淀粉生产基础知识培训

1、2010-10-02Corn Process Training 12010-10-02Corn Process Training 22010-10-02Corn Process Training 32010-10-02Corn Process Training 42010-10-02Corn Process Training 52010-10-02Corn Process Training 62010-10-02Corn Process Training 72010-10-02Corn Process Training 82010-10-02Corn Process Training 9Cor

2、n Process 玉米加工过程2010-10-02Corn Process Training 11湿磨生产基础知识培训湿磨生产概述和特点基本上是个物理分离的过程，在分离过程中将玉米分离成基本上是个物理分离的过程，在分离过程中将玉米分离成4种主要组成部分，种主要组成部分，该生产工艺唯一有化学反应的工段是玉米浸泡系统；该生产工艺唯一有化学反应的工段是玉米浸泡系统；水参与整个生产过程，所以叫做湿磨工艺；系统水平衡是湿磨生产较难和重水参与整个生产过程，所以叫做湿磨工艺；系统水平衡是湿磨生产较难和重要的控制指标；要的控制指标；各产品收率的平衡是最重要的控制指标，也是生产水平的直观反映；各产品收率的平衡

3、是最重要的控制指标，也是生产水平的直观反映；水、电、汽单耗能衡量出生产水平；水、电、汽单耗能衡量出生产水平；生产过程中的物料是菌类繁殖很好的营养基，温度也特别适合菌类生长，所生产过程中的物料是菌类繁殖很好的营养基，温度也特别适合菌类生长，所以湿磨生产对菌类的控制相对较难；以湿磨生产对菌类的控制相对较难；生产过程中所使用设备处理物料的性质较繁杂，如渣浆类的物料较多，设备生产过程中所使用设备处理物料的性质较繁杂，如渣浆类的物料较多，设备故障率相对较高，另外，设备几乎没有备机，所以湿磨生产对设备的维护水故障率相对较高，另外，设备几乎没有备机，所以湿磨生产对设备的维护水平要求较高，需要较完善的预维护和

4、可靠性运行计划；平要求较高，需要较完善的预维护和可靠性运行计划；系统到处使用系统到处使用SO2，所以环境气味较差；，所以环境气味较差；湿磨生产系统是流水性较强的系统，一环套一环，环环紧相连，某一环有问湿磨生产系统是流水性较强的系统，一环套一环，环环紧相连，某一环有问题，链就断；题，链就断；我公司采用比较先进的软件程序控制系统。我公司采用比较先进的软件程序控制系统。2010-10-02Corn Process Training 12玉米加工过程玉 米 净 化浸泡胚 芽 分 离纤 维 细 磨和 分 离淀 粉 / 蛋 白 分离粉 尘 和 碎 玉 米胚芽洗 涤纤 维 单 元淀 粉 洗 涤（淀 粉 乳）

5、蛋 白 单 元新鲜水蛋白粉玉米浆CSL粗玉米油饲料LSW初净化玉米蛋 白 浓 缩淀 粉 干 燥（干 淀 粉）胚 芽 干 燥 和 榨 油淀 粉 糖纤 维 洗 涤轻 浸泡 液 蒸 发胚芽饼2010-10-02Corn Process Training 13Introduction（简介）nThe wet milling process is a physical separation of maize into its four main constituents湿磨过程是一个物理的分离过程，在过程中将玉米分离成四种主要的组成部分:qGerm（胚芽）: Oil rich fraction（含有丰富

6、的油）qFiber（纤维，皮渣）qGluten（蛋白） : Protein rich fraction（含有丰富的蛋白质）qStarch（淀粉）nThe separation is archived in 3 ways（通过三种方式实现分离):qMilling（破碎）- to reduce particle size（降低物体的尺寸）qScreening （筛选）- to Separate particles of different sizes（根据物体的尺寸进行分离）qCentrifugal separation（离心分离） - To separate particles of diffe

7、rent density（根据物体密度不同进行分离）2010-10-02Corn Process Training 14Introduction（简介）nAs its name implies, the process is wet and water is used as the transport and milling medium. The water must be ultimately removed by(象名称所表示的那样，整个过程是在湿的状态下进行的，水被用作输送和破碎的介质。过程中的水最终要通过以下途径分离)：qDewatering(脱水）- Remove the wate

8、r out by mechanic way(使用机械方式将物料中的水分离）nScreen （筛）- DSM， ICMnSqueezing （挤压） - Veter, nCentrifuge （离心）- peeling centrifuge (刮刀离心机）nVacuum（真空）- Vacuum filter (真空转鼓）qEvaporation （蒸发） - Evaporator，（蒸发器）qDrying （干燥）- Tube boundle dryer, Flash dryer（管束干燥，闪蒸干燥机）2010-10-02Corn Process Training 15Introduction（

