Malt syrup preparation process
2018-09-12 / FAQ
Maltose syrup is produced from yellow dent corn or rice, broken rice, all kinds of starch etc.
Below mainly introduce the malt syrup preparation process from Doing Company:
The first step of malt syrup preparation process is mixing starch slurry.
Mixing starch and certain water to get the certain density slurry, then adding certain enzyme, and maintaining a certain temperature for particular time to make sure the proceeding of physical reaction between starch and enzyme.
Malt syrup preparation
The second step of malt syrup preparation is continous liquifaction
Pumping starch slurry into the mixing tank, there could be some brown floater appearing on the surface of mixing tank, which is likely to be caused by high protein content. It will cause high dosage of activated carbon, increasing the load of ion exchange, and reducing the service life of ion-exchange resin, so we must ensure that the starch milk protein content is below 0.5% in the process of malt syrup preparation. In order to make full use of the mother liquor, the part starch milk can be recycled in the mixing slurry process, and the normal return amount can reach up to 2/3. The overuse will affect the quality. Average concentration is 35% - 36%. Mixing temperature is 29 ℃ -34 ℃ . Then pumping starch slurry into the ejector.
The third step of malt syrup preparation process is sacchrification.
The liquefied liquid (solid content of 30% -35%) is pumped to the saccharification tank and cooled to 60 ° C. Adding acid to adjust the pH to around 4.5. The brix is 31-32Bx; the adjusted concentration is 34.67% -35.6%; adding the saccharification enzyme is equivalent to 0.45-0.58L / ton dry starch. The liquefied liquid DE value is 28.85% -31.53%, the pumping time is 4-6 hours for one tank. Each tank of saccharification time is 50 hours to make malt syrup preparation process. The DE value is about 95-97 when finished. The saccharification liquid is pumped into the pre-coated perlite drum filter to separate protein, and then entering the third time injectors for enzyme deactivation after saccharification. The third injection temperature is about 99℃; the injection pressure is 0.39Mpa; and the saccharification liquid yield is about 98% -105%.
Malt syrup preparation machine
Forth, then, it will be decolor and decarbon process.
The normal sequence in this section for malt syrup preparation is:The first decolorization→the first decarburization→The second decolorization→the second decarburization.
The saccharification liquid will be pumped into a decolorization tank for malt syrup preparation process, adding the waste activated carbon of the second plate frame filter pressing then killing enzyme and decolorization for 30 minutes. Then pumping the discolored syrup liquid into the first plate frame, the activated carbon will be filter out. Pumping the first discolored syrup liquid into the second decolorization tank, adding new activated carbon, decolorization for 30 minutes. The second decolored syrup liquid is subjected to plate and frame filtration, and then it will be pumped into the ion exchange system storage tank through the plate heat exchanger.
The fifth step is removing the impurities
This process aims to remove the impurities and different ions to ensure the purity of syrup, made by DOING ion exchange column in the process of malt syrup preparation. Normally, it needs the anion-cation process, pump the discolored syrup liquid into the storage tank, keep the temperature about 30 ℃, And then pump the liquid syrup into the cation exchange column to remove the Ca2+ and Mg2+ etc; and then pump syrup into the cathode column to remove the negative ions. Finally pump the syrup into the adjusting pillars for conductance and pH adjustment for malt syrup preparation process.
Malt syrup processing plant
Lastly, Getting the final maltose syrup:
After ion exchange, the syrup will be pumped into the storage tank(full stainless steel), after heating exchange and then enter into the evaporator. Evaporator commonly used multiple-effect evaporator for example three-effect etc. Pump the ion exchange liquid syrup into the three-effect evaporator. The first effect evaporator vacuum degree is 0.01-0.03Mpa, the temperature is about 105 ℃, the second-effect evaporator vacuum degree is 0.015-0.028Mpa, the temperature is 84 ℃-90 ℃, the third-effect evaporation vacuum degree is 0.04-0.05Mpa, the temperature is 55℃-60 ℃ etc. After evaporation for malt syrup preparation process, it will be the high density liquid syrup according to the requirement.
