comparison of generally applied processes for protein ... · pdf filegea mechanical equipment...

GEA Mechanical Equipment / GEA Westfalia Separator Process

Comparison of Generally Applied Processes for Protein Separation with Common Starch

Containing Raw Materials

61. Starch Convention, Detmold, 21. April 2010

Dr. Willi Witt

GEA Mechanical Equipment / GEA Westfalia Separator2

World Protein Production


World Protein Meal Consumption 2008

Source: USDA

230 Million Tons Protein Meal


World Protein Production Estimated for 2010

Source: USDA

Corn Gluten 3,2 Mill. Tons per Year

Wheat Gluten 0,9 Mill. Tons per Year

Potato Protein 0,1 Mill. Tons per Year

Soy Protein Isolate/Concentrate 0,9 Mill. Tons per Year

Total 5,1 Mill. Tons per Year


Molecular Protein Structure


What are Proteins

Proteins are highly complex organic compounds

They are composed of varying amounts of the same amino acids, which in the intact protein are united through covalent chemical

linkages called peptide bonds

A protein with a molecular weight of 100.000 would contain about 850 amino acid residues

Amino acids are classified as essential (incl. dispensable), and

conditionally essential (conditionally indispensable)

Proteins are large molecules with high molecular weights


What are Proteins

The amino acids, linked together, form linear unbranched polymeric structures called polypeptide chains; such chains may contain hundreds of amino-acid

residues; these are arranged in specific order for a given protein

Reaction of amino acids to form a peptide bond R O R O R O H R O

H2N – C – C – OH + H2N – C – C – OH -> H2N – C – C – N – C – C – OH + H2O H H H H

Depending on the source, the protein has a different structure and combination of amino acids in its chemical make-up. Every protein molecule has a characteristic

three dimensional shape or confirmation which is determining its properties

Every protein molecule has a characteristic three dimensional shape or confirmation which is determining its properties


Protein Structure

Primary Secondary Tertiary Quaternary

alaaf


Protein Properties

Water Binding

Gel Forming

Emulsifying

Foaming

Nutritive Value

Solubility


Comparison of Raw Materials

for Protein Processing from

Carbohydrate Containing Plant


Protein Containing Plant

Starch and Carbohydrates Containing Plant:Corn, Wheat, Rye, Barley, Oat, Rice

Legume:Pea, Lupine

Root:Potato, Tapioca, Manioc

Oil Containing Plant:Soy, Rape Seed, Sun Flour

GEA Mechanical Equipment / GEA Westfalia Separator

Cross Section of diff. Types of Grain

12

Barley Rye Wheat

Oat Corn

Rice

Pea


Chemical Composition of the Different Raw Materials

13

Starch Protein Fat Fiber% DS % DS % DS % DS

Corn 71-74 9-10,5 4-5 3-4Wheat 60-75 8-25 2-2,5 2-3Rye 65-70 8-16 1,8-2,2 1,8-2,7Pea 26-59 22-32 5-7 2,2-10Barley 68-78 10,5-14,5 1,9-2,6 4,5-7,2Oat 40-50 14-16 4,5-5,8 11,5-14Rice 65-75 7-10 1,5-2,5 9,5-12,5Potato 76 8 5 6


Processes for the Recovery

of Proteins out of

Different Raw Materials


Steps of Pre-Conditioning for Protein Recovery

Main Issue: Opening of the Cell StructureDry Milling

• Cleaning

• Conditioning

• Grinding

• Sifting

• Air Classification

• Combined Processes

Wet Milling

• Cleaning

• Steeping

• Wet Grinding

• Extraction


Simplified Milling Principal

Kernel Endosperm Germ Bran


Wheat „Short“ Mill - (Roller Principal)

M

M

M

M

M

M

M M

M

M

M

M M

M

M

M

MM

MMaturation

Tanks

Bran Finisher

Weigher

Weigher

Water

Wheat

Sifter

Roller Mill

Bran

Flour

17


Wheat „Short“ Mill - (Ultra-Rotor Principal)

