt discharge. snap-in plastic supporting media and easily adaptable discharge mechanisms. which obviously saves on the energy required to thermally dry a high moisture product. Minimal maintenance Dorr-Oliver Eimco E-Belt Drum Filter Dorr-Oliver Eimco E-Belt Drum Filter Dorr-Oliver Eimco E-Belt Drum Filters for corn wet milling applications have been adapted to meet the industry’s specific needs for corrosion resistance and sanitation Filters are of stainless steel construction and are equipped with streamlined internal piping and valves. 5 .

equipment size. wheat. which minimizes the required filter area. Cake discharge from filter Filter enclosed in sanitary housing The most common throughput sizes for single filters on native starches are in the range of 6 to 25 metric tons per hour dry solids and for modified starch are in the range of 4 to 20 metric tons per hour dry solids. number of moving parts and maintenance downtime Advanced filter media design and effective filter media cleaning provide very clean filtrate Mechanically simple design eliminates consumables such as diaphragms and seals Filter plates are made completely from 316 stainless steel An isolatable plate design provides very high equipment availability Sanitary or industrial design with optional filter housing. Germany.Starch Washing and Filtration Pneumapress® automatic pressure filters were successfully introduced into the starch washing and dewatering process in 1997. industrial and food grade varieties. Pneumapress has recognized this need and created a patented sanitary design option to enable ease of cleaning and sanitization. Significant repeat business and referral sales are indicative of the success of the Pneumapress design. Korea. potato and tapioca starches – including modified. This option incorporates a fully automatic clean in place (CIP) system. The Pneumapress filter can be totally enclosed to prevent product contamination and provide increased safety for those working in the vicinity. structure cladding. The design focus of Pneumapress for the starch industry is to provide a mechanically simple. Pneumapress filters do not require rubber seals or diaphragms. sanitary and efficient filter. The starches processed on the Pneumapress include corn. France and Italy. Since that time. Benefits of Pneumapress Filters Very dry filter cakes with highly effective cake washing when required Highest throughput per unit area of any filter. simplifying the operation and maintenance of the equipment. Thailand. and CIP systems Single-sided cake discharge Low installation costs Pneumapress Sanitary Multi-Module Filter The cleaning and hygiene requirements at food starch plants are becoming more stringent. 6 . This enclosure may be designed in 316 stainless steel to provide the ultimate in sanitary design and safety. the Pneumapress design has evolved to meet the changing needs of the industry and Pneumapress equipment is now installed by the majority of the major starch producers worldwide. Pneumapress filters are installed in starch plants the USA.

The unit’s exclusive scraper design enables the operator to better control removal of impurities with minimum loss of precoat material. Indexing Belt Filter Dorr-Oliver Eimco IBF is one of the many products in our portfolio for vacuum filtration of a wide range of hydrogenated compounds. simply because precoat filters produce the clearest syrups. Dorr-Oliver Eimco Indexing Belt Filter (IBF) Benefits of Pre-Coat Filters Consistently clear and better quality syrup. Dorr-Oliver Eimco Precoat Filter 7 . Longer operating cycles and equipment life. Hydrogenation: Through Catalytic reactions. Revolutionary precoat discharge system electronically control for reduced precoat consumption and longer filtration cycle. Totally enclosed execution for solvent washing Smooth filtration with no particle size modification. The precoat material can be applied to the filter in varying thicknesses and users get longer processing cycles between filter medium replacements. The continuous operation together with a simple mechanical design reduce maintenance offering steady and reliable operation. lowers operating costs. Effective use of precoat. starch can be converted into a wide family of “low calories sugar” used in food and pharmaceutical products. Superior washing efficiency for maximized product recovery. general industry practice is to use a precoat vacuum filter. without waste. and this also keeps operating costs down.Starch Conversion and Hydrogenation Polishing syrup To remove impurities from syrup in the sweetener plant. IBF. Can be readily adapted to meet varying process needs. Dorr-Oliver Eimco’s Precoat Filter features a slow and precise knife advance system that assures the lowest precoat expense without affecting the machine’s high throughput rates. Cleaning in place for complete sanitation. Benefits of IBF Filters Food design. FDA validated.

