Starch Protein Potatoes B RR 10-11-0003

7/31/2019 Starch Protein Potatoes B RR 10-11-0003

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Starch and Protein from Potatoes

GEA Mechanical Equipment /GEA Westfalia Separator Group

LiquidstoValue


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A Versatile Tuber

In order to guarantee quality and yield, as well as

a high degree of added value in the process of

recovering potato starch, the overall process must

be designed right down to the smallest detail to meet

the specific needs of the product to be processed.

The water content of potatoes, which are used for

starch extraction for more than 150 years, is notably

high at 75 percent which limits its storability.

Extraction of potato starch thus takes place by

seasonal working.

For the process and machine technology this means

100 percent performance no less from the first day

of the season, 4 hours a day, after a production break of

several months. GEA Westfalia Separator Group

provides the outstanding reliability essential for

success in this sector.

GEA Westfalia Separator Group has been playing an

instrumental part in the advancement of mechanical

separation technology for more than 115 years now.

The basis of the innovative capability of the company

are enormous investments in research and develop-

ment as well as close cooperation with universities,

research institutes and industry. With this approach

GEA Westfalia Separator Group has developed numer-

ous innovative separation processes and brought them

to market by applying first class engineering. Today,

the company can handle a total of 3000 processes.

With this knowledge GEA Westfalia Separator Group

has for example succeeded in developing a process for

making efficient use of fruitwater with the aid of

decanters. This not only makes for additional value

of the overall process in form of more marketable

protein. The fruitwater process also reduces the

consumption of fresh water significantly.


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Before starch can be extracted from a potato, the

starch granules must first be released from the cell

structure. High-performance raspers are used for

this purpose which grate the potatoes quickly and

thoroughly and thus release the starch granules,

fibres and fruitwater.

Water containing SO2 is then mixed with the potato

gratings in order to stabilize the microbiological

conditions in the process and to avoid oxidization.

The soluble constituents of the potato contained in

the fruitwater have to be removed from the overall

process as quickly as possible. Decanters are used

for this purpose; these machines separate the pota-

to fruitwater from the gratings, and thus remove

more than 70 percent of the soluble constituents from

the process.

The clarified fruitwater, which is discharged underpressure from the decanter by means of a centripetal

pump, is conveyed to the protein installation for

further processing. Process water is then added to

the dewatered gratings, and the mixture is passed

through a desanding cyclone in order to remove

sand and other erosive constituents effectively. This

arrangement protects downstream machines against

wear and increases the purity of the end starch.

After desanding, the free starch is extracted in four

stages from the potato gratings with the aid of

centrifugal strainers. This task is performed by

conical and rapidly rotating strainer baskets with a

corresponding strainer perforation and an integrated

washing fac ility. Process water is again used for

intensively washing the starch / fibre mixture. Fibres

and starch are separated from each other via strainers.

The counter-current principle is used in order to

minimize the losses. The fibres pass through the next

strainer stages and are eventually discharged from

the extraction process via the fourth stage for

subsequent pulp dewatering. The starch recovered inevery stage is pumped to the upstream strainer until

it leaves the extraction process via the first strainer

stage. The raw starch milk is then pumped to the

Pure Starch, High Yield, Low Water Consumption

4

3-phase technology

Potatoes

Starch

extraction

Disintegration

Fruitwater

separationDesanding

Starch concentration

and washing


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actual starch washing process via a buffer tank. A

rotary brush strainer is installed upstream of the

multistage separator washing line in order to prevent

larger particles from entering the centrifuges, where

they might clog up the nozzles. The washing line itself

consists of 3-phase nozzle type separators in three

stages working in accordance with the counter-

current principle. Fresh water is added to the final

stage only. The separators separate the starch milk

into fractions of starch, fine fibres and water. The

starch is concentrated in the bowl, where it is washed

and continuously discharged via the nozzles. After

the final washing stage, the starch is conveyed via a

buffer tank to the dewatering stage. The fine fibres

as well as part of the fine-grain starch are discharged

under pressure via the middle phase as a defined

volume. They leave the washing facility via the first

stage and are sent to the fine-fibre straining process.