9、简介）nThe process is called a countercurrent process. The maize and water move in opposite directions through the process（过程被称为逆流逆流过程。玉米和水在过程中相向流动） qFresh water is added at the end of the process for starch washing. This water is reused as process water and finally as light steep water.（净水被加入过程的最后用于淀粉

10、洗涤。水被以工艺水的形式重复利用并最终以轻浸泡液的形式排出。）qThe water quality gradually deteriorates because the level of soluble protein increases, eventually this protein is removed from wet milling with maize gluten feed. （因为在过程中的溶解蛋白量增加，水的质量逐渐变差，这些蛋白最终与蛋白饲料一起从湿磨过程中分离出来。）qThe maize moves forward through the process through

11、several operations. At each stage different fractions are separated. （玉米在过程中向后流动，要经过几个步骤。在每一个步骤中都有一种成分被分离。）2010-10-02Corn Process Training 16Process Introduction （过程简介）nSteeping (浸泡）- soften the corn prior to grinding and increase water content（软化玉米颗粒，增加玉米中的水分）nEvaporation （蒸发）- remove water from we

12、t mill （最终分离出玉米湿加工过程中的水分）nDegermination（胚芽分离）- 2 millings and 2 separation stages of germ in hydroclones （二级磨和二级的胚芽旋流分离）nFiber milling and washing（纤维精磨和洗涤）- fiber is screened out from starch and gluten, recovery starch from fiber（筛分纤维和淀粉，蛋白，尽可能地回收淀粉）nStarch/gluten separation （淀粉/蛋白分离）- using Dorrclo

13、nes and centrifuge separate starch and light protein（使用旋流器和离心机将淀粉和轻麸质分离）2010-10-02Corn Process Training 17Process Introduction (过程简介）nStarch washing （淀粉洗涤）- multi-stages countercurrent washing and separation system to wash the final traces of protein from the starch 使用多级逆流洗涤和分离系统将淀粉中最后的蛋白洗涤出来。nCo-pr

14、oduct drying and storage（副产品干燥和储存） - tube bundle dryers for germ, fiber and gluten drying（使用管束干燥机对胚芽，纤维和蛋白进行干燥）nStarch dewatering and drying （淀粉脱水和干燥）- peeler centrifuge firstly dewater starch slurry then flash dryer will dry starch cake to finish product（首先使用刮板离心机对淀粉乳进行脱水，最后使用闪蒸干燥机对淀粉进行最后的干燥）2010-1

15、0-02Corn Process Training 18Corn intake and storage（玉米接收和储存）nTo remove large pieces of straw, cob, stone, chaff, etc.（分离出大尺寸的物体，禾秆，玉米芯，石头，碎的茎叶等）nTo properly handle and store corn after receiving（在接收后正确的输送和储存）nTo sample and analysis corn upon receiving（对接收的玉米进行取样和分析）nTo abide by FIFO (first in first

16、out) （采用先进先出的原则）2010-10-02Corn Process Training 19Corn cleaning（玉米净化）nTo remove none corn product,remove broken corn and dust. （分离出非玉米类物质，碎玉米和粉尘）nTo supply cleaned corn to steeping （为浸泡过程供应净化玉米）nTo record amount of processed corn for financial calculation（为进行财务计算准确记录进入过程的玉米量）nTo handle broken corn a

17、nd dust （对碎玉米和粉尘进行处理）2010-10-02Corn Process Training 20Corn Cleaning 玉米净化nNon-corn products (非玉米类物质) :q Straw, other grains or seeds, other material. (禾杆，其它种粒，其它物)nBroken corn (碎玉米)qFrom corn handling: transport, silo circulation (在运送过程中产生：运输，仓储，计量)qComposition(成份): analogous to total corn(与整粒玉米相近)q

18、If used in corn process(如果进入过程，会造成):nBlockage of steeps (堵塞浸泡罐)nFree oil: oil yield, protein and starch quality (游离的油含量增加)nYield of starch and protein (影响淀粉和蛋白的收率)nDust:粉尘qFrom broken corn (Floury endosperm)由碎玉米产生qHeavely contaminated(污染物):nMicrobiology(微生物)nMycotoxins(真菌毒素)2010-10-02Corn Process Tr

19、aining 21Why steeping(浸泡的目的)nWeakening of kernel （软化玉米颗粒）qSoften the fiber, endosperm, germ（软化纤维，内胚乳，胚芽）nExtraction of salts and solubles（析出盐和可溶解物质）qDecrease germ density, reduce solubles in supply starch washing battery （降低胚芽密度，减低淀粉洗涤单元供料的溶解物含量）nDestruction of sulphur bridges（破坏S键连接）qNaHSO3 - SO2 -

