1 - Presentation Genencor 2011 05 25

Starch-Protein-Separation-Analysis
Mechanical Separation Technologies

in the
Grain Processing Industry
Genencor
May 25th, 2011, Leiden, NL
Dr. Willi Witt, ProAmid Consult GmbH
After the lecture discussion about different laboratory methods

that can be used for various separations like:
- Starch - gluten separation
(how can we best measure the influence of different enzyme
on the separation and quality of the products)
- Separation of residual starch, syrup, lipids from
Introduction Dr. Willi Witt
10 years school
3 years bakers apprentice
2 years worked as a baker
2,5 year study at Technische Fachhochshule Berlin
2,5 years study at Technische University Berlin
1 year assistant at the Institute of Biotechnology at the
University of Berlin
15 years technical manger in a wheat starch factory, Germany
20 years Business Unit Manager GEA Westfalia Separator
Group GmbH
Introduction Dr. Willi Witt
Study Technische Universitt Berlin andTechnische

Fachhochschule Berlin
- StarchTechnology
- Milling Technology
- Food Technology
- Fermentation Technology
- DistilleryTechnology
-Biochemistry
Thesis Technische Universitt Berlin
-Process and Economic Comparison of MethodsTreating of Waste
Water from a Wheat Starch Plant with Special Reference to
Anaerobic-Aerobic Treatment
Separation technology in process engineering

procedures
Basic
operations
Automation
Mixing
Thermal
Treatment
Screening Technology
Static Filtration
Filter
centrifuges
Peeler
centrifuges
Separators
Separation
Packing
Storage
Centrifugal Separation Technol.
Membr.techn.
Sedimentation
Centrifuges
Strainer
centrifuges
Decanters
Flow
Handling
Sedimentation/
Flotation
Mechanical
Separation
Techn.
Other
centrifuges
Centrifugal
Separation
Techn.
Mechanical Process Engineering
A common task of the process technology is the

separation
of
substances
of
one
or
more properties. In the mechanical processes usually
solid mixtures according to one or more particle
characteristics are separated . Quality and yield
of the separation is an important criteria for the
technical process.
Withn the basics of mechanical operations, it may be
the following process steps: act crushing, sorting,
grading, sedimentation, pressing, centrifugation,
filtration and flotation.
Mechanical Process Engineering

Type of the mechanical process
steps
Crushing
Sorting
Classification
Sedimentation
Pressing, squeezing
Centrifugation
Filtrieren
Flotation
Application
Roller mill, Sifter mill
Cleaning of cereals
Separation of starch and proteins
Separation of starch granules
Dewatering of potatopulp
Separation of starch and fibres
Dewateing of starch
Separation of corn gluten
Thermal Process Engineering
Thermal separation processes are using differences in

the concentration of solids in different streams. The
second phase is generated by the supply and
dissipation of energy (heat) or/and additives.
Thermal separation processes are carried out in one or
several stages and intermittently or continuously. The
main targets for assessing the separation efficiency is
the purity of the product as well as the throughput or
capacity.
Thermal Process Engineering

Type of thermal process
steps
Evaporation
Mild evaporation - drying
condensation
Destillation
Rektifikation
Kristallisation
Extraction
Application
Concentration of waste water

Drying of starch in a flash dryer
Heat recovery after a dryer
Recovery of ethanol
Separation of water and ethanol
sugar
Proteinextraction out of flour and
starch
Extraction with supercritical Fat and coffein extraction
gases
Absorption
Carbon filtration von Glucosesirup
Membrane filtration
Process and waste water treatment
Solving the problem phase separation solid-liquid
Process parameter
-Volume stream
- Temperature
- Pressure
Nature of the
solids
Phase separation
Process technology
Mechanical
Engineering
Nature of the
fluid
Methods for the separation solid-liquid
Filtration
Phase separation solidliquid as a result of a
Pressure Difference
which is the motive power

for enabling the liquid phase
to flow through the
capillaries of the solid phase
Sedimentation
Phase separation solidliquid as a result of the
Centrifugal Force
which is the motive power

for separating the phase of
lower specific gravity from
the phase of higher
specific gravity
Basic knowledge of separation technology
Fundamentals
Stoke's law
Clarification area
Equivalent clarification area
Fundamentals of Centrifugation
Centrifugal Force
Vz = VE =
Gravity: 1 x g
VE =
D
g
18
D
R .w
g T
18
g
- Separation path / Number of discs

