Equipment and Systems

for Corn Wet Milling

s Increase efficiency
s Better sanitation
s Reliable product quality
from Dorr-Oliver, EIMCO,
Krebs and Pneumapress
s 60+ years of experience
2
Corn Wet Milling Process Flowsheet
 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.
Gravity-Fed DSM Screen
Benefits of Gravity-Fed DSM Screens
s No maintenance necessary as
screen media is rugged stainless
steel and there are no moving parts.
s 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.
s Operation is trouble free due to
non-blinding, wedge wire screen
surface.
s No fumes and spillage as screens
are totally enclosed.
Pressure-Fed DSM Screen
Fiber Washing
To get maximum starch recovery, while
keeping any fiber in the final product Benefits of Pressure-Fed 120 DSM
to an absolute minimum, it is necessary Screens
to wash the free starch from the fiber s Close tolerance, engineered feed
during processing. system distributes feed flow across
screen surface with high velocity for
highly effective separation.
Pressure-Fed s System’s multi-stage countercurrent
120 DSM® Screens flow design assures maximum
Most plants accomplish this very starch yield.
economically today with the Dorr-Oliver s High capacity compact design
Fiber Washing System. The system consists drastically curtails space needed for
of six stages of 120 DSM screens. The fiber washing operations.
pressure fed screens are arranged for s Requires little operator attention
countercurrent washing of the fiber, with because system is designed for
the starch reporting to the undersize. The small sumps, uses standard pumps
extremely fine separations are possible and has simple instrumentation.
only with our highly polished wedge wire s Long service life due to no moving
screen surfaces with openings as fine as parts, quick reversible and totally
50 microns. The DSM screen’s precisely enclosed design.
selected screen media and its proven s Screens available in single, double
reliability are unmatched by equipment and triple width configurations for
using fragile textiles or thin etched screens. maximum flexibility in system design.
3
 Germ Separation and 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.
Germ Separation
DorrClone System
Benefits of Germ Separation
DorrClones
s Maximum germ oil recovery (very low
loss of the valuable process fraction).
s Easy maintenance and quick
replacement of individual cyclone
units because of the quick opening
couplings.
s Rapid response to process changes
through single instrument control.
s Totally enclosed design assures
clean and fume-free operating area. Starch Washing Hydrocyclone System
s Lightweight construction and
overflow wash water stream. The multi-
shipment as a complete factory
stage systems provide easy and precise
assembled package means low cost
control of the process, resulting in the
installation.
uniform, high quality starch required in
s Modular system design allows
today’s highly demanding marketplace.
easy expansion when production
The latest in starch washing technology
demands dictate.
incorporates recently developed high-
efficiency 10mm cyclones for the
Starch washing
Starch Washing System. These high
The starch slurry from the primary
capacity units incorporate advanced
separation contains some insoluble
flow channeling with superior materials
protein and much of the solubles. They
and layout to save money in installed
have to be removed before a top quality
cost and operating power. Varying plant
starch can be made. Modern plants
capacities can be handled.
are using Dorr-Oliver Starch Washing
Systems for this important task.
Benefits of Starch Washing
Hydrocyclones
Hydrocyclone Starch Washing
s Easy operation because simplified
System
control system uses self regulation
A typical Dorr-Clone or Hydrocyclone
of intermediate stages.
Starch Washing System consists
s Improved sanitation since system is
of batteries of 10 mm cyclones in
completely closed and pressurized
completely unitized and enclosed
s Low maintenance. The only moving
housings, arranged for efficient
parts are in the standard centrifugal
countercurrent washing. The centrifugal
pumps.
forces needed to make the separation
s Capital cost is less because of the
are derived from energy supplied by
system’s compactness, which saves
pumps. The high rotational velocities
on space, and easy expandability
in the individual cyclones cause the
when additional capacity is needed.
starch to concentrate in the underflow
while the suspended gluten follows the