303 7.02 364. Please contact FLSmidth for specific information or data that may relate to your interests 8 .5 . This brochure makes no offers.144 7.816 28.941 9. Cleland.725 0.0 21.736 20.* 0.024 2.0322 1.43 Lbs Gal 8.467 0.0 1.231 1.1556 1.090 7.936 2.22 2.044 5. = Be deg x 1.024 10.0 14.156 0.531 0.62 1.585 6.946 8.424 18.328 8.32 30.920 0. and information and data contained in this brochure are for general reference only and may change at any time.363 9.11 8.751 8.416 8.566 8.54 28.384 33.849 1.5 18.28 63.784 8.198 7.89 9.596 8.17 3.5 17.390 3.1986 1.424 63.55 12.420 0.065 Lbs Gal 0.150 Temperature Corrections Temperature 67 73 79 85 91 97 103 113 118 123 Add (°Be) .662 9.9 1.7770 Specific Gravity of Starch 1.95 497.84 318.919 5.473 9.776 53.846 0.815 8.335 3.77 15.210 0.75 2.006 0.25 341.88 25.908 7.5 14.283 8.44 21.106 6.22 7.63 2.662 7.5 4.289 0.1 .593 Lbs H2O Lb Starch 111.0 11.630 0.0663 1. troubleshooting.475 8.253 1.93 55.357 8.227 2.0 22.07 11.399 9.1744 1.0782 1.com ©FLSmidth Group 2010.89 397.4 .99 32.824 71.1 These tables are based on the work of J.409 6.586 2.272 13.658 8.820 9.02 2.5 23.32 38.330 0.21 31.008 12.0069 1.66 19.235 0.504 8.161 0.0703 1.2036 1.336 1.114 9.1.051 8.472 Dry Solids Content Oz Gal 1.0 5.0903 1.32 263.28 36.570 1.643 6. 1943 Customer Service FLSmidth is your One Source for spare parts.77 18.688 0.976 32.58 447.30 1.248 36.584 4.99 16.6 Suspension @ 60°F Be 0.982 6.6 .98 330.0396 1.167 0.848 8.56 231.636 4.1888 1.495 0.544 58.1419 1. Fauser and W.440 26.5 16.460 7.95 45.248 8.527 6.98 40.0 8.1500 1.548 9.434 3.149 9.074 0.592 44.1465 1.2086 % D. we deliver it! 9.0 16.737 3.0 19.92 4.192 29. We design and install your processing systems with quality Dorr-Oliver.99 24.5 .76 34.036 6.0 10.62 5.E.590 1.364 4.0508 1.88 17.54 44.49 140.00 8.34 1.15 160.0035 1.32 22.979 9.511 7.523 0.113 2.82 307.0470 1.360 54.25 4.66 27.016 7.0140 1.1071 1.50 1. All rights reserved.0433 1.45 1.0 www.5 24. and operational services.09 39.50 6.36 4.5 7.21 23.672 50.800 6.944 56.1649 1.5 10.609 0.381 0.982 10.859 7.725 5.303 0.160 39.33 3.756 2.790 5. Krebs and Pneumapress equipment.52 2.02 472.5 25.16 180.E.901 9.75 1.534 3.0358 1.33 6.586 9.1375 1.376 0.89 1.139 3.78 2.0 3.384 3. and commissioning of new plants.14 387.289 6.702 9.25 Gal H2O Lb Starch 13.13 2.616 47.0 6.0 4.0 2.55 4.385 2. asset management.11 522.363 0.09 170.33 14.79 296.477 2.0 18. maintenance.66 3.346 0.662 2.5 21.65 253.224 0.1199 1.203 2.65 43.468 6.752 66.23 8.96 120.675 0.880 8.437 6.957 7.104 42. Vol. Analytical Edition.66 7.55 20.294 2.77 26.861 9.49 484.52 376.042 3.763 7.18 54.0211 1.453 0.556 0.251 7.32 91.80 460.89 1.808 35.1791 1.048 21.15 21.5 15.780 0.04 5.1286 1.151 4. Indeed.0176 1.79 101.676 1.256 9.0547 1.10 31.38 7.10 23.81 1.48 435.013 9.812 7.98 274.713 7.S.39 1.108 1.65 35.004 7.0624 1.5 22.758 6.436 9.5 13.25 9.356 7.0822 1.0 12.000 0.180 0.267 0.871 6.63 72.5 2.926 6.080 25. process and mechanical analysis.54 36. pp 193-200.386 8.50 3.1696 1.67 130.624 9.3 .77 10.096 45.184 2.5 8.23 411.257 4.66 11.88 33.5 3.44 5.300 0.68 1.510 9.34 190.767 0.316 0.10 15.720 24.256 0.327 9.5 20.0862 1.145 8.720 8. all the time.0742 1.22 15. Fetzer.1330 1.409 7.87 17.98 82.845 0. E.2 .0 7.277 0.0 1.5 5.S.981 5.072 64.0248 1.400 0. representations or warranties (express or implied).291 9.0 23.591 0.047 4.0585 1.946 3.816 16. Our experts provide the tools to ensure that your systems continue to operate at optimum levels.53 200.99 242.5 Sp Gr 1.536 14.5 11.5 19. It is by no means a radical concept. 15.0 9.41 2.1840 1.88 2.613 7.814 6.781 9.851 2.379 1.0105 1. equipment installation.85 26.84 35.5 6.57 27.93 535.1937 1.170 0.7 .38 110.56 1.416 68. EIMCO.0944 1.420 1.89 285.31 2.76 Water Content Lbs H2O Gal Susp 8.236 3.224 51.32 150.63 353.63 4.099 8.552 Gr Gal 518 1043 1568 2100 2632 3171 3717 4263 4816 5369 5922 6482 7049 7623 8197 8771 9352 9940 10535 11130 11732 12334 12943 13552 14168 14791 15421 16058 16695 17339 17983 18634 19292 19957 20622 21294 21973 22652 23345 24038 24738 25445 26159 26873 27594 28329 29057 29799 30548 31304 Gm Liter 8.626 8.741 9.43 37.0 20.41 510.080 9.535 8.443 0.0 13.5 1.1242 1.133 1.762 1.69 3.96 1.942 4.237 8.376 22.689 8.792 61.260 2.60°F *% D.007 1.87 41.220 9.174 0.496 9.1028 1.0 24.04 6.047 9.744 11.136 48.0000 1.701 6.76 42.49 423.Baume Conversion Tables for Starch Suspensions .07 13. everyone promises it.854 5.12 3.505 1.228 6.584 30.635 3.1602 1.445 8.660 5.54 17.809 1.0986 1.192 8.194 0.245 0.562 7.185 9.149 0.R. See Industrial and Engineering Chemistry.0 0.0285 1.202 0.71 211.00 0.44 13.089 1. Our Customer Services provide a wide range of services for food processing equipment and systems including process design.350 6.569 2.914 8.49 10.168 6.1156 1.171 1.FLSmidthMinerals.0 17.43 29.632 41.112 69.5 12.21 39.0 15.839 3.112 17.160 59. service.926 1.328 8.04 1.187 0.14 221.1114 1.89 3.704 38.

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