- thicknes of spacers
- height of bowl
Stokes law
Sedimentation
D *
Vs =
* g
18 *
D
= particle diameter
= difference in density
= dynamic vicosity
= gravitational force
2.2
Centrifugation
Vz =
r
= radius of
= ancle acceleration
D *
* r *
18 *
Vs
2.3
Accelarat ion f act ors
G=
2.4
Loading of clarif icat ion surf ace
Qf
r *
g
Q = volume st ream [cm/sec]

A = Clarif icat ion surf ace [cm]
Q
[cm / sec]
A
Separation procedure in a disc stack
Clarified Liquid
VS
r2
Vr
Sediment
r1
Suspension
Main Target for Usage of Mechanical Separation
Concentration
Clarifying
Separation - Classification
Dewatering
Nature of the fluids
Viscosity
pH-value
Corrosivity
Temperature
Specific weight / Density difference
Concentration of the solids / Interaction with fluid
Type of Machines for Mechanical Separation

Type of Machine
Principal
Solid Wall Disc Separator
Discontinuously
Self Cleaning Disc Separator
Partly Discontinuously
Job to be Done
Two Phase Separator
Clarifying
Three Phase Separator
Separation
Nozzle Bowl Disc Separator
Continuously
Two Phase Nozzle Separator
Separation - Clarifying
Three Phase Nozzle Separator

Two and Three Phase
with Washing Device
Separation - Clarifying
Washing
Viscon Nozzle Separator
Concentration
Decanter
Continuously
Two Phase Decanter
Concentration
Three Phase Decanter
Separation - Concentration
Hydrocyclon
Continuously
Separation - Washing
Membran Filtration
Continuously
Separation - Concentration
Product Related Conditions Influencing

the Separation Efficiency

Concentration of the Feed Stream

Composition of the Feed Stream
Viscosity
pH
Temperature

Particle Size
Particle Distribution
Density of Particle
Density of the Liquid
Behavior of Particles like Water Binding Behavior
Ratio of Volume %/Suspended Solid % DS
Feed Volume
Machine related conditions influencing

the separation efficiency
G-Force
Clarification Area
G-Volume
Retention Time
Feed Design
Internal Flow Geometry
Motor Size
Ejection Time in Case of Self Cleaning Separator
Volume of Solid Holding Space
Liquid Load of the Disk Stack in l/m/h
The challenge: to remove shear sensitive particles by

centrifugal force
vs.
Holding time
Space requirement
Acceleration
Capacity
approx. 3600 sec.

1000 m2
1 x g-force
100.000 l/h
approx. 2 sec.
2 m2
approx. 10.000 x g
100.000 l/h
Particle size and separation technology

Centrifugal
Separator
NF/RO
Separation
Technology
Decanter
Micro-/Ultrafiltration
< optical Microscop
< REM
Micrometer
(Log.- Scale)
Angstrom
(Log.-Scale)
Molecule weight
(Dalton)
0,001
2 3
5 8
10
0,1
0,01
2
2 3
5 8
10
5 8
10
100 200 1.000 10.000 20.000 100.000
solved minerals
1,0
2 3
active carbon
10
2 3
5 8
10
100
2 3
5 8
10
2 3
5 8
10
2 3
sugar
colloid silica
beach sand
bacteria
red blood
cells
hair
metall. ion
albumin protein
5 8
colour pigment
yeast cells
virus
1000
500.000
pyrogene
Relative size of
common
material
< visible for naked eye
flour
1 Angstrom = 10 -10 meter = 10 -4 micrometer
10
2 3
5 8
Fields of application of centrifuges

in accordance with particle size
Particle size in m
0,1
Separator with clarifier bowl
Separator with self cleaning bowl
Separator with nozzle bowl
Decanter
Basket centrifuge
Knife centrifuge
Pusher centrifuge
10
100
1000
10.000
100.000
Possible ways of separation according

to the nature of particles
Possible ways of separation
Nature of the particles
coarse dirt, sand

fibres
salts, crystals
crystals
big microorganisms
Sedimenter/Hydrocyclone/Sandfilter/Vibration
screen
Inclined screen/Vibration screen
Pusher-Peeler-Centrifuges/Decanter
Centrifuges/CMF/Settling filter
Centrifuges/CMF/UF/Sheet filter
cell material, particles
Centrifuges / CMF/UF/membrane filter/sheet

filter
colloidal, incompressible
Bacteria
Centrifuges / CMF/UF/membrane filter/sheet

filter
colloidal, compressible
cell material, cell particles, Centrifuges / CMF/UF/membrane filter/sheet

particles of the cell wall
filter
coarse, incompressible
coarse, compressible
Coarse = > 1m
colloidal = < 1 m
Data of important industry centrifuges
Basic type
Solids content
(Vol.-%)
Solids particle size

