cornwetmilling brochure

7/17/2019 CornWetMilling Brochure

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Equipment and Systems

for Corn Wet Milling



Corn Wet Milling Process Flowsheet



3

Dewatering, Germ Washing,and Fiber Washing

Dewatering and Germ Washing

Economical corn wet milling practice

requires dewatering of the supply

stream ahead of the degerminating

mills. Also the separated germ must

be washed to get a high purity germ

product free of starch.

Gravity-Fed DSM® Screens

Dewatering and germ washing are

done more effectively with Dorr-Oliver

DSM screens. The DSM screens for

these applications are gravity fed over

a weir. A single stage screen is used

for dewatering. For germ washing,

however, three stages of DSM screens

are used. The wash water flows

countercurrently and removes the

starch quite efficiently as the germ

moves forward from stage to stage.

Benefits of Gravity-Fed

DSM Screens

• No maintenance necessary as

screen media is rugged stainless

steel and there are no moving parts.

• Space needed is minimal since

units are compact and handle

high throughputs. Cascade

mounting arrangement of three

screens also makes effective use

of available space.

• Operation is trouble free due to

non-blinding, wedge wire screen

surface.

• No fumes and spillage as screens

are totally enclosed.

Fiber Washing

To get maximum starch recovery,

while keeping any fiber in the final

product to an absolute minimum, it is

necessary to wash the free starch

from the fiber during processing.

Pressure-Fed 120 DSM® Screens

Most plants accomplish this very

economically today with the Dorr-

Oliver Fiber Washing System. The

system consists of six stages of 120

DSM screens. The pressure fed screens

are arranged for countercurrent

washing of the fiber, with the starch

reporting to the undersize. The

extremely fine separations are possible

only with our highly polished wedge

wire screen surfaces with openings as

fine as 50 microns. The DSM screen’s

precisely selected screen media and its

proven reliability are unmatched by

equipment using fragile textiles or

thin etched screens.

Benefits of Pressure-Fed

120 DSM® Screens

• Close tolerance, engineered feed

system distributes feed flow

across screen surface with high

velocity for highly effective

separation.

• System’s multi-stage

countercurrent flow design

assures maximum starch yield.

• High capacity compact design

drastically curtails space needed

for fiber washing operations.

• Requires little operator attention

because system is designed for

small sumps, uses standard

pumps and has simple

instrumentation.

• Long service life due to no

moving parts, quick reversible

and totally enclosed design.

• Screens available in single,

double and triple width

configurations for maximum

flexibility in system design.

Gravity-Fed DSM Screen

Pressure-Fed DSM Screen



Germ Separation &Starch Washing Systems

Germ Separation

After the corn kernels are steeped for

softening, they are cracked open to

release the germ. The germ contains

the valuable corn oil. The germ is

separated from the heavier density

mixture of starch, hulls and fiber

essentially by “floating” the germ

segments free of the other substances

under closely controlled conditions. This

method serves to eliminate any adverse

effects of traces of corn oil in later

processing steps.

Manifolded DorrClone Systems

To accomplish this critical separation

most efficiently, most plants today use

Dorr-Oliver’s compact manifolded

two-stage Germ Separation System.

Specially sized DorrClone cyclones and

engineered flow distributions are

specifically designed for the magma/

germ separation. Because of the high

centrifugal forces employed, germ is

separated instantly. The first pass makes

a selective separation for optimum

purity and the second pass increases

germ recovery by capturing any germ

that may have been bypassed in the

first stage. This system has given

processors a new standard of process

control and sanitation.

Benefits of Germ

Separation DorrClones

• Maximum germ oil recovery (very

low loss of the valuable process

fraction).

• Easy maintenance and quick

replacement of individual cyclone

units because of the quick opening

couplings.

• Rapid response to process changes

through single instrument control.

• Totally enclosed design assures

clean and fume-free operating

area.

• Lightweight construction and

shipment as a complete factory

assembled package means low

cost installation.

• Modular system design allows easy

expansion when production

demands dictate.

Starch washing

The starch slurry from the primary

separation contains some insoluble

protein and much of the solubles. They

have to be removed before a top

quality starch can be made. Modern

plants are using Dorr-Oliver Starch

Washing Systems for this important

task.