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.
Gluten Dewatering
Its reliable filtration enhances product
recovery minimizing protein loss.
Benefits of E-Belt Drum Filters
s 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.
s Delivers high rates of filtration and
high hydraulic capacity for cake dryness
enhancement.
s Hi Hydraulic capacity
s Food design for cleaning and sanitation
s Innovative cloth alignment design
s Low installation costs and clean working
environment due to compact design.
s No operator attention required.
s Minimal maintenance
Dorr-Oliver Eimco E-Belt Drum Filter
5
 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 Pneumapress
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
diaphragms, simplifying the operation
and maintenance of the equipment.
Significant repeat business and referral
sales are indicative of the success of the
Pneumapress design.
6
Cake discharge from filter
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.
Pneumapress Sanitary Multi-Module Filter
The cleaning and hygiene requirements
at food starch plants are becoming more
stringent. Pneumapress 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.
Filter enclosed in sanitary housing
The Pneumapress filter can be
totally enclosed to prevent product
contamination 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
s Very dry filter cakes with highly
effective cake washing when
required
s Highest throughput per unit area
of any filter, which minimizes the
required filter area, equipment
size, number of moving parts and
maintenance downtime
s Advanced filter media design and
effective filter media cleaning
provide very clean filtrate
s Mechanically simple design
eliminates consumables such as
diaphragms and seals
s Filter plates are made completely
from 316 stainless steel
s An isolatable plate design provides
very high equipment availability
s Sanitary or industrial design with
optional filter housing, structure
cladding, and CIP systems
s Single-sided cake discharge
s Low installation costs
 Starch Conversion and Hydrogenation
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 throughput 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.
s Longer operating cycles and
equipment life.
s Can be readily adapted to meet
varying process needs.
s Effective use of precoat, without
waste, lowers operating costs.
s Revolutionary precoat discharge
system electronically control for
reduced precoat consumption and
longer filtration cycle.
Dorr-Oliver Eimco Indexing Belt Filter (IBF)
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. The continuous operation
together with a simple mechanical design
reduce maintenance offering steady and
reliable operation.
Benefits of IBF Filters
s Food design, FDA validated.
s Totally enclosed execution for
solvent washing
s Smooth filtration with no particle
size modification.
s Superior washing efficiency for
maximized product recovery.
s Cleaning in place for complete
sanitation.
Dorr-Oliver Eimco Precoat Filter
7
 *% D.S. = Be deg x 1.7770
Baume Conversion Tables for Starch Suspensions - 60°F

Suspension @ 60°F Dry Solids Content Water Content

Specific Gravity of Starch 1.5 - 1.6
Lbs Lbs Oz Gr Gm Lbs H2O Lbs H2O Gal H2O
Temperature Corrections Be Sp Gr % D.S.*
Gal Gal Gal Gal Liter Gal Susp Lb Starch Lb Starch

Temperature Add (°Be) 0.0 1.0000 0.00 8.328 0.000 - - - 8.328 - -

67 .1 0.5 1.0035 0.89 8.357 0.074 1.184 518 8.87 8.283 111.93 13.437

73 .2 1.0 1.0069 1.78 8.386 0.149 2.384 1043 17.85 8.237 55.28 6.636

79 .3 1.5 1.0105 2.66 8.416 0.224 3.584 1568 26.84 8.192 36.57 4.390

85 .4 2.0 1.0140 3.55 8.445 0.300 4.800 2100 35.95 8.145 27.15 3.260

91 .5 2.5 1.0176 4.44 8.475 0.376 6.016 2632 45.18 8.099 21.54 2.586

97 .6 3.0 1.0211 5.33 8.504 0.453 7.248 3171 54.28 8.051 17.77 2.133

103 .7 3.5 1.0248 6.22 8.535 0.531 8.496 3717 63.63 8.004 15.07 1.809

113 .9 4.0 1.0285 7.11 8.566 0.609 9.744 4263 72.98 7.957 13.07 1.570

118 1.0 4.5 1.0322 8.00 8.596 0.688 11.008 4816 82.32 7.908 11.49 1.379

123 1.1 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
These tables are based on the work of
J.E. Cleland, E.E. Fauser and W.R. Fetzer. 6.0 1.0433 10.66 8.689 0.926 14.816 6482 110.96 7.763 8.38 1.006

