Westfalia Separator Industry

Mechanical Separation Division

Take the Best - Separate the Rest

Starch from Wheat

Always the Right Solution

Technology Leader in Starch Extraction

Wheat is worldwide one of the most important raw materials for the production of starch wheat gluten and starch derivatives, such as sugar syrups. The wheat starch industry introduced centrifugal separation technology, because of the central economic significance and high environmental standard for such process lines. Two unique features of wheat, which are leading to special processing techniques are the presence of two fractions of starch granules which differ considerably in size and shape A+- and A--Starch and the ability of one part of its protein fractions to swell up with water and form, under the influence of mechanical energy, a cohesive visio-elastic mass-gluten. Because of these unique features of wheat, the introduction of the Westfalia Separator patented 3-phase-separation, whether in the starch/gluten extraction or in the starch washing and recovery, will often be the optimal technological solution. In the flow sheet below an illustration of this set up is given.

Decanter CB 505
Main Constructive Changes of decanter CB 50

CA 755
The right size for high capacities CA 755

SDA 130
3-Phase Nozzle Separators

SC 150
Clarification of process water-desludging separators

Long inspection and maintenance intervals No leackages or vapour outlet at liquid discharge Main bearings out of process area 8 (CB 505) and 15 (CB 506) cone angle available Liquid phase discharge with internal centripetal pump under pressure 2-phase or 3-phase versions available Hermetic feed

Highest throughput capacity Design for hydro hermetic feed Various cone angle of bowl Regulation of differential speed even for low Dn High torque because of 2-gear-drive Low energy concept Long operation time

Clarification Classification Concentration Displacement washing High throughput capacity Efficient dismoval of fibres via the middle fraction Clear overflow for process water recycle Low water process

Oxidation due to ambient air is prevented by means of a hermetic liquid seal Short spindle drive for soft, vibration-free operation and low sensitivity to unbalance of bowl Three-phase AC motor for slow acceleration starting Belt drive; no clutch Easy to service by removing the complete drive spindle and the oil pan A hydrohermetic feed can be supplied for shear-sensi tive products depending on the capacity

Endosperm

The morphological structure of a wheat kernel is illustrated by this cross section, demonstrating the problems to transform wheat into wheat flour. The efficient removal of the outer layers of the kernel, called brans is of essential importance and can be realised after thorough conditioning and resting with multiple passage roller milling. Special plan sifter in the sieving section for the adjustment of particle size are used. After all the flour has to surpass a maturation time before processing it into the next separation section. A challenge for the miller is to obtain a high yield on flour besides a very low level of damaged starch.

Cell filled with Starch Granules in Protein Matrix Cellulose Walls of Cells Aleurone Cell Layer (part of endosperm but separated with bran) Nucellar Tissue Seed Coat (Testa) Tube Cells Cross Cells Hypodermis Epidermis Scutellum Sheath of Shoot Rudimentary Shoot Rudimentary Primary Root Root Sheath Root Cap

Individual solutions

Reliable Systems, Environmentally Friendly Process Technique

Flour Conditioning and Gluten Separation

Decanter CB 505/506
Wheat Flour

SDA 130

CA 755
Rotary Brush Strainer
M

SC 70
Fresh Water

Rotary Brush Strainer

M
M

A
M

Weigh Belt Feeder

M
M M

Vital Gluten to Evaporator

M

A - Starch Concentrate to Feed Dryer

Mixer
M
M

Homogenizer

Gluten Finisher

HC-Unit

Starch Slurry to Dewatering Vital Gluten to Gluten Dryer

A continuous pneumatic conveying system of the mill is used for feeding the flour storage silo. Before the flour is mixed with water it passes the weighing system. The water is heated (max. 55C) before it enters the mixer through a dosing system. By use of this special designed mixer it is possible to achieve a smooth pasty consistence of the slurry. The ratio of water to flour is approx. 1:1 depending on the quality of flour. This slurry is pumped by an eccentric screw pump to the high pressure pump. This high pressure pump introduces the mechanical force to aggregate the gluten particles. Thereby shearing forces are being produced which disintegrate the gluten-starch-agglomerates. This is a very important step to achieve high yields and a high quality of final products along with low water consumption and therefor a reduced effluent stream. The slurry coming from the high pressure pump is fed via a buffer tank to centrifugal decanters. These decanters are of 3-phase design. The 3-phase technology was originally developed and firstly installed by Westfalia Separator in the early eighties.

This technology allows to separate the A+-Starch from the slurry and to concentrate it for most effective displacement of soluble substance and suspended impurities, to separate the A--Starch and the gluten, to separate the pentosanes and other slimy gums in one single process step. After the gluten has left the decanter it already forms lumps before it enters the screening system where the A--Starch is washed off. During this washing stage the typical gluten structure is formed. Once the gluten has passed the screening system it is conveyed to the gluten finisher where the protein content is adjusted and sent to the dewatering equipment in front of gluten drying. The underflow from gluten screening which consists mainly of A--Starch still contains some fine gluten particles. In order to recover these fine particles the slurry is check-screened and conveyed to the A--Starch concentration section. The recovered gluten is recycled. The Pentosane fraction leaves the decanter as light phase and is directly sent to effluent treatment. The concentrated A+-Starch passes a check screen in order to separate some fine gluten particles which are recycled via gluten screening. The A+-Starch filtrate is then sent to fibre screening.