Hydrocyclone Starch

Washing System

A typical Dorr-Clone or Hydrocyclone

Starch Washing System consists of

batteries of 10 mm cyclones in

completely unitized and enclosed

housings, arranged for efficient

countercurrent washing. The centrifugal

forces needed to make the separation

are derived from energy supplied by

pumps. The high rotational velocities in

the individual cyclones cause the starch

to concentrate in the underflow while

the suspended gluten follows the

overflow wash water stream. The

multi-stage systems provide easy and

precise control of the process, resulting

in the uniform, high quality starch

required in today’s highly demanding

marketplace. The latest in starch

washing technology incorporates

recently developed high-efficiency

10mm cyclones for the Starch Washing

System. These high capacity units

incorporate advanced flow channeling

with superior materials and layout to

save money in installed cost and

operating power. Varying plant

capacities can be handled.

Benefits of Starch

Washing Hydrocyclones

• Easy operation because simplified

control system uses self regulation

of intermediate stages.

• Improved sanitation since system is

completely closed and pressurized

• Low maintenance. The only

moving parts are in the standard

centrifugal pumps.

• Capital cost is less because of the

system’s compactness, which saves

on space, and easy expandability

when additional capacity is needed



Gluten Dewatering

Gluten Dewatering

Before the gluten moves on to drying

it is good practice to dewater the

gluten slurry from the gluten

thickener, which obviously saves on

the energy required to thermally dry a

high moisture product. This is usually

accomplished economically on a

rotary drum filter with belt discharge.

Dorr-Oliver Eimco

E-Belt Drum Filter

Dorr-Oliver Eimco E-Belt Drum Filters

for corn wet milling applications have

been adapted to meet the industry’s

specific needs for corrosion resistance

and sanitation. Filters are of stainless

steel construction and are equipped

with streamlined internal piping and

valves, snap-in plastic supporting

media and easily adaptable discharge

mechanisms.

Its reliable filtration enhances product

recovery minimizing protein loss.

Benefits of E-Belt Drum Filters

• No more blinding problems and

greatly improved washing and cloth

tracking with the revolutionary

swivel roll concept that doesn’t

require filter cloth rubber edges.

• Delivers high rates of filtration and

high hydraulic capacity for cake

dryness enhancement.

• Hi Hydraulic capacity

• Food design for cleaning and

sanitation

• Innovative cloth alignment design

• Low installation costs and clean

working environment due to

compact design.

• No operator attention required.

• Minimal maintenance



Starch Washing and Filtration

Pneumapress® automatic pressure

filters were successfully introduced into

the starch washing and dewatering

process in 1997. Since that time, the

Pneumapress design has evolved to

meet the changing needs of the

industry and Pneumapress equipment

is now installed by the majority of the

major starch producers worldwide. The

starches processed on the Pneuma-

press include corn, wheat, potato and

tapioca starches – including modified,

industrial and food grade varieties.

Pneumapress filters are installed in

starch plants the USA, Germany,

Thailand, Korea, France and Italy.

The design focus of Pneumapress for

the starch industry is to provide a

mechanically simple, sanitary and

efficient filter. Pneumapress filters do

not require rubber seals or dia-

phragms, simplifying the operation

and maintenance of the equipment.

Significant repeat business and

referral sales are indicative of the

success of the Pneumapress design.

The most common throughput sizes

for single filters on native starches are

in the range of 6 to 25 metric tons

per hour dry solids and for modified

starch are in the range of 4 to 20

metric tons per hour dry solids.

The cleaning and hygiene require-

ments at food starch plants are

becoming more stringent. Pneuma-

press has recognized this need and

created a patented sanitary design

option to enable ease of cleaning and

sanitization. This option incorporates

a fully automatic clean in place (CIP)

system.

The Pneumapress filter can be totally

enclosed to prevent product contami-

nation and provide increased safety

for those working in the vicinity. This

enclosure may be designed in 316

stainless steel to provide the ultimate

in sanitary design and safety.

Benefits of Pneumapress Filters

• Very dry filter cakes with highly

effective cake washing when

required

• Highest throughput per unit area

of any filter, which minimizes the

required filter area, equipment

size, number of moving parts and

maintenance downtime

• Advanced filter media design and

effective filter media cleaning

provide very clean filtrate

• Mechanically simple design

eliminates consumables such as

diaphragms and seals

• Filter plates are made completely

from 316 stainless steel

• An isolatable plate design

provides very high equipment

availability

• Sanitary or industrial design with

optional filter housing, structure

cladding, and CIP systems

• Single-sided cake discharge

• Low installation costs

Pneumapress Sanitary Multi-Module Filter

Filter enclosed in sanitary housing

Cake discharge from filter



7

Starch Conversion andHydrogenation

Polishing syrup

To remove impurities from syrup in

the sweetener plant, general industry

practice is to use a precoat vacuum

filter, simply because precoat filters

produce the clearest syrups.