20、 SO3nFermentation of the sugars（分解游离糖）2010-10-02Corn Process Training 22Steeping fermentation(浸泡的发酵)nOpen protein matrix(打开蛋白质基体)qSolubility of prolamins in organic acids(在有机酸中溶解醇溶蛋白)qIn situ proteolysis (通过蛋白水解作用)nDestruction of NSP (non-starch-polysaccharids ) (分解无淀粉多聚糖):qProduction of glucanases;

21、 （葡聚糖酶）qProduction of pentosanases; （戊聚糖）nMinimize Maillard browning reaction during evaporation(在蒸发过程中有最小的褐变反应）:qConversion of sugars with reducing end to acids（将糖的还原性尾端变为酸）;nControl microbiology(微生物的控制）qSO2（含量）qLactobacilli2010-10-02Corn Process Training 23Degermination（胚芽分离）nGrind enough corn to

22、maintain starch production as desired rate（破碎足量的玉米以保证淀粉的生产速度）nEfficiently separate whole germs in the first stage and control germ purity（在一级分离中有效地分离胚芽并控制胚芽纯度）nAdjust Bauer mill grists to prevent over/under grinding and keep low oil content in the product.（调整磨的齿间距以防止破碎不足或过量，保持二级分离底流低的含油量）2010-10-02C

23、orn Process Training 24Degermination（胚芽分离） nMilling（破碎）qMechanical separation through size reduction（通过降低尺寸进行的机械分离）q1st stage（头道磨）: Broken the corn kernel, release the germ from kernel（破碎玉米颗粒，从玉米粒中分离出胚芽）q2nd Stage（二道磨）: Broken the remains whole corn（破碎剩余的整粒玉米）nSeparation（分离）q1st stage（一级分离）: separat

24、ion the germ from corn slurry（从玉米浆中分离出胚芽）q2nd stage（二级分离）: recycle the remanding germ（回流剩余的胚芽）nGerm washing（胚芽洗涤）qWash the starch out of germ, have a high purity germ.将游离淀粉从胚芽中洗涤出来，得到合适纯度的胚芽。2010-10-02Corn Process Training 25Equipment: Bauer Mill（ Bauer磨）2010-10-02Corn Process Training 26Equipment:

25、Hydrocyclone（旋流器）2010-10-02Corn Process Training 27Fiber milling and washing(纤维细磨和洗涤）nTo separate the fiber from the starch gluten slurry从淀粉蛋白浆中分离出纤维nTo remove, by milling, the bound starch adhering to the fiber通过细磨分离开联结在纤维上的联结淀粉nBroken the bond between starch and gluten in endosperm打开内胚乳中的淀粉和蛋白间的键联

26、结nWash the free starch out of fiber将游离淀粉从纤维中洗涤出来2010-10-02Corn Process Training 28Equipment: DSM Screen（曲筛）2010-10-02Corn Process Training 29Equipment: Entoleter（纤维细磨）2010-10-02Corn Process Training 30Starch Gluten Separation/Gluten concentration(淀粉蛋白分离/蛋白浓缩）nTo produce light gluten with correct pro

27、tein content生产出有正确蛋白质含量的轻麸质nTo produce heavy gluten（生产出重麸质）nTo produce process water（生产出工艺水）qSteeping （浸泡）qGerm washing（胚芽洗涤）qFiber washing（纤维洗涤）2010-10-02Corn Process Training 31Equipment: Centrifuge分离机2010-10-02Corn Process Training 32Starch washing（淀粉洗涤）nWash out the soluble protein and non-solub

28、le protein(洗涤出淀粉乳中的可溶解和不溶解蛋白质）qHigh color in finial glucose（会影响淀粉糖的颜色）qReduce exchange resin life（降低离子交换树脂的寿命）.nWash out the fine fiber in crude starch（从粗淀粉乳中洗涤出细纤维）nProduce starch slurry with correct density（生产出正确密度的淀粉乳）2010-10-02Corn Process Training 33Starch dewatering and drying（淀粉脱水和干燥）nDry sta

29、rch at the rate consistent with the request（按照要求的产量干燥淀粉）nProduce starch as the correct pH and moisture（生产的淀粉要有正确的pH值和正确水分）nProduce starch as the correct microbiological（生产的淀粉要有正确的微生物指标）nProduce starch as the correct bulk density（要有正确的虚密度）2010-10-02Corn Process Training 34Equipment: Peeling centrifuge（刮刀离心机）A. 淀粉乳B. 滤液C. 固体颗粒1 供料管2 机壳3 滤