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
GEA Mechanical Equipment / GEA Westfalia Separator3
World Protein Meal Consumption 2008
Source: USDA
230 Million Tons Protein Meal
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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
GEA Mechanical Equipment / GEA Westfalia Separator5
Molecular Protein Structure
GEA Mechanical Equipment / GEA Westfalia Separator6
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
GEA Mechanical Equipment / GEA Westfalia Separator7
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
GEA Mechanical Equipment / GEA Westfalia Separator8
Protein Structure
Primary Secondary Tertiary Quaternary
alaaf
GEA Mechanical Equipment / GEA Westfalia Separator9
Protein Properties
Water Binding
Gel Forming
Emulsifying
Foaming
Nutritive Value
Solubility
GEA Mechanical Equipment / GEA Westfalia Separator10
Comparison of Raw Materials
for Protein Processing from
Carbohydrate Containing Plant
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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
GEA Mechanical Equipment / GEA Westfalia Separator
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
GEA Mechanical Equipment / GEA Westfalia Separator14
Processes for the Recovery
of Proteins out of
Different Raw Materials
GEA Mechanical Equipment / GEA Westfalia Separator15
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
GEA Mechanical Equipment / GEA Westfalia Separator16
Simplified Milling Principal
Kernel Endosperm Germ Bran
GEA Mechanical Equipment / GEA Westfalia Separator
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
GEA Mechanical Equipment / GEA Westfalia Separator
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
GEA Mechanical Equipment / GEA Westfalia Separator
Milling Equipment
www.muehlenbau.de www.buehlergroup.com
Roller Mill Plan Sifter Hammer Mill
Peeler Rubber Roll Peeler
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Ultra Rotor for Milling and Drying
www.jaeckering.de
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Peeling
Schule Mühlenbau
GEA Mechanical Equipment / GEA Westfalia Separator
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
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Air Classification
GEA Mechanical Equipment / GEA Westfalia Separator24
Air Classification
1 Flour Feed2 Sifter Wheal3 Outlet Fine Fraction4 Outlet Coarse Fraction5 Aspiration
31 2
4
5
ALPINEHOSOKAWA
Fine Sifter
Sifter Mill
GEA Mechanical Equipment / GEA Westfalia Separator25
Different Types of Protein Recovery
Mechanical TreatmentCorn, Wheat
Chemical TreatmentPea, Barley, Oat, Rye, Rice
Thermal TreatmentPotato
GEA Mechanical Equipment / GEA Westfalia Separator
Solubility of Soy Protein Depending on the pH
26
pH of the Solution
% N
-Sol
ubili
ty
GEA Mechanical Equipment / GEA Westfalia Separator
Solubility of Rape Seed Globulin Protein
27
pH of the Solution
% N
-Sol
ubili
ty
AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA
GEA Mechanical Equipment / GEA Westfalia Separator
Solubility of Rape Seed Protein
28
% N
-Sol
ubili
ty
pH of the Solution
GEA Mechanical Equipment / GEA Westfalia Separator29
Corn Processing
for
Protein Recover
GEA Mechanical Equipment / GEA Westfalia Separator
Corn Kernel
30
Floury Endosperm
Horny Endosperm
Germ
Flower Stalk
Dark Surface Layer
GEA Mechanical Equipment / GEA Westfalia Separator
Cross Sections of a Corn Kernel
31
GEA Mechanical Equipment / GEA Westfalia Separator
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
GEA Mechanical Equipment / GEA Westfalia Separator
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
GEA Mechanical Equipment / GEA Westfalia Separator
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
GEA Mechanical Equipment / GEA Westfalia Separator
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
GEA Mechanical Equipment / GEA Westfalia Separator
Wet Milling from Corn
Steeping
CornGerm Washing Germ Dewatering
Dewatered Germs
PW
Husks, Fibres, Starch, Gluten
PW
Grinding & GermSeparation
GEA Mechanical Equipment / GEA Westfalia Separator
Wet Milling from Corn
PW
fromMilling
Dewatered Husks
Dewatered Coarse Fibres
Starch
PW
DewateredGlutenPW
PrimarySeparation
GlutenConcentration
GlutenDewatering
Fibre Dewatering
FibreExtraction
Husk Dewatering
StarchWashing
GEA Mechanical Equipment / GEA Westfalia Separator
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
GEA Mechanical Equipment / GEA Westfalia Separator
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
GEA Mechanical Equipment / GEA Westfalia Separator
Dewatered Corn Gluten
40
GEA Mechanical Equipment / GEA Westfalia Separator
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
GEA Mechanical Equipment / GEA Westfalia Separator
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
GEA Mechanical Equipment / GEA Westfalia Separator43
Wheat Processing
for
Protein Recovery
GEA Mechanical Equipment / GEA Westfalia Separator
Wheat Kernel
44
GEA Mechanical Equipment / GEA Westfalia Separator
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
GEA Mechanical Equipment / GEA Westfalia Separator
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
GEA Mechanical Equipment / GEA Westfalia Separator
Wheat Quality Depending on Flour Yield
47
AleuronLayer
Bran
Endosperm
Flour Yield
GlutenContent
ProteinContent
MineralContent
RMTVolume
AAAAAAAAAAAAAAAAAAAAAAAAAAaaaaaa
GEA Mechanical Equipment / GEA Westfalia Separator
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
GEA Mechanical Equipment / GEA Westfalia Separator
Wheat Flour Process
49
Homogenizing
Separation
Sieving
Washing ProcessWaterProcessWater
StarchStarch
Mixing
WaterWaterFlourFlour
PentosansPentosans
SievingWashing
Dewatering Recovery
Drying
FiberFiberGlutenGluten
GEA Mechanical Equipment / GEA Westfalia Separator
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
GEA Mechanical Equipment / GEA Westfalia Separator
Dough mixingDough Mixer in Process
51
GEA Mechanical Equipment / GEA Westfalia Separator
The high pressure introduced by a homogenizer ensures the necessary Energy Input for agglomerating the Gluten.