Bran

ExhaustFan

Air Lock

Bag Filter

BufferSilo

M

M

M

M

M

M

M MM

Ultra-Rotor

Rotary Valve

MaturationTanks

Bran Finisher

WeigherWeigher

BranSilo

WheatFlourSilo

compressed air

compressed air

M

Water

Wheat

Sifter Flour

18


Milling Equipment

www.muehlenbau.de www.buehlergroup.com

Roller Mill Plan Sifter Hammer Mill

Peeler Rubber Roll Peeler


Ultra Rotor for Milling and Drying

www.jaeckering.de


Peeling

Schule Mühlenbau


Peeling of Wheat Kernels

22

Removing of the Outer Cell Wall after Cleaning and Humidifying of the Bran

by Interaction of the Grain between Rotor and Screen

Before Peeling After


Air Classification


Air Classification

1 Flour Feed2 Sifter Wheal3 Outlet Fine Fraction4 Outlet Coarse Fraction5 Aspiration

31 2

4

5

ALPINEHOSOKAWA

Fine Sifter

Sifter Mill


Different Types of Protein Recovery

Mechanical TreatmentCorn, Wheat

Chemical TreatmentPea, Barley, Oat, Rye, Rice

Thermal TreatmentPotato


Solubility of Soy Protein Depending on the pH

26

pH of the Solution

% N

-Sol

ubili

ty


Solubility of Rape Seed Globulin Protein

27

pH of the Solution

% N

-Sol

ubili

ty

AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA


Solubility of Rape Seed Protein

28

% N

-Sol

ubili

ty

pH of the Solution


Corn Processing

for

Protein Recover


Corn Kernel

30

Floury Endosperm

Horny Endosperm

Germ

Flower Stalk

Dark Surface Layer


Cross Sections of a Corn Kernel

31


Corn Gluten Lab Wash Test

32

Particle Diameter (µm.)

Volume (%)

0

10

20

0

10

20

30

40

50

60

70

80

90

100

1.0 10.0 100.0 1000.0

Mais Ansatz 3


Typical Products Isolated from Corn and Yields

Content of Yield [% DS]

Starch 66 - 70 %

Gluten 5 - 6 %

Germ 6 - 7 %

Fiber 9 - 12 %

Step Water 5 - 8 %

Broken Kernels 1 - 4 %

33


Corn

Steeping

Grinding

Fine Grinding

Fiber Screening

Starch Separation

Washing

Drying

Dewatering

Drying

Corn Starch Corn GlutenGerms Fibers Steep Water

Germ Separation

Corn Processing into Protein and other Products

34


Process Steps with WS Key Equipment

Corn Starch

Starch Washing

Mill Starch Thickening

Gluten Thickening

Primary SeparationMiddling Separation

Process Water

Starch Drying Gluten Drying

Starch Dewatering Gluten Dewatering

Corn Gluten

Mill Starch

35


Wet Milling from Corn

Steeping

CornGerm Washing Germ Dewatering

Dewatered Germs

PW

Husks, Fibres, Starch, Gluten

PW

Grinding & GermSeparation


Wet Milling from Corn

PW

fromMilling

Dewatered Husks

Dewatered Coarse Fibres

Starch

PW

DewateredGlutenPW

PrimarySeparation

GlutenConcentration

GlutenDewatering

Fibre Dewatering

FibreExtraction

Husk Dewatering

StarchWashing


Simplified Flow Sheet for Corn Gluten Dewatering with Decanter

Clarified Phaseto Process Water

Hot Water

Hot Water

GlutenConcentrate

Caustic Soda

TIC

Dewatered Gluten

QICFIC

Decanter feed conditions:Feed concentration (separable solids)

approx. 35 (30 - 50) g/l

4,7(4,0 - 6,7) oz/gal

Feed temperature 58 - 60 °C 136 - 140 °F

pH-Value 5,3 - 5,8

SO2 content 400 - 500 mg/kg

NaOH-concentration 4 - 10 %

hot water temperatur max. 65 °C max 149 °F

38


Requirements for Corn Gluten Ewatering in a Decanter

pH-control for the range of approximately 5,3 – 5,8 – equipped with pH measurement, control valve and caustic pump

Temperature control for raising the temperature of the corn gluten to approximately 58 – 60 °C – equipped with temperature measurement, control valve and plate heat exchanger

Feed system for feeding the decanter – equipped with eccentric srew pump, inductive flow meter and static mixer


Dewatered Corn Gluten

40


Continious High Pressure Corn Steeping Process

FeaturesShort Steeping TimeNo SO2Low solubilisation of Solidsand ProteinsNo Steep Water EvaporationAnaerobic Waste WaterTreatment PlantLow Space Requirement

M

Corn

FineSolidsProcessWater

Steeped

Transport

WarmWater

Corn

Circuit


High Pressure Disintegration for SelectiveGrinding of the Corn Endosperm

High PressureDesintegrator

Corn Fibre Fragments

Working Princip of theDesintegration Valve

M

M

M

Processwater

Coarse and Fine FibresM

Steeped Corn

Mill Starch


Wheat Processing

for

Protein Recovery


Wheat Kernel

44


Wheat „Short“ Mill - (Roller Principal)

M

M

M

M

M

M

M M

M

M

M

M M

M

M

M

MM

MMaturation

Tanks

Bran Finisher

Weigher

Weigher

Water

Wheat

Sifter

Roller Mill

Bran

Flour

45


Flour Extraction Rate [%]0 10 20 30 40 50 60 70 80 90 100

Whole Wheat FlourWhole Wheat Flour

Straight Grade FlourStraight Grade Flour Shorts and BranShorts and Bran

Patent FlourPatent Flour Low Grade FloursLow Grade Flours

Grades of Flour Obtained from Wheat

The Miller can Produce a Type of Flour Quality suitable for the Wheat Starch Industry with a certain Extraction Rate .

