Glucose Plants

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Vogelbusch Glucose Technology

Glucose, also known as dextrose, is a natural sweetener, which is obtained from starch containing plants such as corn, wheat, rice and cassava.

As a liquid intermediate product, glucose syrup serves as a feedstock for fermentation processes and it can be further processed to gain sorbitol or fructose. Crystallization of glucose syrup produces dextrose anhydrate or monohydrate, which are used in foodstuff as a sweetening agent, and in medical applications.

Starting out from starch milk, we design and supply plants for the production of liquid and crystalline types of glucose.

For key figures for glucose plant construction

CHECK OUT OUR » FAQ's

Block diagram

Vogelbusch process for glucose production from starch milk

Starch is processed into glucose, a high DE (dextrose equivalent) starch sugar, that can be further processed into other types of starch sugar and to biobased chemicals.

Conditioning of starch milk

RAW MATERIAL PREPARATION

The feedstock for glucose production is starch milk at a purity ranging from 98 to 99 % of starch in dry substance.

Starch mixed with process water is buffered in a starch milk vessel to allow homogenization of the starch slurry.

Hydrolysis

BIOREACTION

Conversion from starch to sugar is carried out as a two-step enzymatic process.

In the liquefaction step, the starch slurry is treated with enzymes and fed to a jet cooker, where the starch is pre-liquefied. This solution is cooled down in an expansion vessel and placed in an intermediate storage tank for final liquefaction.

In the saccharification tanks, further enzymes are added to convert the dextrin into glucose and minor amounts of higher sugars (maltose, isomaltose, maltotriose etc.). By carefully selecting the process parameters, DE values of up to 98 can be reached within 30 - 60 hours of saccharification time.

Purification

PRODUCT ISOLATION AND CONCENTRATION

For the separation of suspended particles such as fibers and proteins Vogelbusch offers a broad range of filtration technologies. State-of-the-art cross flow membranes can be employed with the aim to recover the separated solids as a valuable animal fodder. Filter presses, vacuum drum or disk filters still form a cheap alternative and hence are widely used mainly for processing low DE syrups.

Deashing of the filtered solution is done in a pair of strong acidic and weak basic ion exchangers. Color bodies and foreign tastes are reduced to a minimum by activated carbon treatment. This is done either by passing through vessels filled with granular activated carbon or by suspending and subsequent filtering of the activated carbon powder.

To concentrate the solution, a finely tuned system of multiple effect plate type or falling film evaporators is deployed. It is heated by steam and powered by mechanical or thermal vapor re-compression, thus ensuring utmost energy efficiency in combination with minimal thermal stress for the product.

The final dry substance content is adjusted to the market demand, or to the subsequent processing steps.

Biotechnological complexes

GRAIN PROCESSING FACILITIES

Glucose is only one of many compounds in the starch sweetener and fermentation business.

Besides starch milk and sweeteners, grain processing facilities additionally can include the production of a whole range of valuable products and by-products such as

Dry native starch
Dry protein fraction (gluten)
Germ fraction
Dried and pelletized animal fodder
Modified starch and other upgraded starch products
Fermentation products

We understand the interaction among substrate, bioconversion, recovery and purification and can assist you in developing your complete grain-processing project, from raw material selection through to the final product range.

Contact us for

Pre-engineering and feasibility studies including comparison of different product scenarios
Determination of the most suitable technical solutions and equipment for drying, filtration, evaporation, ...
System integration of all involved technologies (dry milling, wet milling, starch processing, product drying, ...)

More about » Cross Integration Services

Production of biobased chemicals

FURTHER PROCESSING

Besides the production of glucose syrups, dextrose, high fructose syrup and sorbitol, glucose serves as a carbohydrate source for the fermentation of biochemicals such as

Amino acids
Organic acids
Antibiotics
Polysaccharides
Vitamins
Enzymes
Bioplastics

We realize biochemical production plants based on our proprietary bioprocess technology, and with licensed technology from third parties.