(m)
Throughput (t/h)
Typical applications
Basket oscillating screen

centrifuge
6080
50010.000
20300
Kali residues, coal

sludge, sea salt
Screen centrifuge
5.60
10 10.000
0,5100
Crystalline and fibrous

substances
Pusher centrifuge
2075
100 40.000
0,8.50
As above mentioned
e.g. polymers
PVC
Peeler centrifuge
560
510.000
30 kg .. 2 t per bowl
filling
Polymers,cellulose,
suspensions
Decanter centrifuge
360
1 20.000
280
Proteins,
pharmaceuticals,
clarification sludge
Disc centrifuge
125
0,110.000
.1000
Kaolin, pigments,
catalysts
Baffle ring centrifuge
895
500.10.000
20200
Synthetic granules
Centrifuge choice according to the process requirement
Liquid-LiquidExtraction
Pusher centrifuge
Worm/screen
centrifuge
Peeler centrifuge
Decanter
discontinuous
separator
self-cleaning
separator
Nozzle type
separator
Separation
of liquid
mixtures
Dewatering of Dewatering of
Clarification of Concentration solid-liquid amorphic
cristalline
liquids
of Sludges
extraction materials
materials
Wet classification
Technological evaluation of Systems applied

for mechanical separation
Particle
structure/
Features
Pusher and
peeler
centrifuge
Separators
Decanters
CMF/UF
VDF
Chamber filter
(press)
++
++
++
+++
+++
++
+++
+++
++
++
Fibres /
Micelles
(compressible)
++
+++
++
++
Anorganic
colloids up to
nanoparticles
+++
Crystalline
Colloids from
biological
sources
(compressible)
Yeasts/
Bacteria
Technological evaluation of Systems applied for mechanical

separation
Pusher &
Peeler
centrifuge
Separator
Decanter
CMF/UF
VDF
Chamber filter
(press)
Solids high
concentration
+++
+++
+++
Throughput
high capacity
+++
+++
++
++
+++
++
Sanitary Design
+++
++
++
+++
Continuous
operation
+++
+++
++
++
++
Centrifugal force
Centrifugal force
Pressure
difference
Pressure
difference
Pressure
difference
Centrifugal Force
Features
High D.S.
Price / Capacity
Active
principle
Choice of centrifuges because of solid concentration

Disc Separator
Disc Separator
Chamber
Desludging
- up to 0,5 Vol%
- up to 10 Vol%
- manual
Nozzle Bowl Separator
- up to 25 Vol%
- continous
- automatic
Decanter
- up to 60 Vol%
- continous
Spin Test Results
Sch e m a t i sc h e D a r st e l l u n g d e r
Be ch e r s ch l e u d e r
n = 6 0 0 0 m i n -1
100
90
80
70
60
50
40
30
20
10
Liquid Fraction with Colloidal and Soluble Solids
a
b
a =
m i t t l e r e z = 4 3 0 0 x g (m s )
b = m a x i m a l e z = 6 2 0 0 x g ( m s )
Soft and Cremy Solids like Pentosanes, Fine Fibres
5
1
0,1
Heavy Solids like Starch, Proteins, Coarse Fibres
Product Specification for Wheat
100
90
80
70
62 % Liquid = 3,6 % DS soluble solids
60
50
40
30
20
10
5
1
0,1
18 % Vol. Protein+Micro Fibre = 1,9 % DS

insoluble solids
20 % Vol. Fiber = 4,8 % DS insoluble solids
Particles from biological sources are stress-sensitive

with flocculants they form large collectives which settle immediately.
Trub micelle
Collective floc structure
Collective of shear-sensitive
particles
Floc structure after influence of

shear/acceleration force
Disc Type Separator

with Chamber Bowl
Disc-Type Separators with Chamber Bowl
Solid wall bowls are mainly used for separation processes with little or no solids in feed.
They are available as clarifiers and separators
The valuable solids are separated out in the single chambers and have to be removed manually
for fermentation suspension, human blood plasma, diamond containing dust
Clarifier bowl
with open discharge
Separator bowl
with open discharge
Disc Type Separotor

with Nozzles
Two Phase Version
Three Phase Version
Wash Water Device
Belt Drive
Direct Drive
Standard nozzles bowl of a 2-Phase nozzle separator

In case of 2- phase nozzle type bowls the product feed is separated into concentrate
and Clarified liquid. The concentrate is discharged via nozzles
Nozzle type separators operate continuously.
continuously. They can handle up to 25 % solids by
volume in the feed
Discharge of
Clarified
Phase
Feed
Concentrate
Discharge
1 bowl wall
2 nozzle holder
3 sealing ring
4 hard metal nozzle
Flow pattern in a disc