The water phase is likewise discharged under pressureas overflow and used as process water. This installation

makes for minimum fresh water consumption and

energy costs for the entire process. This can only be

achieved by 3-phase nozzle separators. It also

simplifies subsequent processing of the fine fibres

considerably. The washed and concentrated starch

milk is dewatered by means of vacuum rotary filters

before it is conveyed to the starch drying process. The

filtrate water is recycled to the starch washing stage

in the form of process water. The fine fibres from the

middle phase of the separators are initially separated

from the starch milk in a -stage centrifugal straining

unit. They are simultaneously washed and subse-

quently subjected to further intensive washing before

being conveyed to pulp de-watering. Any filtrate water

is again recycled to the previous stage. A decanter is

used for dewatering the fine fibres as well as the pulp

from the extraction strainers. The clarified phase is

returned in the form of process water to the wet starch

process. The dewatered pulp can either be dried or

removed from the process and used for example as

animal feed.

Fine fiber

screening

Pulp

dewatering

Fruitwater to

protein recovery

Pulp

Starch

to dryer

Starch

dewatering

Fresh water

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The potato fruitwater from starch recovery contains

high-quality and thus valuable protein that can be

recovered in subsequent process stages. It can, for

instance, be used in the animal feed industry.

Additional benefit is achieved as a result of the

considerable reduction in the effluent load. The

protein installation is an important criterion for

treating the effluent in view of the downstream

evaporator or for a biological effluent treatment plant.

The quality of fruitwater separation in the upstream

starch recovery process is extremely important for

the benefit of the protein installation. Depending

on the process configuration used, up to 95 percent

of potato fruitwater can be separated in starch

installations from GEA Westfalia Separator Group

and used subsequently for protein recovery. The sepa-

rated fruitwater is conveyed under pressure and in the

absence of oxygen directly to the protein installation;

this arrangement avoids negative phenomena suchas heavy foaming and product oxidization. Effective

acid-heat coagulation ensures precipitation of the

potato protein.

Additional Value From the Potato

Dual benet

Steam

Acid

Fruitwater feed

CIP system

CIP liquid

Protein coagulation

Protein dewatering

Pre-heater

CIP recycle

Caustic


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Two heat exchanger stages heat the fruitwater

initially from 0 to more than 100 C. At the same

time, acid is added to adjust the pH value to the

isoelectric point as well as direct steam. This is essen-

tial in order to ensure optimum precipitation of the

protein. The mixture is then injected with direct

steam before it is allowed to rest.

This is where the actual flocculation process takes

place, and also where the flocculant stabilizes. In

order to make optimum use of energy, the coagulated

fruitwater is now recycled via a counter-current

arrangement to the second preheating stage, where

it is cooled to approx. 85 C. This is followed by highly

efficient dewatering of the protein by high-perform-

ance decanters from GEA Westfalia Separator Group.

The decanter has been specifically designed for this

application so that it achieves maximum dewater-

ing of the coagulate and optimum clarification of

the residual effluent. A scroll conveys the dewatered

potato protein to the drying stage. Because the digest-

ibility and colour of the protein depends very much

on the temperature, duration and type of drying, the

drying process is very gentle (in ring driers). The

dried product with a residual humidity of approx.10 percent is then sent to storage and packaging. The

clarified fruitwater from the decanter is pumped

through the first preheating stage in a counter-current

arrangement. This enables most of the generated

thermal energy to be used for preheating the fruit-

water and eliminates the costs for external energy

input. The remaining fruitwater can be sprinkled on

fields, evaporated in evaporators or treated appropri-

ately in effluent treatment plants.