Average consumption figures for glucose production

All figures given here are typical and can vary depending on plant configuration and equipment.

Glucose syrup DE96 (75 % DS)

Consumption for 1,000 kg final product
Starch	kg	710
Steam	kg	750
Power	kWh	60

Glucose monohydrate (91 % DS)

Consumption for 1,000 kg final product
Starch	kg	1,250
Steam	kg	1,800
Power	kWh	460

Our glucose showcase projects

Glucose Plant for Processing Complex in Volgodonsk
DONBIOTECH - Volgodonsk, Rostov Region, Russia

OOO «DonBioTech», a joint venture of Russian Varshavsky group and German industrial group Evonik, sets up a grain processing facility for the production of L-lysine from wheat.

Vogelbusch has been awarded…

Showcase Projects

Biotechnological Complex in Kaluga
BIOTECH ROSVA - Kaluga, Russia

The biotechnological complex put up by JSC «Biotech Rosva» uses wheat as a feedstock to produce speciality goods such as starch, gluten and various starch sugars, which are intended as…

Showcase Projects

Glucose plant for processing compex in Ishim
AMINOSIB - Ishim, Tyumen Region, Russia

ZAO Agroholding «Yubileinii» sets up a wheat processing complex - AminoSib - in Ishim in the Tyumen Region. Vogelbusch has been assigned by the general contractor, Talmax Engineering s.r.o., with the supply…

Showcase Projects

FAQ

All information given here is typical and can vary depending on plant configuration. For particular information please send us a message with your project details.

What’s the difference between glucose and fructose syrups?

Glucose syrups are produced in a two stage enzymatic process yielding mainly glucose and higher sugars, but virtually no fructose. Fructose syrups are produced subsequently by enzymatic conversion of glucose.

What is the difference between maltose syrups, low and high DE syrups?

Again, those syrups differ in their share of higher sugars, maltose and glucose

Low DE syrups are ranging from DE 20 - 40 and contain mainly higher sugars
In maltose syrups, ranging from DE 45 - 60, maltose has the biggest portion
High DE syrups with a DE value of > 96 contain mainly glucose

How many different products can be made in a high DE plant?

Since the composition (sugar profile) of the final product is solely defined by the enzymatic conversion mode, a broad range of products from DE 32 to DE 98 can be achieved by variation of types of enzymes and process parameter.

Which minimum capacity is recommended?

Owing to rather low profit margins of glucose syrups the minimum economic capacity is rather high, normally starting at 25,000 tpa. However, if the glucose syrup is used as an intermediate for more profitable products, considerably lower capacities may be commercially interesting.

Can I combine several feedstocks?

Glucose plants connected to grain processing facilities are run with one type of feedstock, which is the starch milk available from there.

Nevertheless, plants can also be designed to run on dry starch and in such case different types of native starch (e. g. wheat, corn, cassava) can be processed with only minor adjustments of process parameter.

Is the production of starch included?

The technology for the production of starch is offered by specialized companies and is not part of the Vogelbusch service package.

Which location is favorable?

Decisive factors for the location of the glucose plant are the same as for grain processing

Short transport routes for raw material & the final product
Availability of energy and water

The most suitable location is therefore next to a grain processing facility.

How much space do I need?

A small glucose plant excluding utilities can be placed in a building of approximately 50 m x 36 m x 18 m (L x W x H). Additionally, space for product storage according to ruling logistics has to be foreseen.

And the investment for such plant?

Capital expenditure always depends on plant capacity and configuration as well as local conditions. Costs for the process plant (excluding building, auxiliaries, infrastructure) for glucose syrup are from euro 5 million upwards.

This figure is for general reference only since each project has its own particularities that need consideration.

How long does it take to set up the plant?

With permits on hand the engineering, delivery of equipment and construction takes 12 - 18 months depending on capacity and complexity of the plant.

How can I get more information for my glucose plant project?

Complete our design questionnaire (check Links & Downloads section below) and send it back to us to get a professional opinion on your project.