Ⅰ.The production process of corn syrup made in factory:
corn starch - pulping - liquefaction - saccharification - neutralization - decolorization - filtration - ion exchange - evaporation - finished corn syrup products.
Next will introduce the details of corn syrup production process in factory, but before this, you need to know that the liquid syrup produced from corn main include the glucose syrup, maltose syrup, fructose syrup or named high fructose corn syrup(HFCS), all liquid syrup produced from corn can be called as corn syrup. On the other side, the glucose/maltose/fructose syrup technical processing is similar, and the fructose syrup now is the most widely used one, so below adopt the fructose syrup made in factory as the example to answer how is corn syrup made in factory.
Corn syrup making factory
Ⅱ. The corn syrup making factory process operation points:
① Pulping & liquefaction: Add some water in the mixing tank, add corn starch under stirring, and continue to add water to make the starch milk reach the specified concentration (40%), then add hydrochloric acid to adjust to ph value of 18. The adjusted starch milk is fully contacted with steam through the injection port, rapidly heats up, make the starch chain open, the starch is fully liquefied, and the liquefaction enzyme is inactivated by a high-temperature, high-pressure jet.
② Saccharification: Adjusted starch milk, use water-resistant pump to send starch milk into saccharification tank, after the feed is finished, open the steam valve and raise the pressure to about 2.8kg/cm2, and keep the pressure for 3-5 minutes. Samples were then taken and the saccharification effect was checked with 20% iodine. The saccharification solution for corn syrup made in factory can be neutralized when the iodine is reddish.
③ Send the saccharification liquid into the neutralization tank for neutralization, adding quantitative waste charcoal as a filter aid when stirring is started, gradually adding 10% sodium carbonate solution to neutralize, when the pH is 4.6-4.8, opening the discharge valve, using the pump sends the sugar liquid to the plate and frame filter, and the filtered sugar liquid is cooled to 60 degrees Celsius. After cooling, the sugar liquid is send to decolorization process. In corn syrup making factory process, this saccharification part is very important.
DOING saccharification tank
④ Decolorization: Put the sugar liquid into the decolorization bucket, add the quantitative activated carbon, keep stiring when adding, during the decolorization process, the stirring time should not be less than 5 minutes, then send it to the filter, filter out the supernatant and put it in the storage tank.
⑤ Ion exchange: The decolorized and filtered clean liquid is sent to the ion exchange column for desalination, purification and decolorization. After the liquid passes through the four resin filter beds of yang-yin-yang-yin, the pH value is adjusted to 3.8-4.2 in the sugar storage bucket of how is corn syrup made in factory.
⑥ Evaporation: After ion exchange, accurately adjust the pH of the liquid and pump it to the evaporation tank to maintain the vacuum above 500 mm Hg. The heating steam pressure should not exceed 1kg/cm2, and when the concentration of the syrup liquid is about 42% -50%, it can be discharged.
Produced corn syrup
⑦ Isomerization: the solid phase isomerase is packed in an erected reaction column, the reaction temperature is controlled at 65 degrees Celsius, the refined syrup liquid is fed from the top of the column, flows through the enzyme column, and isomerized, and then the bottom of the column is discharged, continuously operated, and can also be fed from the bottom of the column, and passed through the enzyme column to discharge from the top of the column. When the enzyme activity is at an appropriate pH value, the catalytic action can be fully exerted, the reaction speed is fast, the time is short, the degree of occurrence of the sugar decomposition side reaction is low, and the obtained isomerized sugar liquid is light in color and easy to be purified, so for how is corn syrup made in factory, the isomerization pH of the sugar solution should be determined by the type of isomerase used.
⑧ Secondary decolorization: After the isomerization reaction, the obtained syrup liquid contains a coloring matter, and impurities such as color and ash are generated during storage, so that secondary decolorization is required. The syrup liquid is sent to the decolorization tank, and the quantitative fresh activated carbon is added, and the operation is the same as the first decolorization.
⑨ Secondary ion exchange: the second decolorization of the liquid corn syrup requires another ion exchange process, the same as before. After that, the ph value of the syrup liquid flowing out is high, for corn syrup made in factory, the pH should be adjusted to 4.0-4.5 with hydrochloric acid.
⑩ Evaporation and concentration: the refined syrup liquid is concentrated to the desired concentration by a vacuum evaporation equipment, that is, the fructose syrup is obtained. Since glucose is easily crystallized, in order to prevent crystallization of syrup during storage, the syrup cannot be evaporated to an excessively high concentration, and it is generally required to be between 70% and 75% (dry matter concentration).
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