Nozzle Separators
Three Examples of Nozzle Separators
SDC 130
for Starch Application
HFB 100
DC 130
for Mineral Application
for Fermentation Application
Clarifier / Separator
Nozzle Separators can be 2- oder 3-Phase Separators

(Clarifiers or Separators)
Nozzle Separator with Recycling

Recylcling
Feed
Overflow
Feed
SDA 2-Phase Separator for Starch and Yeast Recovery
Feed
Clarified
Liquid
Concentrate
Wash Water Feed as Special Feature of

Starch Separators
Disc Type Separotor

Viscon Nozzle
Two Phase
Three Phase Version
Belt Drive
Direct Drive
Overview of Components
The nozzles are located close to the center in the top area of
the bowl. The concentrate is
discharged under pressure by centripetal pump
15 VISCON
nozzles
5 Concentrate phase
via centripetal pump
Functional principle of the viscon nozzle
Decreasing viscosity of the concentrate in front of the nozzle due to

decreasing concentration of the product fed into the bowl
high turbulence in the chamber in front of the nozzle
reduced discharge volume
Increasing viscosity of the concentrate in front of the nozzle due to

increasing concentration of the product fed into the bowl
low turbulence in the chamber in front of the nozzle
increased discharge volume
HFC 15 trials with washed BakersYeast

Solids Concentration of Nozzle Discharge
100
Viscon Nozzle Separator HFC 15
Feed Concentration
Trials with washed bakers yeast

Solids concentration of nozzle discharge
Concentration of
nozzle discharge
3,0 min / 20C
3,0 min / 20C
Nozzle diameter 1 mm
Solid concentration of nozzle
discharge [vol%]
100
90
80
70
60
50
40
30
20
10
Nozzle diameter 0.8 mm
Nozzle diameter 1.5 mm
Supernatant
70 vol. %
Yeast 30 vol. %
100
90
80
70
60
50
40
30
20
10
5
1
0,1
0,1
0
0,00
0,50
1,00
1,50
Flow of concentrate [m / h]
Also at lower flow rates higher concentration of nozzle discharge compared to

conventional nozzle separator
A variation of feed capacity and feed concentration has very little influence on
the separating quality
No blocking of nozzles due to special nozzle design in the bowl top of the
separator
Supernatant
20 vol. %
Yeast 80 vol. %
Self Cleaning
Disc Type Separotor
Two Phase
Three Phase Version
Belt Drive
Direct Drive
with Nozzle in Sliding Piston
Disc Type Separator with Self Cleaning Bowl
The Discharge of Solids Happens at Full Bowl Speed by Total or Partial Desludging
Controlled over the Time or Turbidity
Feed
inlet
Supernatant
discharge
Solids discharge
Operating water discharge
Operating water feed
e.g. SC 70-06-777
Recovery and Clarification Separator

Cross Sectional Drawing of HSB Separator
Clarification Area up to 400.000 m
Target 1
Target of the Separation with Cleaning Disc Type Separators is to Optimize the Feed Rate at Highest
Concentration of the Solid Discharge and Clear Supernatant.
Figures below are Examples and Product Dependent
100
90
80
70
60
50
40
30
20
10
90 vol% liquid
100
90
80
70
60
50
40
30
20
10
20 vol% liquid
80 vol% concentrate
100
90
80
70
60
50
40
30
20
10
0,1
0,1
10 vol% solids
0,1
feed
concentrate discharge
99,8-99,9 vol% liquid
0,1-0,2 vol% solids
supernatant
Self Cleaning Disc Type Separator
Overflow Losses Depending on Feed Volume

Separable Solids 10 % by Volume in Feed Stream
Ejection Intervalls Every 1 Second
Feed Solids m/h

Solid Discharge m/h
OF Vol. %
Feed m/h
Self Cleaning Disc Type Separator with Nozzles

Ejection Intervalls every 2 Seconds
Solid Discharge m/h

Feed Solids m/h
OF Vol. %
Feed m/h
Target 2
Target of the Separation with Cleaning Disc Type Separators is to Optimize the Feed Rate at Highest
Concentration of the Solid Discharge and Clear Supernatant.
Figures below are Examples and Product Dependent
100
90
80
70
60
50
40
30
20
10
90 vol% liquid
100
90
80
70
60
50
40
30
20
10
20 vol% liquid
80 vol% concentrate
100
90
80
70
60
50
40
30
20
10
0,1
0,1
5 vol% solids
0,1
feed
concentrate discharge
99,8-99,9 vol% liquid
2 - 4 vol% solids
supernatant
Self Cleaning Disc Type Separator