The main benets at a glance Optimum product quality and maximum yield

due to the use of the latest centrifugal separation

technology, such as high-performance

decanters and -phase nozzle type separators

Consistent and intelligent use of process water

requires extremely low consumption of

fresh water to minimize the effluent load and

the energy costs of the entire process

Compact closed systems and CIP capability of

the entire process line for meeting the latest

hygiene requirements

In-line recovery of potato protein under

pressure by means of heat coagulation for

efficient utilization of protein

Dual benefit from coagulation:

More marketable protein

Less effluent load Depending on the specific requirements, a fully

automatic computer-driven process control

facility can be supplied

Protein drying

Residual fruitwater to evaporator

Protein

powder

to silo


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Fine-Tuning for Maximum Dewatering

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Platzhalter Motive

GEA Westfalia Separator Group supplies decanters

in a wide range of sizes and designs always

customized for the specific processing capacity and

the separating task in hand.

In the process of recovering starch and protein

from potatoes, decanters are used for separating the

fruitwater, dewatering the coagulated protein and

for dewatering the pulp. Sophisticated drive systems

ensure a high dry matter content. Decanters from

GEA Westfalia Separator Group have specially designed

drive systems which allow a very smooth adjustment

of the differential speed to the starch or protein

quantity to be separated. This is the only way in which

maximum dewatering and separating capacities can

be achieved.

Drive systems

GEA Westfalia Separator Group decanters have

specially designed drive systems.

2-gear drive

With this drive, the main drive motor drives the bowl

and the housing of the primary gear. An additional

secondary gear allows part of the power required for

the scroll drive to be provided by the secondary motor.

The current of this motor serves as a measure of

torque-dependent differential speed control. The

drive is electronically monitored and can thus

be restarted. Downtimes due to overloading are

thus ruled out and smooth operation is guaranteed.Decanters with this drive, which is patented in many

countries, are used when high torques are required

for maximum yields at low differential speeds.

Differential gear drive

The differential gear drive is recommended when

automatic control of scroll speed is required in

addition to bowl speed control. This is made possible

by the use of two gears. The secondary motor drives

the central inlet shaft and generates the differential

speed proportionally to its own speed. A second inlet

shaft with no speed is connected to the housing. This

makes differential speed independent of bowl speed.

Differential gear drives are used primarily for the lower

differential speed range.

Westfalia Separatorvaripond

reliable mastery of solids concentration

This control system uses existing capacities so

accurately that maximum results are achieved for

minimal duty. Westfalia Separatorvaripond means

variable pond depth with machine running. Even if

feed concentration varies dramatically, the

system controls the liquid level in the decanter bowl

so accurately that the concentration of the con-

centrated solids can be set to a constant value and

maintained exactly. Westfalia Separatorvaripond

facilitates much lower-energy operation, because

adapting the g-force to feed conditions and the

associated reduction in speed allow electrical

energy to be saved. Wear to the components is reduced

and their service life is increased.

2-gear drive Differential gear drive Westfalia Separator varipond


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Solids

discharge

Pressure

discharge

of clarified

liquid

In addition, the simple and optimum facility for adjust-

ing the pond depth can also be used for increasing

the relative clarifying area; this means that extremely

small particles can be separated during the protein

recovery process itself, and excellent separating effi-

ciencies can be achieved. As the clarified liquid is dis-

charged under pressure, the bowl chamber is hydro-

hermetically sealed.

This arrangement avoids additional oxygen

intake and also particularly avoids foaming which

would result in product losses. GEA Westfalia

Separator Group decanters are also CIP-capable in

line with the requirements applicable for process

management which meets the requirements of the

food industry. The twin frequency converter drive

enables the machine to operate at low bowl speeds

to ensure that chemical cleaning is even more effi-

cient. In addition, the decanters are lined completely

with stainless steel, which means that no corrosion

damage can occur. Automatic circulation of lubricat-

ing oil ensures that the decanters have a long servicelife and high availability; the compact design means

that the decanters do not require much space when

they are installed.