See Industrial and Engineering 6.5 1.0470 11.55 8.720 1.007 16.112 7049 120.67 7.713 7.66 0.920
Chemistry, Analytical Edition, Vol. 15, pp 7.0 1.0508 12.44 8.751 1.089 17.424 7623 130.49 7.662 7.04 0.845
193-200, 1943
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
Customer Service 9.5 1.0703 16.88 8.914 1.505 24.080 10535 180.34 7.409 4.92 0.591
FLSmidth is your One 10.0 1.0742 17.77 8.946 1.590 25.440 11130 190.53 7.356 4.63 0.556
Source for spare parts, 10.5 1.0782 18.66 8.979 1.676 26.816 11732 200.71 7.303 4.36 0.523

service, maintenance, asset 11.0 1.0822 19.55 9.013 1.762 28.192 12334 211.14 7.251 4.12 0.495

management, and operational 11.5 1.0862 20.44 9.047 1.849 29.584 12943 221.56 7.198 3.89 0.467

services. Our Customer 12.0 1.0903 21.32 9.080 1.936 30.976 13552 231.99 7.144 3.69 0.443

Services provide a wide 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
range of services for food
13.5 1.1028 23.99 9.185 2.203 35.248 15421 263.98 6.982 3.17 0.381
processing equipment and
14.0 1.1071 24.88 9.220 2.294 36.704 16058 274.89 6.926 3.02 0.363
systems including process
14.5 1.1114 25.77 9.256 2.385 38.160 16695 285.79 6.871 2.88 0.346
design, equipment installation, 15.0 1.1156 26.66 9.291 2.477 39.632 17339 296.82 6.814 2.75 0.330
troubleshooting, process 15.5 1.1199 27.54 9.327 2.569 41.104 17983 307.84 6.758 2.63 0.316

and mechanical analysis, and 16.0 1.1242 28.43 9.363 2.662 42.592 18634 318.98 6.701 2.52 0.303

commissioning of new plants. 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

We design and install your 17.5 1.1375 31.10 9.473 2.946 47.136 20622 353.02 6.527 2.22 0.267

processing systems with quality 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
Dorr-Oliver, EIMCO, Krebs
19.0 1.1500 33.76 9.586 3.236 51.776 22652 387.89 6.350 1.96 0.235
and Pneumapress equipment.
19.5 1.1556 34.65 9.624 3.335 53.360 23345 397.23 6.289 1.89 0.227
Our experts provide the tools
20.0 1.1602 35.54 9.662 3.434 54.944 24038 411.49 6.228 1.81 2.170
to ensure that your systems 20.5 1.1649 36.43 9.702 3.534 56.544 24738 423.48 6.168 1.75 0.210
continue to operate at 21.0 1.1696 37.32 9.741 3.635 58.160 25445 435.58 6.106 1.68 0.202

optimum levels, all the time. 21.5 1.1744 38.21 9.781 3.737 59.792 26159 447.80 6.044 1.62 0.194

It is by no means a radical 22.0 1.1791 39.09 9.820 3.839 61.424 26873 460.02 5.981 1.56 0.187

concept. Indeed, everyone 22.5 1.1840 39.98 9.861 3.942 63.072 27594 472.49 5.919 1.50 0.180

promises it; we deliver it! 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

©FLSmidth Group 2010. All rights reserved. This brochure makes no offers, representations or warranties (express or implied), and information and data contained in this
www.FLSmidthMinerals.com brochure are for general reference only and may change at any time. Please contact FLSmidth for specific information or data that may relate to your interests