Feed Solids m/h
OF Vol. %
Solid Discharge m/h
Feed m/h
Self Cleaning Disc Type Separator with Nozzles

Feed Solids m/h
OF Vol. %
Solid Discharge m/h
Feed m/h
Comparison nozzle separator selfcleaning separator
Selfcleaning Separator
Nozzle Separator
Good clarification efficiency
Good clarification efficiency
Partly continuously operation
Fully continuous operation
Relatively high solids concentration, if partial

ejections are possible
Usually low solids concentration compared to

selfcleaning separators in case of partial
ejections
can be connected to CIP- circulation
CIP- circulation possible with special

installation (if product produces product segments in between
nozzles)
Relatively low throughput capacities compared

to nozzle separators
High throughput capacities
Decanter
Two Phase
Three Phase Version
Decanter
Decanter
OPERATION OF DECANTER WITH MAXIMUM "NEGATIVE WEIR"
Gear
box of
scroll
drive
Immersion disc (other names:Baffle disc, Dip Weir)

Feed (thin sludge)
Varipond E/M
Clarified liquid
Rotor with bowl and

gear box
Scroll
Thickened sludge
Housing of decanter
Decanter Research & Development 3522-BDR, 9/97
Distributor
Distributor
Decanter with optional Centripetal Pump
Option
Features:
Centripetal pump
Special drive
Distributor
Up to 50% more
throughput than
Minimum energy
consumption due to
deep pond rotor
Low service costs due
to compact design and
36% less parts than
Extraction out of a Protein Containing Flour

3,0 min / 30C
100
90
80
70
60
50
40
30
20
10
5
1
0,1
opaque liquid phase

approx. 20 Vol % dark yellow very soft solids
approx. 25 Vol % slightly yellow soft solids
Total Solids
24,50 % ds
Soluble Solids
3,50 % ds
Suspended Solids 21,00 % ds
Ratio Vol.%/Solids approx. 2,1
Extraction of Protein out of a Protein Containing Flour
Typical Decanter Application
Feed
3,0 min / 30C
opaque liquid phase
approx. 20 Vol % dark yellow very soft solids
approx. 25 Vol % slightly yellow soft solids
Total Solids
24,50 % ds
Soluble Solids
3,50 % ds
Overflow
3,0 min / 20C
opaque liquid phase
approx. 1,5 Vol % dark yellow very soft solids
Total Solids
4,20 % ds
Soluble Solids
3,50 % ds
Three Phase Decanter for Wheat Strach Gluten

Separation
Overflow [Vol-%]
Feed [Vol-%]
100
90
80
70
60
50
40
30
20
10
5
1
10% Water
25% Pentosanes
35% B-Starch /
Gluten/Fiber
35 % A-Starch
100
90
80
70
60
50
40
30
20
10
5
1
0,1
99 % Pentosanes
Solubles
M
1 % Starch
Dilution Water
0,1
Nozzle Phase [Vol-%]

100
90
80
70
60
50
40
30
20
10
5
1
0,1
20 % Water
10 % Pentosanes
65 % B-Starch /
Gluten /
Fiber
5 % A-Starch
Concentrate [Vol-%]
100
90
80
70
60
50
40
30
20
10
5
1
0,1
5 % Water
15 % Fiber /
B-Starch
80 % A-Starch
Lysin broth typical particle size distribution
Volume (%)
10
100
90
80
70
60
50
40
30
20
10
0
0
0.1
1.0
10.0
Particle Diameter (m.)
100.0
Biomass decantion of lysin broth - practical results
Centrate
Biomass from Lysine
fermentation process
Spin. Solid: < 1,0 % vol.
Total solids:
15 % DS
Dissolved solids: 14 % DS
Spin. Solids:
18 % vol.
Sep. temp.:
65 C
pH:
4,5
Sludge
Total solid: 30 % DS
Stillage treatment with decanters

Typical massbalance for wheat stillage

Feed capacity:
Total solids:
Sep. temp.:
pH:
20-35 m/h
max. 10,3 %
65100 C
4,5
Wheat-Stillage
62 % Liquid = 3,6 % DS
soluble solids
18 % Vol. Protein+Micro Fibre = 1,9 %
DS insoluble solids
20 % Vol. Fiber = 4,8 % DS insoluble solids
Separation efficiency: 70 85 %
Thin-Stillage
Spinable solids: 20 % Vol.
Total solids: 5,5 %

soluble solids: 3,6 %
Solids Cake
Total solids: up to 32 %
Test results of stillage treatment with a decanter

