CN111100892A - High fructose corn syrup production process - Google Patents
High fructose corn syrup production process Download PDFInfo
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Abstract
The invention relates to a high fructose corn syrup production process, relates to the technical field of syrup production, and specifically comprises starch size mixing, liquefaction, saccharification, sugar residue extraction, sugar residue re-saccharification, saccharified liquid separation, evaporative concentration, ion exchange, glucose isomerization, ion exchange, evaporative concentration, chromatographic separation, mixed bed and finished product concentration and storage. The invention utilizes the compound biological saccharification technology to realize the reconversion of the sugar residues into the monomolecular sugar solution, thereby reducing the emission of the sugar residues, improving the utilization rate of starch, and realizing energy conservation, emission reduction and green production; in addition, the high-purity fructose corn syrup can be obtained in the filtering process of the high-fructose corn syrup production without adding diatomite and active carbon, and the extracted sugar residue without the diatomite and the active carbon can be used as an animal feed raw material, so that waste is changed into valuable, and the economic benefit is improved.
Description
Technical Field
The invention relates to the technical field of syrup production, in particular to a high fructose corn syrup production process.
Background
High fructose syrup is a starch sugar crystal produced by hydrolysis and isomerization of plant starch, and its composition is mainly fructose and glucose, so that it is called high fructose syrup, and is an important sweetener. The sweetness of the high fructose syrup is close to that of sucrose with the same concentration, the flavor is a little similar to that of natural fruit juice, the high fructose syrup has faint scent and refreshing feeling due to the existence of fructose, and on the other hand, the high fructose syrup has the cold and sweet characteristic below 40 ℃, and the sweetness is increased along with the reduction of the temperature. The high fructose syrup can replace sucrose, is widely applied to the food and beverage industry like sucrose, and is particularly applied to the beverage industry, and the flavor and the mouthfeel of the high fructose syrup are superior to those of the sucrose.
Chinese patent with the publication number of CN105255968B discloses a preparation method of F55 high fructose corn syrup, which comprises the following steps: (1) liquefying starch milk; (2) cooling to 60-70 ℃ after heat preservation treatment; (3) adding the mixture into a saccharification tank, adjusting the pH value to 4.0-4.5, and adding glucoamylase for saccharification; (4) after saccharification, heating the solution to 70 ℃ for enzyme deactivation; (5) filtering and removing impurities by using diatomite; (6) desalting with cation exchange column, anion exchange column and mixed ion exchange column; (7) decoloring by using activated carbon; (8) vacuum concentrating to obtain a solution with the solid content of 45-50%; (9) adjusting the pH value to 7.0-7.5, introducing the sugar solution into equipment containing immobilized isomerase for isomerization, and preparing the sugar solution; (10) desalting part of the sugar solution obtained in the step (9) by an ion exchange column, decoloring by using activated carbon, and performing vacuum concentration to obtain F42 high fructose corn syrup; (11) concentrating the other part of sugar liquor obtained in the step (9) until the solid content is 55-60%, feeding the concentrated sugar liquor into another chromatographic equipment for separation, and then desalting, decoloring and vacuum concentrating to obtain F90 high fructose corn syrup; (12) and (3) compounding the F42 high fructose syrup obtained in the step (10) and the F90 high fructose syrup to obtain F55 high fructose syrup, wherein the fructose content in the F55 high fructose syrup is 58-60%. The high fructose syrup prepared by the method can not generate crystallization within three months, and the storage and use convenience of the high fructose syrup is improved.
The above prior art solutions have the following drawbacks: the high fructose corn syrup generates partial sugar residues in the production process, sugar liquor is decolorized and filtered by adding diatomite and active carbon, and the sugar residues containing the diatomite and the active carbon cannot be used as animal feed raw materials and can only be discharged as solid waste materials, so that the high fructose corn syrup is not environment-friendly.
Disclosure of Invention
The invention aims to provide a high fructose corn syrup production process, which utilizes a compound biological saccharification technology to realize the reconversion of sugar residues into a monomolecular sugar solution, reduces the emission of the sugar residues, improves the utilization rate of starch, and realizes energy conservation, emission reduction and green production; in addition, the high-purity fructose corn syrup can be obtained in the filtering process of the high-fructose corn syrup production without adding diatomite and active carbon, and the extracted sugar residue without the diatomite and the active carbon can be used as an animal feed raw material, so that waste is changed into valuable, and the economic benefit is improved.