Flour Milling

ca.75 – 78%

46


Wheat Quality Depending on Flour Yield

47

AleuronLayer

Bran

Endosperm

Flour Yield

GlutenContent

ProteinContent

MineralContent

RMTVolume

AAAAAAAAAAAAAAAAAAAAAAAAAAaaaaaa


Moisture approx. 15,0 %Protein (N x 5,7) approx. 12,0 % DSAsh approx. 0,63 % DSFat approx. 1,5 % DSCrude Fibre approx. 1,5 % DS(all based on Dry Matter)Wet Gluten approx. 28,0 %Flour Particle Size max. 3 % > 250 µmAmylogram approx. 500Falling Number approx. 250

A-Starch Potential > 70 % DSStarch Granule Size < 30 % < 10 µm

Typical Requirements for a Wheat Flour Suitable for Starch Processing.

Flour Specification

Wash Test

48


Wheat Flour Process

49

Homogenizing

Separation

Sieving

Washing ProcessWaterProcessWater

StarchStarch

Mixing

WaterWaterFlourFlour

PentosansPentosans

SievingWashing

Dewatering Recovery

Drying

FiberFiberGlutenGluten


Wet Milling from Wheat Dough Preparation and Gluten Extraction

Wheat Flour

Water

Dosing

Mixing

Agglomeration GlutenWashing Gluten

Finishing

3 Phase Separation

Pentosan Fraction to Fermentation

A-Starch Fractionto Starch Washing

Vital Glutento Dryer

B-Starch Fraction


Dough mixingDough Mixer in Process

51


The high pressure introduced by a homogenizer ensures the necessary Energy Input for agglomerating the Gluten.

Energy Input

Energy Input

52

Slurry Preparation


Bend Screens for Gluten Separation

53


Vital Gluten Drying and Conditioning

HeaterSifter Mill

Bag Filter

ExhaustFan

Air Lock

DryingRing Duct

Gluten

Steam

Condensate

Recycle Screw

CoolingColumn

ExhaustFan

MFiltrate Recycle

RecyclePump

FeedPump

Disintegrator

Bag Filter

FiltratePump

M

M

M

M

M

Bagging

25 kgWheatVital

Gluten

Buffer Silo

54


Protein Structure

55

Wheat Protein Rye Protein

Source: Margit Beck, Tagung für Getreidechemie, 24.06.09


Wheat Protein Aggregates

56


bar=100 µm

57

Protein Network after Agglomeration of the Protein


Isolated Wet Wheat Gluten

58


Potato Processing

for

Protein Recover


https://www.nottingham.ac.uk/ncmh/lecture.../D2DBT1_Sandra_Starch.ppt

Micrographs of Potato and Root Cells


Micrographs of Potato Cells

61


Processing of Potatoes into Proteins and other Products

62

ReceptionWashing & StorageReceptionWashing & Storage

Rasping De-SandingRasping De-Sanding

Fruit Water RemovalFruit Water Removal

Starch WashingStarch Washing

ExtractionExtraction

StarchDewatering

StarchDewatering

Starch DryingStarch Drying

Pulp DewateringPulp Dewatering

Fresh WaterFresh Water

SandSand

PotatoesPotatoes

StarchStarch

PulpByproduct

PulpByproduct

ProteinProtein Waste Water

Waste Water

ReceptionWashing & StorageReceptionWashing & Storage

Rasping De-SandingRasping De-Sanding

Fruit Water RemovalFruit Water Removal

Starch WashingStarch Washing

ExtractionExtraction

StarchDewatering

StarchDewatering

Starch DryingStarch Drying

Pulp DewateringPulp Dewatering

Fresh WaterFresh Water

SandSand

PotatoesPotatoes

StarchStarch

PulpByproduct

PulpByproduct

ProteinProtein Waste Water

Waste Water


• All parts coming in contact with the product are made of stainless steel

• Reversible Rotation Direction• Very Robust Design• High Grinding Efficiency• Easy Accessibility• Blades robust for changing

no rework

RaspingRasping

Rasping

63


WS Decanters for Potato Starch Processing

In the Potato Starch Process Decanters are mainly used for:

CB 635

CB 635

Fruit WaterRemoval Decanter

Pulp DewateringDecanter

64


Dewatered Gratingsapprox. 45 % DS

FeedVol-%

Concentrate

100

0,1

90807060504030201051

55 Vol% Gratingsapprox. 22,5 % DS

Ideal Separation Line

OverflowVol-%

0,2 % coagulatedProtein and Fibres

99,8 % Fruit Water= 5 % soluble DS

100

0,1

90807060504030201051

Fruit Water Decanter Performance

The Spin Test of the Different Decanter Flows Shows the Efficient Separation.