Finally, any questions for malt syrup preparation process, please conact us freely. By the way, except malt syrup preparation machine, we also supply complete set of machines for glucose syrup and high fructose syrup preparation.
Below mainly introduce the malt syrup preparation process from Doing Company:
The first step of malt syrup preparation process is mixing starch slurry.
Mixing starch and certain water to get the certain density slurry, then adding certain enzyme, and maintaining a certain temperature for particular time to make sure the proceeding of physical reaction between starch and enzyme.
Malt syrup preparation
Pumping starch slurry into the mixing tank, there could be some brown floater appearing on the surface of mixing tank, which is likely to be caused by high protein content. It will cause high dosage of activated carbon, increasing the load of ion exchange, and reducing the service life of ion-exchange resin, so we must ensure that the starch milk protein content is below 0.5% in the process of malt syrup preparation. In order to make full use of the mother liquor, the part starch milk can be recycled in the mixing slurry process, and the normal return amount can reach up to 2/3. The overuse will affect the quality. Average concentration is 35% - 36%. Mixing temperature is 29 ℃ -34 ℃ . Then pumping starch slurry into the ejector.
The third step of malt syrup preparation process is sacchrification.
The liquefied liquid (solid content of 30% -35%) is pumped to the saccharification tank and cooled to 60 ° C. Adding acid to adjust the pH to around 4.5. The brix is 31-32Bx; the adjusted concentration is 34.67% -35.6%; adding the saccharification enzyme is equivalent to 0.45-0.58L / ton dry starch. The liquefied liquid DE value is 28.85% -31.53%, the pumping time is 4-6 hours for one tank. Each tank of saccharification time is 50 hours to make malt syrup preparation process. The DE value is about 95-97 when finished. The saccharification liquid is pumped into the pre-coated perlite drum filter to separate protein, and then entering the third time injectors for enzyme deactivation after saccharification. The third injection temperature is about 99℃; the injection pressure is 0.39Mpa; and the saccharification liquid yield is about 98% -105%.
Malt syrup preparation machine
The normal sequence in this section for malt syrup preparation is:The first decolorization→the first decarburization→The second decolorization→the second decarburization.
The saccharification liquid will be pumped into a decolorization tank for malt syrup preparation process, adding the waste activated carbon of the second plate frame filter pressing then killing enzyme and decolorization for 30 minutes. Then pumping the discolored syrup liquid into the first plate frame, the activated carbon will be filter out. Pumping the first discolored syrup liquid into the second decolorization tank, adding new activated carbon, decolorization for 30 minutes. The second decolored syrup liquid is subjected to plate and frame filtration, and then it will be pumped into the ion exchange system storage tank through the plate heat exchanger.
The fifth step is removing the impurities
This process aims to remove the impurities and different ions to ensure the purity of syrup, made by DOING ion exchange column in the process of malt syrup preparation. Normally, it needs the anion-cation process, pump the discolored syrup liquid into the storage tank, keep the temperature about 30 ℃, And then pump the liquid syrup into the cation exchange column to remove the Ca2+ and Mg2+ etc; and then pump syrup into the cathode column to remove the negative ions. Finally pump the syrup into the adjusting pillars for conductance and pH adjustment for malt syrup preparation process.
Malt syrup processing plant
After ion exchange, the syrup will be pumped into the storage tank(full stainless steel), after heating exchange and then enter into the evaporator. Evaporator commonly used multiple-effect evaporator for example three-effect etc. Pump the ion exchange liquid syrup into the three-effect evaporator. The first effect evaporator vacuum degree is 0.01-0.03Mpa, the temperature is about 105 ℃, the second-effect evaporator vacuum degree is 0.015-0.028Mpa, the temperature is 84 ℃-90 ℃, the third-effect evaporation vacuum degree is 0.04-0.05Mpa, the temperature is 55℃-60 ℃ etc. After evaporation for malt syrup preparation process, it will be the high density liquid syrup according to the requirement.
Finally, any questions for malt syrup preparation process, please conact us freely. By the way, except malt syrup preparation machine, we also supply complete set of machines for glucose syrup and high fructose syrup preparation.