Starch Separation and washing

The A+-Starch milk from gluten extraction is fed to a centrifugal screen installation where bran particles and fibres are removed. They are mixed with the A--Starch. The starch milk is collected in a buffer tank and then concentrated in 3-phase nozzle separator equipped with washing devices. While the clarified overflow from the separator is used as process water the middle phase containing starch and most of the suspended impurities is fed to starch recovery. Finally the concentrated starch milk is washed with fresh water in a multistage hydrocyclone system in countercurrent operation. In order to improve the starch yield even the small granule starch can be recovered. Therefore the A--Starch coming from gluten extraction is subject fine fibre removal by means of centrifugal screening. The filtrate as well as the middle phase from prime separation are fed to a buffer tank which is preceded to the recuperation. For starch recuperation a 3-phase separator is being used. The recovered A+-Starch concentrate is recycled in front of prime separation. The A--Starch phase (middle phase) is pumped to the A--Starch concentration section. The overflow of the separator can be used as process water.

A--Starch Concentration and Process Water System. A--Starch and Bran Recovery
The A--Starch fraction as a mixture of the middle phase of A--Starch recovery, along with the pentosanes and fibres dewatered by means of a decanter. The light phase from the A--Starch decanter is fed to a clarifying separator. The concentrate is collected with the dewatered A--Starch. The clarified liquid is recycled to balance the process water demand, any surplus is discharged towards effluent treatment. The process water system is a cascade tank arrangement comprising several tanks for three different water qualities. The fresh water passes through a heat exchanger where it is heated before it enters the system. The various process water streams are distributed inside the wet process in accordance with the technological requirements. The Cleaning-In-Place (CIP) installation is an integrated part of the process water preparation system.

Innovative Concepts
Flour

Innovative Technology
Fields of application:
Corn starch industry Potato starch industry Wheat starch industry Root starch industry Rice starch industry

Slurry Preparation

DA 250 Nozzle Bowl Centrifuge DA 250-06-173 Concentrator

Technical data and capacity Installed power Number of nozzles Rated capacity feed Rated capacity wash water max. 400KW 24 max. 400.000 l/h max. 80.000 l/h

Gluten Washing

3-Phase Decanter CB 505

DA 250-76-173 Concentrator with washing device or concentrate recycling system

Concentration Decanter CB 505

Fibre Sieving

Fibre Sieving

Separation 3-Phase Separator

Processwater 1

CB 505 High Performance Decanter CB 505-02-12 3-Phase Decanter with 2-year drive

Technical data and capacity Installed power Rated Capacity Wheat Flour Processing max. 110KW 68.000 l/h up to 8 t/h

Separation Dekanter CB 505

Separation 3-Phase Separator

CB 506-01-32 2-Phase Decanter for clarification with deep pond

Processwater 2

Sieving

Clarification SC 150

Separation Dekanter CB 505

Washing 3-Phase Separator

Washing Hydrocyclone

Effluent Treatment

SDA 130 Nozzle Bowl Centrifuge SDA 130 Concentrator/3-Phase Separator SDA 130 Concentrator/3-Phase Separator with washing device or concentrate recycling system SDB 110 Concentrator/3-Phase Separator SDB 110 Concentrator/3-Phase Separator with washing device or concentrate recycling system

Technical data and capacity (SDA 130). Installed power Number of nozzles Rated capacity feed Rated capacity wash water 132KW 18 max 180.000 l/h max 40.000 l/h

Gluten

Starch (B-Starch)

Starch (A-Minus)

Starch (A-Plus)

Effluent

Innovative Wheat Starch Processing with 3-Phase Technology

3-Phase Separation has become a well known key element in wheat starch industry, which is today an environmentfriendly and competitive technology. Westfalia Separator decanters as well as nozzle separators in 3-phase design have been configured for special different applications in a wheat starch plant. This process developed by Westfalia Separator offers a lot of economical and operational advantages, based on the fact, that classification and concentration steps are carried out in a single process stage. After effective separation of the wheat vital gluten by means

of a 3-phase decanter, nozzle separators in 3-phase design are operated for A-starch recovery at highest yields and quality but minimized fresh water consumpton. High gluten yield High starch yields Low water consumption In the washing stage, various technical solutions can be offered. For starch granule sizes (> 10um, here the A-plus recovery) several alternatives can be offered. Depending on the requirements, a hydrocyclone or a 3-Phase separator can be integrated. For the recovery and washing of small starch granules (A-minus) the optimum choice for this process step is the 3-Phase separator.

SDB 110. Technical data and capacity Installed power 110KW Number of nozzles 18 Rated capacity feed max 160.000 l/h Rated capacity wash water max 40.000 l/h

SDA 90 Nozzle Bowl Centrifuge SDA 90 Concentrator/3-Phase Separator SDA 90 Concentrator/3-Phase Separator with washing device or concentrate recycling system SDA 70 Concentrator/3-Phase Separator SDA 70-76-107 Concentrator /3-Phase Separator with washing device or concentrate recycling system

Technical data and capacity (SDA 90). Installed power Number of nozzles Rated capacity feed Rated capacity wash water 90KW 12 max 130.000 l/h max 30.000 l/h

SDA 70. Technical data and capacity Installed power Number of nozzles Rated capacity feed Rated capacity wash water 70KW 12 max 125.000 l/h max 20.000 l/h

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Westfalia Separator Industry GmbH

Take the Best - Separate the Rest

A company of mg technologies group

Westfalia Separator Industry GmbH Werner-Habig-Strae 1 D-59302 Oelde (F.R. Germany) Tel.: +49 (0) 25 22/77-0 Fax: +49 (0) 25 22/77-28 28 Internet: www.westfalia-separator.com E-mail: info@gea-westfalia.de

9997-0816-000/0301

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