90
80
4,5
70
60
Spent Grain T.S.
3,5
Thin Stillage T.S.
50
Capture Efficiency %
40
Thin Stillage %w/w
2,5
2
30
1,5
20
10
0,5
0
0
76
92
100
110
115
Flow Rate ( gpm)
125
133
Insoluable Solids %w/w
Dryness %T.S.
Stillage Treatment Plant Backset 42%
Test results of stillage treatment with a decanter

Stillage from Wet Mill - Influence of Diff. Speed on

Capture Efficiency
80
70
Cap. 60
Eff. 50
&
40
Cake DS
30
[%]
20
10
Feed const.: 45 m/h, 198 gpm
0
4
5
6
7
8
2,0
1,5
Centrate
DS
1,0
[%]
0,5
Manildra, Australia, Data 28.10.03
0,0
9
10
11
12
13
Differential Speed, 1/min.

Cake % DS
Centrate insol. % DS
69
General demonstration between

Efficiency over feed rate
efficiency %
100
80
60
40
20
0
28
30
32
34
36
Feed rate m/h
Separation efficiency
Linear (Separation efficiency)
dry matters %
Linear (dry matters %)
38
Calculation method for separation efficiency

Wheat-Stillage
Total solids:
Unsolved solids:
Fine particles:
Coarse particles:
Thin Stillage
9,5 %
5,9 %
1,3%*
4,6%
Unsolved solids: 1,4 %
Separation Efficiency =
Q0verflow * unsolved DS
( 1 - --------------------------------------- )*100 %
QFeed * unsolved DS
Separation Efficiency =
85 * 1,4
( 1 - ---------------) *100 % = 80 %
100 * 5,9
* Please notice the solids split in fine and coarse particles. Only few of the fine
particles
can be separated with a decanter, due to the physical properties of the fine particles.
Please refer to the picture of the spin test tubes.
Ceramic Membrane
Two Phase
Three Phase Version
7
2
Ceramic Membrane Element

Filtrate
Membrane
Retentate
Support
Stillage Treatment with Ceramic Membrane Technology

Filtration of Corn Stillage
UF-UNIT FOR FILTRATION OF SLUDGE FROM THE ETHANOL PRODUCTION
Membrane:
Al2O3 / ZrO2
filtrate outlet
Membrane area:
72 m
6 modules
cooling water backflow
Filtrate volume flow:

10 12 m3/h
cooling water supply
Energy consumption
per m3 filtrate:
6,7 7,2 kW/m3
at DS = 15 %
product to working tank

water to spray ball
water supply
Space requirement:
LxWxH = 4,5x2,2x4,5 m
circulation pump
drain
product inlet
feed pump
Stillage Treatment with Ceramic Membrane Technology

Filtration of Corn Stillage
Product from UF-unit
filtrate
concentrate
DS = 15 - 17%, crude protein 35,6 %, crude fat 41,4

%, crude fiber 5 %, Ca 0,4 g/kg,
Zn 73 mg/kg, K 3,6 g/kg, Mg 1,2 g/kg,
Mn 18mg/kg,Fe 217 mg/kg.
*) Fa. PROVIMI, Netherlands
Ceramic Membrane
Hybrid Solution
Glucose Syrup Spin Test
fat / protein
1 - 5 % v/v
The important phase for blocking
membranes and filter
unsaccharified
dextrose,
1 - 5% v/v
Generally unimportant for the
complete process.
Used as animal feed or
recycled in the process
As much as possible should be

removed
Quantity depends on raw material,
process and season
glucose syrup,
17, 40, 65 DE
Valuable phase
Maximum yield is necessary
Proposal Process way without VDF`s
Separation of the fat and protein in combination with MUD Separator and Ceramic Membrane system
Clear permeate
Saccharifiaction
with ENZYME
Retentate
FEED
FAT
Industrial Size MUD Separator
Centrifugal Machines (DA 100 MUD Version)

1. Feed
2. Inner bowl Space
3. Centripetal pump for
light phase
4. Light phase outlet
5. Disc set
6. Outer bowl space
7. Nozzles
8. Concentrate catcher
9. Centripetal pump for
heavy phase
10.Heavy phase outlet
Mud-Separator
Discharge of FAT
out of Separator
DS = 60- 70 %
Cross flow Ceramic membrane filtration

UNIT HES 400 B
~ 5000 mm/sec.
Type :
E 196 R 1200
Channel diameter :
Number of channels:
6 mm
19
Filtration surface pro Element: 0,427 m

Total surface module with 7 elements :
2,96 m
Pore size : 50 nm. // 200 nm. // 500 nm. //
800 nm.
Test was done on: 50 nm. 40 DE // 65 DE
200nm. 65 DE // 40 DE
//
HM 45 DE
500nm. 17 DE
800nm. 17 DE
Filter Centrifuges
Peeler Centrifuges
Pressure Drum Filtration