The main benets at a glance Variable drive, torque-dependent differential

speed regulation for constant and extremely

high solids concentration even in conjunction

with fluctuating feed concentrations

Adjusted drive concepts: -phase motor with

frequency converter for regulating the bowl

speed or motor for controlled torque starting

Automatic lubricating oil circulation: long

bearing lives due to cooling lubrication and

filtering

Patented pond depth regulator

Westfalia Separatorvaripond: pond depth

adjustment while the machine is running

Paring disc: hydrohermetic operation and

energy saving due to small diameter

Maximum dewatering combined with

maximum separating efficiency

Material and sealing systems matched to the

specific product


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Wash water

Intelligent Machine Technology

for Efficient Processes

High purity, high concentration

A major advantage of 3-phase nozzle type separators

is their ability to enable the water phase to be used

as process water in the entire process and thus to

enable the overall consumption of fresh water to be

significantly reduced. Upon request, GEA Westfalia

Separator Group can of course also supply nozzle-

type separators in 2-phase design.

Nozzle type separators are primarily used for

recovering potato starch. The concentrated starchmilk is extremely pure. It is continuously ejected

through nozzles at the periphery of the bowl, and

then discharged.

An important aspect is guaranteeing a high and also

constant starch concentration. For this purpose, the

starch mass in the bowl is continuously measured. An

intelligent density regulating facility automatically

compensates for any fluctuation by recycling the

necessary amount of concentrate; this arrangement

means that the separator always discharges a constant

starch concentration. The nozzle type separator with

washing facility is used whenever the process requires

additional washing of the suspension.

As the starch fraction is washed with water directly

before the nozzle discharge, process water of poor

quality is displaced from the concentrate area. This

displacement washing ensures that the starch which

is recovered has a high concentration and is very pure.

The quantity of wash water depends on the through-put capacity of the separator and the required degree

of purity of the starch.

In a 3-phase bowl fine fibres which are separated

from the starch are discharged under pressure by a

centripetal pump as a defined volume together with

a proportion of small granule starch. The water

phase is clarified in the built-in disc stack and is also

discharged from the separator under pressure via the

overflow as process water.

Discharge,

light phase

Product feed

Discharge,

middle phase

Discharge,

solids

concentrate

Wash water

3-phase nozzle separator with

at belt drive


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The -phase separator separates into a heavy starch

suspension and a light clear phase consisting of

process water, fine fibres and small granule starch.

With the direct drive, developed by GEA Westfalia

Separator Group, the power is transmitted to the bowl

directly. Due to the gearless drive there is no trans-

formation of speed anymore. Therewith motor sizes

of up to 600 kW are possible which provide for a tre-

mendous boost of performance. Moreover, no energy

is wasted as the transmission is virtually loss-free.

Another great advantage is that the gearless drives

require a minimum of service and maintenance.

The main benets at a glance

Discharge of the concentrate under pressure

via nozzles, discharge of the other phases via

centripetal pump this permits very efficient

counter-current washing with a small number

of washing stages and minimum consumption

of fresh water

The latest sophisticated drive concepts ensure

maximum performance with minimum

maintenance

Washing of the starch suspension before the

nozzle, resulting in high purity and concentration

of the discharged potato starch

Clarifier bowl with closed feed and discharge of

the product phase to avoid oxygen absorption

The solids concentrate is discharged

continuously from the bowl through special

nozzles which save energy due to their specificdischarge angle

CIP cleaning at operating speed

Short spindle drive for low-vibration running

Speed monitoring

Irrespective of whether small or large

capacities are involved GEA Westfalia

Separator Group provides nozzle-type separators

for all desired processing capacities

Discharge,

light phase

Product feed

Discharge,

solids

concentrate

Wash water

2-phase nozzle separator with direct drive


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The information contained in this brochure merely

serves as a non-binding description of our productsand is without guarantee.

Binding information, in particular relating to capacity

data and suitability for specific applications, can only beprovided within the framework of conc rete inquiries.

Westfalia, Westfalia Separator and varipond areregistered trademarks of GEA Mechanical Equipment GmbH.

Printed on chlorine-free bleached paperwww.kabutz.de

B_RR-10-11-0003 ENPrinted in GermanySubject to modification

Werner-Habig-Str. 1 59302 Oelde (Germany)

Phone +49 2522 77-0 Fax +49 2522 77-1794

www.westfalia-separator.com

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Starch Protein Potatoes B RR 10-11-0003

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