65


Protein Recovery from Potato Fruit Water

66

Steam

Acid

FruitwaterFeed

Preheater

CIP Recycle

CausticCIPSystem

CIP Liquid

ProteinCoagulation

ProteinDewatering

ProteinDrying

Residual Fruitwaterto Evaporator


Ideal Separation Line

All figures are approximateand varying according toraw material and process design

FeedVol-%

Concentrate

100

0,1

90807060504030201051

12 % Separable Solids= 4 % DS

85 % Water

OverflowVol-%

0,3 % Separable Solids

99,7 % Process Water

100

0,1

90807060504030201051

Dewatered Proteinapprox. 40. % DS

Feedapprox. 35 m³7h

The spin Test of the Different Decanter Flows Shows the Efficient Separation.

67

Protein Decanter Performance


Other Raw Materials

for

Protein Recover


Soy Flour Processing

for

Protein Recovery

As Basic Process for other Starch and

Carbohydrates Containing Raw Materials


Cross Section Soy Bean

70


Soy Protein Process

Protein Extraction

ProteinPrecipitation

Protein Washing

ConditioningModification

Protein Extraction

ProteinPrecipitation


Sugar Removal


AlcoholExtraction


White Flakes

Protein Concentrate

Protein Concentrate

Protein Concentrate

Protein Isolate


Soy Protein Process


Extraction of Soy Protein from Soy Flakes or Flour

73


Protein Precipitation and Washing

74

Spray DryerUHT


Membranfiltration in Protein Process Lines

75


Protein Precipitation and Washing

76


Pea Processing

for

Protein Recover


Some Pea Types

78


Composition of peas

The great variations of the composition refer to the great variety of peas and growing

conditions!

Pod

Seed with Hull

Dry Substance 83 - 93 % (after Drying)

Starch (%DS) 26 - 59 %

Sugars (%DS) 5 - 7 %

Protein(%DS) 22 - 32 %

Fat (%DS) 0,6 - 5,5 %

Fibres (%DS) 2,2 - 10 %

Ash (%DS) 1,8 - 3,3 %

79


Usage of Peas

Different Pea types are used for:

• Animal Feed and Fish Feed (Chick Peas, Field Peas,…)

• Human Feed(Wrinkled Pea, Round Pea, Sugar Pea)

• Protein for Human and Animal Consumption, Adhesives, Tensides

• Starch for Human Consumption, Plastics (Amylose)

• Fibres for Animal FeedHuman Consumption (Dietary)

Typicall usage of pea fractions:

80


Processing of Peas into Proteins and other Products

Pea Seed

Dehulling Steeping

Grinding Wet Grinding

Air - Classification Pea Flour

Concentrated Protein Flour

Wet Process Line

Wet Process Line

Starch, Protein, Fibres

Starch, Protein, Fibres

81


Pea Processing


Pea Processing

Steeping

Disintegration

Fruit WaterRemoval

PeasPeas

Fine FiberScreening

3-PhaseConcentrationand Washing

Dewatering

Starchto Dryer

Starchto Dryer

PulpDewatering

Fiber(to Dryer)

Fiber(to Dryer)

ProteinPrecipitationand Dewatering

Proteinto Dryer

Proteinto Dryer

Water

NaOHH

2SO

4

Hot

Wat

er


Rice Processing

for

Protein Recover


Rice Processing

Steeping

Disintegration

Extraction

Rice FlourRice Flour

Fine FiberScreening

3-PhaseConcentrationand Washing

Dewatering

Starchto Dryer

Starchto Dryer

ByproductDewatering

Byproduct(to Dryer)

Byproduct(to Dryer)

ProteinPrecipitationand Dewatering

Proteinto Dryer

Proteinto Dryer

EffluentEffluent

Water

NaOH

H2SO4


Protein Recovery

From Ethanol Processes


Bioethanol – The Dry Mill Process


Protein and Oil Recovery in an Ethanol Plant


Many Thanks for Your Attention!

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