Hydrogenation:

Through Catalytic reactions, starch

can be converted into a wide family

of “low calories sugar” used in food

and pharmaceutical products.

Dorr-Oliver Eimco’s

Precoat Filter

features a slow and precise knife

advance system that assures the

lowest precoat expense without

affecting the machine’s high through-

put rates. The precoat material can be

applied to the filter in varying

thicknesses and users get longer

processing cycles between filter

medium replacements. The unit’s

exclusive scraper design enables the

operator to better control removal of

impurities with minimum loss of

precoat material, and this also keeps

operating costs down.

Benefits of Pre-Coat Filters

• Consistently clear and better

quality syrup.

• Longer operating cycles and

equipment life.

• Can be readily adapted to meet

varying process needs.

• Effective use of precoat, without

waste, lowers operating costs.

• Revolutionary precoat discharge

system electronically control for

reduced precoat consumption

and longer filtration cycle.

IBF, Indexing Belt Filter

Dorr-Oliver Eimco IBF is one of the

many products in our portfolio for

vacuum filtration of a wide range of

hydrogenated compounds. Thecontinuous operation together with a

simple mechanical design reduce

maintenance offering steady and

reliable operation.

Benefits of IBF Filters

• Food design, FDA validated.

• Totally enclosed execution for

solvent washing

• Smooth filtration with no particle

size modification.

• Superior washing efficiency for

maximized product recovery.

• Cleaning in place for complete

sanitation.

Dorr-Oliver Eimco Indexing Belt Filter (IBF)

Dorr-Oliver Eimco Precoat Filter



Copyright ©2010 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth is a (registered) trademark of FLSmidth A/S. This brochure makes no offers, representations or

warranties (express or implied), and information and data contained in this brochure are for general reference only and may change at any time.

Minerals Processing

Technology Center

FLSmidth Salt Lake City, Inc.

7158 S. FLSmidth Drive

Midvale, UT 84047-5559Tel: +1 801 871 7000

email: [email protected]