Vacuum Drum Filtration

Screens
Vacuum Drum Filter
Hydrocyclon
Screens and Vacuum Drum Filtration

Hydrocyclon
Laboraty Methods
Parameters for analysing an unknown sample


Total Dry Solids

Soluble Solids (after Centrifugation)
Insoluble Soldis (after Centrifugation)
Spin Test % Vol.
Microscopy
Particle Size Distribution

Settling Test in a Cylinder or Imhoff Cone
Centrifugation of a Sample
% Vol. after 1,2,3,4,5,10 Minutes of Centrifugation
Test with a small scale Decanter
Test with a small scale Separator
Imhoff Cone and Glas Cylinder

Vaccum Lab Filter (Nutsche

Lab Centrigufe
100
90
80
70
60
50
40
30
20
10
5
1
90 vol% liquid
5 vol% solids
0,1
feed
100
90
80
70
60
50
40
30
20
10
5
1
100
90
80
70
60
50
40
80 vol% concentrate 30
20
10
5
1
20 vol% liquid
0,1
concentrate
discharge
0,1
2 - 4 vol% solids
supernat
ant
Laboraty Decanter
Laboraty Separator
Gluten Wash Test
Centrifugal
Gluten
Washtest
WS-Centrifugal-Washtest
1. Scope
This laboratory method is applicable to wheat flour as raw material for

recovery of starch and vital gluten. The results obtained should give an
indication about the suitability of a particular raw material for processing it
in a wheat starch plant.
Part of this analysis, is the determination of yield and quality of extracted Astarch and gluten.
2. Principal
A wheat flour sample is separated under specific test conditions into different
fractions. These fractions, under the conditions of the test, are:
Vital gluten
A-starch
B-starch
Fibers
Solubles
All fractions are quantitatively isolated and determined on dry basis. These
products can then be subject for further analytical characterisation.
2. Principal
wheat flour +
water (35 C)
Mixed in a
blender
Separate in a
centrifuge
Wet gluten
determine on dry
basis
Gluten washed
out by hand
Solubles,
pentosanes,
gluten, fibers,
starch
Other fractions
Sieved on sieve
column (50 m)
select fibers
Starch fractions
separate to A-and
B-starch fraction
3. Apparatus / Reagents
Blender:
Standard household blender (out
of glass for visibility) and built-in
double-knife (possibly of 6 cm
length), 8000 rpm (e.g. BRAUNBlender)
Sieves:
Laboratory Sieve column 200
m
for gluten washing
Sieves:
Laboratory Sieve column 50 m
for fiber screening
Centrifuge:
Laboratory Centrifuge for min 4
centrifuge glas beakers of 100 ml
volume each. Speed equivalent to
min 3500 g (e.g. 4000 min-1 at
average radius of 20 cm)
3. Apparatus/ Reagents
Tap Water:
pH 7 - 7,5
hardness:5 10 dH
temperature:
35 C +/- 1 C
4. Procedure dough mixing
Weigh 100,0 g of flour sample in a beaker and measure 100,0 g of temperated

water (35 C).
Transfer the water to the blender and then add the flour.
Start the blender and mix 20 seconds (III. stage). Clean the wall of the blender
with a spatula to make sure that all sample material is effected.
Stop for 5 min maturation time and then add 100,0 g of temperated water (35
C).
Mix again for 10 seconds (II. stage).
4. Procedure centrifugation
Distribute the dough quantitatively and well-balanced into the centrifuge glas
beaker.
Separate in the Laboratory centrifuge for 5 min with a speed equivalent to
3500 g.
After centrifugation the different fractions of the flour sample are visible.
4. Procedure centrifugation
4. Procedure fraction selection
All layers are weighted separately
and then transfered on a sieve to
initiate the dough washing.
4. Procedure gluten washing

The gluten is washed out by hand with water to remove other components from
the gluten fraction. At least 1000 ml of wash water should be used.
Dewater the gluten by hand and measure the weight of the wet gluten.
In order to clarify the definiton of gluten agglomeration potential, some additonal
explainations are given. The screen residue shall form a cohesive viscoelastic mass
by means of screening action during washing. The so formed gluten shall
agglomerate in such, that it remains fully on screen surface. A slimy, non fully
agglomerated gluten would pass the screen mesh partially or even totaly, which is
not acceptable and suitable for processing it in the plant.
4. Procedure gluten washing
First gluten after washing out the other

fractions
Finished wet gluten after washing out

on a 200 m sieve
4. Procedure gluten drying
Determine the dry substance by
oven-drying (130 C). The dried
gluten sample is subject for further
analytical characterisation
4. Procedure fiber screening