Energy Input
Energy Input
52
Slurry Preparation
GEA Mechanical Equipment / GEA Westfalia Separator
Bend Screens for Gluten Separation
53
GEA Mechanical Equipment / GEA Westfalia Separator
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
GEA Mechanical Equipment / GEA Westfalia Separator
Protein Structure
55
Wheat Protein Rye Protein
Source: Margit Beck, Tagung für Getreidechemie, 24.06.09
GEA Mechanical Equipment / GEA Westfalia Separator
Wheat Protein Aggregates
56
GEA Mechanical Equipment / GEA Westfalia Separator
bar=100 µm
57
Protein Network after Agglomeration of the Protein
GEA Mechanical Equipment / GEA Westfalia Separator
Isolated Wet Wheat Gluten
58
GEA Mechanical Equipment / GEA Westfalia Separator59
Potato Processing
for
Protein Recover
GEA Mechanical Equipment / GEA Westfalia Separator
https://www.nottingham.ac.uk/ncmh/lecture.../D2DBT1_Sandra_Starch.ppt
Micrographs of Potato and Root Cells
GEA Mechanical Equipment / GEA Westfalia Separator
Micrographs of Potato Cells
61
GEA Mechanical Equipment / GEA Westfalia Separator
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
GEA Mechanical Equipment / GEA Westfalia Separator
• 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
GEA Mechanical Equipment / GEA Westfalia Separator
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
GEA Mechanical Equipment / GEA Westfalia Separator
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
GEA Mechanical Equipment / GEA Westfalia Separator
Protein Recovery from Potato Fruit Water
66
Steam
Acid
FruitwaterFeed
Preheater
CIP Recycle
CausticCIPSystem
CIP Liquid
ProteinCoagulation
ProteinDewatering
ProteinDrying
Residual Fruitwaterto Evaporator
GEA Mechanical Equipment / GEA Westfalia Separator
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
GEA Mechanical Equipment / GEA Westfalia Separator68
Other Raw Materials
for
Protein Recover
GEA Mechanical Equipment / GEA Westfalia Separator69
Soy Flour Processing
for
Protein Recovery
As Basic Process for other Starch and
Carbohydrates Containing Raw Materials
GEA Mechanical Equipment / GEA Westfalia Separator
Cross Section Soy Bean
70
GEA Mechanical Equipment / GEA Westfalia Separator71
Soy Protein Process
Protein Extraction
ProteinPrecipitation
Protein Washing
ConditioningModification
Protein Extraction
ProteinPrecipitation
ConditioningModification
Sugar Removal
ConditioningModification
AlcoholExtraction
ConditioningModification
White Flakes
Protein Concentrate
Protein Concentrate
Protein Concentrate
Protein Isolate
GEA Mechanical Equipment / GEA Westfalia Separator72
Soy Protein Process
GEA Mechanical Equipment / GEA Westfalia Separator
Extraction of Soy Protein from Soy Flakes or Flour
73
GEA Mechanical Equipment / GEA Westfalia Separator
Protein Precipitation and Washing
74
Spray DryerUHT
GEA Mechanical Equipment / GEA Westfalia Separator
Membranfiltration in Protein Process Lines
75
GEA Mechanical Equipment / GEA Westfalia Separator
Protein Precipitation and Washing
76
GEA Mechanical Equipment / GEA Westfalia Separator77
Pea Processing
for
Protein Recover
GEA Mechanical Equipment / GEA Westfalia Separator
Some Pea Types
78
GEA Mechanical Equipment / GEA Westfalia Separator
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
GEA Mechanical Equipment / GEA Westfalia Separator
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
GEA Mechanical Equipment / GEA Westfalia Separator
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
GEA Mechanical Equipment / GEA Westfalia Separator82
Pea Processing
GEA Mechanical Equipment / GEA Westfalia Separator83
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
GEA Mechanical Equipment / GEA Westfalia Separator84
Rice Processing
for
Protein Recover
GEA Mechanical Equipment / GEA Westfalia Separator85
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
GEA Mechanical Equipment / GEA Westfalia Separator86
Protein Recovery
From Ethanol Processes
GEA Mechanical Equipment / GEA Westfalia Separator
Bioethanol – The Dry Mill Process
GEA Mechanical Equipment / GEA Westfalia Separator
Protein and Oil Recovery in an Ethanol Plant
GEA Mechanical Equipment / GEA Westfalia Separator
Many Thanks for Your Attention!
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