www.flsmidth.com

Suspension @ 60°F Dry Solids Content Water Content

Be Sp Gr % D.S.* Lbs/Gal Lbs/Gal Oz/Gal Gr/Gal Gm/Liter Lbs H2O Gal Susp Lbs H

2O Lb Starch Ga l H

2O Lb Starch

0.0 1.0000 0.00 8.328 0.000 - - - 8.328 - -

0.5 1.0035 0.89 8.357 0.074 1.184 518 8.87 8.283 111.93 13.437

1.0 1.0069 1.78 8.386 0.149 2.384 1043 17.85 8.237 55.28 6.636

1.5 1.0105 2.66 8.416 0.224 3.584 1568 26.84 8.192 36.57 4.390

2.0 1.0140 3.55 8.445 0.300 4.800 2100 35.95 8.145 27.15 3.260

2.5 1.0176 4.44 8.475 0.376 6.016 2632 45.18 8.099 21.54 2.586

3.0 1.0211 5.33 8.504 0.453 7.248 3171 54.28 8.051 17.77 2.133

3.5 1.0248 6.22 8.535 0.531 8.496 3717 63.63 8.004 15.07 1.809

4.0 1.0285 7.11 8.566 0.609 9.744 4263 72.98 7.957 13.07 1.570

4.5 1.0322 8.00 8.596 0.688 11.008 4816 82.32 7.908 11.49 1.379

5.0 1.0358 8.89 8.626 0.767 12.272 5369 91.79 7.859 10.25 1.231

5.5 1.0396 9.77 8.658 0.846 13.536 5922 101.38 7.812 9.23 1.108

6.0 1.0433 10.66 8.689 0.926 14.816 6482 110.96 7.763 8.38 1.006

6.5 1.0470 11.55 8.720 1.007 16.112 7049 120.67 7.713 7.66 0.920

7.0 1.0508 12.44 8.751 1.089 17.424 7623 130.49 7.662 7.04 0.845

7.5 1.0547 13.33 8.784 1.171 18.736 8197 140.32 7.613 6.50 0.780

8.0 1.0585 14.22 8.815 1.253 20.048 8771 150.15 7.562 6.04 0.725

8.5 1.0624 15.10 8.848 1.336 21.376 9352 160.09 7.511 5.62 0.675

9.0 1.0663 15.99 8.880 1.420 22.720 9940 170.16 7.460 5.25 0.630

9.5 1.0703 16.88 8.914 1.505 24.080 10535 180.34 7.409 4.92 0.591

10.0 1.0742 17.77 8.946 1.590 25.440 11130 190.53 7.356 4.63 0.556

10.5 1.0782 18.66 8.979 1.676 26.816 11732 200.71 7.303 4.36 0.523

11.0 1.0822 19.55 9.013 1.762 28.192 12334 211.14 7.251 4.12 0.495

11.5 1.0862 20.44 9.047 1.849 29.584 12943 221.56 7.198 3.89 0.467

12.0 1.0903 21.32 9.080 1.936 30.976 13552 231.99 7.144 3.69 0.443

12.5 1.0944 22.21 9.114 2.024 32.384 14168 242.65 7.090 3.50 0.420

13.0 1.0986 23.10 9.149 2.113 33.808 14791 253.32 7.036 3.33 0.400

13.5 1.1028 23.99 9.185 2.203 35.248 15421 263.98 6.982 3.17 0.381

14.0 1.1071 24.88 9.220 2.294 36.704 16058 274.89 6.926 3.02 0.363

14.5 1.1114 25.77 9.256 2.385 38.160 16695 285.79 6.871 2.88 0.346

15.0 1.1156 26.66 9.291 2.477 39.632 17339 296.82 6.814 2.75 0.330

15.5 1.1199 27.54 9.327 2.569 41.104 17983 307.84 6.758 2.63 0.316

16.0 1.1242 28.43 9.363 2.662 42.592 18634 318.98 6.701 2.52 0.303

16.5 1.1286 29.32 9.399 2.756 44.096 19292 330.25 6.643 2.41 0.289

17.0 1.1330 30.21 9.436 2.851 45.616 19957 341.63 6.585 2.31 0.277

17.5 1.1375 31.10 9.473 2.946 47.136 20622 353.02 6.527 2.22 0.267

18.0 1.1419 31.99 9.510 3.042 48.672 21294 364.52 6.468 2.13 0.256

18.5 1.1465 32.88 9.548 3.139 50.224 21973 376.14 6.409 2.04 0.245

19.0 1.1500 33.76 9.586 3.236 51.776 22652 387.89 6.350 1.96 0.235

19.5 1.1556 34.65 9.624 3.335 53.360 23345 397.23 6.289 1.89 0.227

20.0 1.1602 35.54 9.662 3.434 54.944 24038 411.49 6.228 1.81 2.170

20.5 1.1649 36.43 9.702 3.534 56.544 24738 423.48 6.168 1.75 0.210

21.0 1.1696 37.32 9.741 3.635 58.160 25445 435.58 6.106 1.68 0.202

21.5 1.1744 38.21 9.781 3.737 59.792 26159 447.80 6.044 1.62 0.194

22.0 1.1791 39.09 9.820 3.839 61.424 26873 460.02 5.981 1.56 0.187

22.5 1.1840 39.98 9.861 3.942 63.072 27594 472.49 5.919 1.50 0.180

23.0 1.1888 40.87 9.901 4.047 64.752 28329 484.95 5.854 1.45 0.174

23.5 1.1937 41.76 9.941 4.151 66.416 29057 497.41 5.790 1.39 0.167

24.0 1.1986 42.65 9.982 4.257 68.112 29799 510.11 5.725 1.34 0.161

24.5 1.2036 43.54 10.024 4.364 69.824 30548 522.93 5.660 1.30 0.156

25.0 1.2086 44.43 10.065 4.472 71.552 31304 535.76 5.593 1.25 0.150

B a u m e C o n v e r s i o n T a

b l e s f o r S t a r c h S u s p e n s i o n s - 6 0 ° F *% D.S. = Be deg x 1.7770

Specific Gravity of Starch 1.5 - 1.6

Temperature Corrections

Temperature Add ( °Be)

67 .1

73 .2

79 .3

85 .4

91 .5

97 .6

103 .7

113 .9

118 1.0

123 1.1

These tables are based on the work of J.E. Cleland, E.E.

Fauser and W.R. Fetzer.

See Industrial and Engineering Chemistry, Analytical

Edition, Vol. 15, pp 193-200, 1943

Customer Service

FLSmidth is your One Source for spare parts,

service, maintenance, asset management,

and operational services. Our Customer

Services provide a wide range of services for

food processing equipment and systems

including process design, equipment

installation, troubleshooting, process and

mechanical analysis, and commissioning of

new plants.

We design and install your processing

systems with quality Dorr-Oliver, EIMCO,

Krebs and Pneumapress equipment. Our

experts provide the tools to ensure that your

systems continue to operate at optimum

levels, all the time. It is by no means a radical

concept. Indeed, everyone promises it; we

deliver it!

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