To separate the starch fraction from fibers, the screen filtrate from the gluten
washing ist tranfered on a 50 m sieve.
The screen residue should be the fibers and pentosanes.
The residue is measured by weighing.
4. Procedure starch concentration

The raw starch fraction is concentrated by means of a laboratory centrifuge (spin for
five minutes).
Pour off the liquid phase and collect both, concentrate phase and liquid phase
separately.
Dilute the raw starch concentrate with water to the volumetric capacity of two (2)
centrifuge beakers and mix thoroughly. Transfer the slurry quantitatively to two
centrifuge beakers and spin for five minutes. Pour off the liquid phase and add to the
liquid phase obtained previously by concentration.
After centrifugation the B-starch and the A-starch fraction are visible.
Separate the layer of the B-starch accurately at the separation line.
Remove all material quantitately from the beakers and use water for final flush.
Determinate the dry substance of each of the starch fractions by oven drying (130 C).
4. Procedure liquid fraction measuring
Measure finally the volume of the liquid phase and determinate the dry
substance content of an aliquot portion to calculate the total soluble
potential in the flour.
4. Procedure starch concentration
After centrifugation of
the starch fraction the Astarch and the B-starch
fraction is visible
B-starch
A-starch
5. Additional analytical data
For the final evaluation of the Laboratory Method for Wheat Flour Processing the
following additional data are required:
Wheat Flour as used for testing:
Fiber
size spectrum
Vital Gluten is obtained:
- Moisture
- Protein in dry substance
- Ash
in dry substance
- Fat
in dry substance in dry substance - Starch granule
- Protein
- Ash
- Fat
in dry substance
in dry substance
in dry substance
6. Evaluation Mass Balance
Add the dry substance mass figures of all obtainted test fractions and compare
the sum with the dry substance of the corresponding flour sample:
Recovery in % =
dry substance of all fractions x 100

dry substance of flour sample
= Accuracy
The accuracy should be between min 97 % and max 102 %, otherwise the test
should be repeated.
Calculate the results considering the recovery percentage to get 100 % balance.
This corrected mass balance represents the final test result.
6. Evaluation Protein Recovery
Calculate the Protein Recovery as follows:
Protein Recovery in % =
Protein dry substance in Gluten x 100

Protein dry substance of flour sample
Many Thanks
for your
Attention

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Starch-Protein-Separation-Analysis

Mechanical Separation Technologies

Dr. Willi Witt, ProAmid Consult GmbH

After the lecture discussion about different laboratory methods

Introduction Dr. Willi Witt

Introduction Dr. Willi Witt

Study Technische Universitt Berlin andTechnische

Separation technology in process engineering

Centrifugal Separation Technol.

Mechanical Process Engineering

A common task of the process technology is the

Mechanical Process Engineering

Thermal Process Engineering

Thermal separation processes are using differences in

Thermal Process Engineering

Concentration of waste water

Solving the problem phase separation solid-liquid

Methods for the separation solid-liquid

which is the motive power

which is the motive power

Basic knowledge of separation technology

- Separation path / Number of discs

Accelarat ion f act ors

Loading of clarif icat ion surf ace

Q = volume st ream [cm/sec]

Separation procedure in a disc stack

Main Target for Usage of Mechanical Separation

Nature of the fluids

Type of Machines for Mechanical Separation

Solid Wall Disc Separator

Self Cleaning Disc Separator

Two Phase Separator

Three Phase Separator

Nozzle Bowl Disc Separator

Two Phase Nozzle Separator

Three Phase Nozzle Separator

Viscon Nozzle Separator

Two Phase Decanter

Three Phase Decanter

Product Related Conditions Influencing

Concentration of the Feed Stream

Machine related conditions influencing

The challenge: to remove shear sensitive particles by

approx. 3600 sec.

Particle size and separation technology

< optical Microscop

100 200 1.000 10.000 20.000 100.000

< visible for naked eye

1 Angstrom = 10 -10 meter = 10 -4 micrometer

Fields of application of centrifuges

Separator with clarifier bowl

Separator with self cleaning bowl

Separator with nozzle bowl

Possible ways of separation according

Possible ways of separation

Nature of the particles

coarse dirt, sand

cell material, particles

Centrifuges / CMF/UF/membrane filter/sheet

Centrifuges / CMF/UF/membrane filter/sheet

cell material, cell particles, Centrifuges / CMF/UF/membrane filter/sheet

Data of important industry centrifuges

Solids particle size