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industrial production of high fructose syrup

industrial production of high fructose syrup-project on production of high fructose syrup corn

In the contemporary process, corn is milled to produce corn starch and an "acid-enzyme" process is used in which the corn starch solution is acidified to begin breaking up the existing carbohydrates, and then enzymes are added to further metabolize the starch and convert glucose to fructose.

During the high fructose corn syrup production plant process, the first enzyme added is alpha-amylase which breaks the long chains down into shorter sugar chains – oligosaccharides. Glucoamylase is mixed in and converts them to glucose; the resulting solution is filtered to remove protein, then using activated carbon, and then demineralized using Ion-exchange resins. The purified solution is then run over immobilized xylose isomerase, which turns the sugars to ~50–52% glucose with some unconverted oligosaccharides, and 42% fructose (HFCS 42), and again demineralized and again purified using activated carbon. Some is processed into HFCS 90 by liquid chromatography, then mixed with HFCS 42 to form HFCS 55.

(1) Liquefaction:

Starch slurry mixed with 30-35% dry solids and adjust its PH value to 6.0-6.4. Before put into α-enzyme, first add calcium, because calcium ions can stabilize the enzyme. Then mixed heat-stable α-enzyme (Novo’s Termamyl 120L) into the starch slurry, the slurry is instantaneously heated to 100 ℃ and held at this temperature for 10 min before it is cooled to 90 ℃. This temperature is maintained for 1-3h service for further hydrolyze the starch.

This process directly decided the yield in the high fructose corn syrup production plant, also can understand this as the starch using rate.

Liquefaction process technical parameters:

-Starch slurry concentration: 32%-36%

-α-enzyme: 8-10g per ton dry starch

-PH value: before: 6.0-6.4    after: 4.2-4.5

-Temperature: different value in different section

-Liquefaction solution DE value: 15%-20%

Then below is the main equipments and there function in high fructose corn syrup factory:

1.Mixing tank:

Mixing the starch and water to get the right density slurry, add certain enzyme, adjust the PH value and temperature to get the starch milk, in this condition, the starch will not be precipitated, the material used in high fructose corn syrup factory has been prepared for glucose produce.

2. Liquefaction tank & ejector:

Used in the liquefaction process which can convert the starch milk into liquid dextrin, the liquefaction tank include the laminar tank, maintaining tank and neutralization tank in high fructose corn syrup factory. The liquid pumped by the ejector.

3. Plate frame filter press machine:

Actually in the high fructose corn syrup factory, this filter machine will be used in two sections, not only the deproteinization process, but also the decolorization. It's an important machine for the syrup purify. The deproteinization process function is used to separate the protein and other solid impurity from liquid dextrin, with automatic mechanical extrusion method.

And the decolorization process adopt the activated carbon adsorption principle to remove color from the liquid. The decolorization & decarbaurization normal sequence is the first decolorization-the first decarburization-The second decolorization-the second decarburization.

4. Saccharification tank:

After liquefaction, the pH value is reduced to 4.2-4.5, when the solution temperature is cooled to 60 ℃, add the glucomylase (Novo’s AMG 300L) immediately. The reaction time for saccharification is usually between 24-48 hour depending on enzyme reaction speed. Glucoamylase releases single glucose units from the ends of dextrin molecule, syrups of 95% glucose or higher are manufactured by the saccharification tank, important for the fructose syrup production in high fructose corn syrup factory.

5. Ion exchange column:

Ion exchange can remove the Ca2+ and Mg2+ etc, and the negative ions, pure the syrup, the resin need regeneration by acid and alkali washing after working for some days. After the syrup liquid processed by ion exchange column, we can get the product can be eaten by people.

6. Isomerism system:

This process used to converting glucose into fructose, the isomerism system can make the purified glucose solution isomerized by a reactor containing immobilized isomerase to obtain fructose syrup with 42% fructose content. It's honor to tell you that the isomerase we are using is a kind of immobilized enzyme. Converted from soluble state into immobilized state, the stability of isomerism will be increased significantly and it can be uses repeatedly in the high fructose corn syrup factory. This immobilized enzyme used in food processing make food free of enzyme after production, so there is no need to adopt the way of heat treatment to make enzyme inactivated, which can help improving the quality of food as well as economic benefits.

7. Syrup evaporator:

Evaporation process for fructose syrup production is aimed to remove the excess moisture from the syrup liquid. We will suggest you the most suitable type syrup evaporator as your production requests.

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