Low-DE Sugar Plants

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Vogelbusch Low-DE Starch Sugar Technology

Glucose syrup, also known as corn syrup, is a liquid starch sweetener used for foods and beverages. Maltodextrin and other spray-dried glucose syrups are used in the instant food industry as flavor carrier and as thickening agent.

The feedstock for syrup production is starch milk, which is made from common starch plants such as corn, wheat, rice and cassava.

Starting out from starch milk, we design and supply plants for the production of liquid and dried types of low-DE glucose syrups.

For key figures for low-DE sugar plant construction

CHECK OUT OUR » FAQ's

Block diagram

Vogelbusch process for low-DE glucose syrup production from starch milk

Low-DE glucose and maltose syrups are obtained from starch milk by enzymatic hydrolysis and subsequent concentration.

Conditioning of starch milk

RAW MATERIAL PREPARATION

The feedstock for low-DE starch sugar 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.

Enzyme 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. Maltodextrin and syrups with a DE below 20 do not require a further enzymatic treatment and enzyme has to be (thermally) inactivated while a second enzymatic conversions step is necessary for syrups with higher DE values.

In the saccharification tanks, further enzymes are added to convert the dextrin into glucose and higher sugars (maltose, isomaltose, maltotriose etc.). By carefully selecting the process parameters and enzymes, the desired DE values and sugar profiles are reached within 10 – 30 hours of saccharification time. Once the specified values are reached the enzymes are inactivated to stop reaction.

Purification

PRODUCT ISOLATION AND CONCENTRATION

The filtration process to separate suspended solids such as fibers and proteins depends on the product range of the plant.

Since syrups with DE values lower than 40 are highly viscous liquids, classical vacuum drum filters or sintered metal cross flow membranes may be chosen. For syrups with a DE value above 40 also polymer or ceramic cross flow membrane filtration are applied.

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.

Maltodextrin

In case of maltodextrin production, the syrup is concentrated by evaporation to 60 - 65 % DS before final drying. In a spray dryer, concentrated liquid is atomized via nozzles to very fine droplets, which are sprayed into the drying chamber where residual water is evaporated by heated air. The resulting maltodextrin granules are cooled, sifted and packed.

Biotechnological complexes

GRAIN PROCESSING FACILITIES

Syrups are 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.

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

Average consumption figures for low-DE starch sugar production

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

Glucose syrup DE 63 (80 % DS)

Consumption for 1,000 kg final product
Starch	kg	790
Steam	kg	860
Power	kWh	68

Maltose syrup DE 40 (80 % DS)

Consumption for 1,000 kg final product
Starch	kg	810
Steam	kg	860
Power	kWh	72

Maltodextrin DE 20 (95 % DS)

Consumption for 1,000 kg final product
Starch	kg	990
Steam	kg	1,400
Power	kWh	370
Natural gas *	std m³	90

Figures including spray dryer.
*) Steam as alternative heat source for spray dryer possible.

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 is the difference between maltodextrin and glucose syrup?

Basically, syrups differ in their share of higher sugars, maltose and glucose, which is described by the DE (dextrose equivalent) value.

Below DE 20, syrups are called maltodextrin and mainly contain higher sugars and virtually no monomers. Between DE 20 and 98 syrups are generally called glucose syrup.

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

What is special about maltodextrin?

Maltodextrin is mainly made from corn starch. The final product is a spray dried powder.

While maltodextrin is only commercially available as dried product, most glucose syrups are liquid but partly may also be spray dried.

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

In general any product with a DE range of 10 to 50 or even higher may be produced in such a plant since the main criteria - the sugar profile - is achieved by varied enzymatic reactions.

For the production of maltodextrin or other dried low DE products a spray drier has to be added to the line.

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 minimum capacity is recommended?

Production of liquid low DE syrups should have a capacity above 25,000 tpa. Capacities for maltodextrin production may be smaller.

Which location is favorable?

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

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

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

How much space do I need?

A small low DE plant excluding utilities can be placed in a building of approximately 50 m x 36 m x 18 m (L x W x H). If maltodextrin shall be produced an extra 16 m x 12 m x 16 m has to be considered for the spray drier. 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 for glucose syrup (excluding building, auxiliaries, infrastructure) 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 engineering, delivery of equipment and construction takes 12 - 24 months depending on capacity and complexity of the plant.

How can I get more information for my starch sugar 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.