The technical purpose of the invention is realized by the following technical scheme: a high fructose corn syrup production process specifically comprises the following steps:
step 1, starch size mixing: the starch and the water are mixed according to the mass ratio of 1: 1-1.5, adding the starch slurry into a slurry mixing tank, fully stirring to form starch slurry, adjusting the pH of the starch slurry to 5.4-6.1, adding liquefying enzyme, and uniformly stirring, wherein the adding amount of the liquefying enzyme is 0.2-0.5L/t.Ds of the mass of the starch;
step 2, liquefaction: conveying the starch milk obtained in the step 1 into a liquefaction tank, liquefying the starch milk by steam, injecting the starch milk into a flash tank for flash evaporation, controlling the injection temperature to be 103-115 ℃, controlling the injection time to be 6-15 min, controlling the temperature of the flash tank to be 90-100 ℃, and controlling the flash evaporation time to be 5-8 min;
step 3, saccharification: cooling the liquefied liquid liquefied in the step 2 to 57-63 ℃, transferring the liquefied liquid into a saccharification tank, adding saccharifying enzyme into the saccharification tank, wherein the adding amount of the saccharifying enzyme is 0.1-0.2L/t.Ds of the mass of starch, and the saccharification time is 20-30 h;
step 4, sugar residue extraction: after saccharification is finished, light slag floats on the upper layer of the saccharification liquid, heavy slag is precipitated to the lower layer of the saccharification liquid, the upper layer of the saccharification liquid is pumped out from a saccharification tank and used for preparing maltose syrup, and the sugar slag is collected into the saccharification tank after extraction;
step 5, sugar residue re-saccharification: keeping the temperature of the saccharifying tank at 57-63 ℃, continuously adding saccharifying enzyme and uniformly stirring the saccharifying enzyme and the sugar residues collected in the step (4), wherein the adding amount of the saccharifying enzyme is 0.3-0.65L/t.Ds, and the saccharifying time is 10-20 h;
step 6, separation of saccharified liquid: after the re-saccharification of the sugar residues is finished, separating saccharified liquid and solid residues generated in the re-saccharification step;
and 7, evaporation and concentration: evaporating and concentrating the saccharified liquid separated in the step 6 into a sugar liquid with the solid content of 45-50%;
step 8, ion exchange: conveying the sugar solution obtained after evaporation and concentration to an ion exchanger for ion exchange to remove impurity ions in the sugar solution;
step 9, glucose isomerization: enabling the sugar solution after ion exchange to enter an isomerization column, and carrying out glucose isomerization through the isomerization column to obtain the sugar solution with fructose content of 42-44%;
step 10, ion exchange: carrying out ion exchange on the sugar solution subjected to glucose isomerization again;
step 11, evaporation and concentration: evaporating and concentrating the sugar solution subjected to ion exchange in the step 10 to obtain sugar solution with the solid content of 58-62%;
step 12, chromatographic separation: separating sugar solution by chromatographic resin to obtain syrup with fructose content of 90% and syrup with glucose content of 80%;
step 13, mixing the bed: mixing syrup with fructose content of 90% and syrup with fructose content of 42-44% obtained in the step (9) to prepare high fructose corn syrup with fructose content of 55-58%;
step 14, concentrating and storing finished products: concentrating the high fructose corn syrup mixed in the step 13 into high fructose corn syrup with the solid content of 75-80%, and then transferring the high fructose corn syrup into a storage tank for storage.
By adopting the technical scheme, the starch is subjected to size mixing, liquefaction and saccharification to generate saccharified liquid, and the starch or some small molecular oligosaccharides in the sugar residues are not completely hydrolyzed and directly serve as waste residues, so that the waste of starch resources is caused. After the sugar residues are extracted, the sugar residues are further saccharified, so that starch and micromolecular oligosaccharide which are not completely hydrolyzed in the sugar residues can be continuously hydrolyzed and converted into micromolecular saccharides, and the starch conversion rate is improved. After the sugar residues are saccharified again, the finally generated solid residues can be applied to animal feed raw materials, so that the economic benefit can be improved, and waste can be converted into treasure. The sugar solution produced after saccharification is mainly glucose, so that the required fructose needs to be generated through further isomerization, the fructose and the glucose are separated, and the separated fructose and the isomerized fructose are mixed again according to the content requirement of the fructose to produce the fructose glucose syrup with different contents.
The invention is further provided that the liquefying enzyme in the step 1 is α -high-temperature amylase.
By adopting the technical scheme, the α -high-temperature amylase belongs to endo-amylase, can randomly hydrolyze α -1, 4 glucosidic bonds in starch, soluble dextrin and oligosaccharide, and can destroy the hydration of the physical structure of starch granules after α -high-temperature amylase acts, so that the viscosity of gelatinized starch is rapidly reduced to become liquefied starch, dextrin, a small amount of glucose and maltose are generated by hydrolysis, and the liquefaction reaction is promoted.
The invention is further provided that the saccharifying enzyme of step 3 comprises at least one of barley β -amylase and fungal amylase, and the saccharifying enzyme of step 4 is glucoamylase.
By adopting the technical scheme, the barley β -amylase is an exo-amylase, when acting on starch, α -1, 4 glucosidic bonds are cut apart in sequence from a non-reducing end, the hydrolysate is maltose and limit dextrin, the fungal amylase is an endo-amylase, the endo-amylase acts on α -1, 4 glucosidic bonds of dextrin, the hydrolysate is mainly maltose and a small amount of glucose, the glucoamylase hydrolyzes the dextrin from the non-reducing end, hydrolysis α -1, 4 glucosidic bonds enable one glucose unit to be separated to generate glucose, and the hydrolysate only has glucose and no other sugars are generated.
The invention is further provided with: and 6, separating saccharified liquid and solid residues by adopting a three-phase separation horizontal screw sedimentation centrifuge.
By adopting the technical scheme, the three-phase separation horizontal spiral sedimentation centrifuge can realize the three-phase separation of heavy-phase liquid, light-phase liquid and solid residue, filter aids diatomite and active carbon are not required to be added in the separation process for decolorization and filtration, the heavy-phase liquid, the light-phase liquid and saccharified liquid are reprocessed to obtain high fructose corn syrup, and the solid-phase residue can be used as an animal feed raw material because the solid-phase residue does not contain the filter aids and the active carbon.
The invention is further provided with: and (3) the content of glucose in the saccharified liquid obtained in the step (5) is not less than 95%.
By adopting the technical scheme, the content of the glucose is not lower than 95%, and the fructose content in the syrup can be high only when the glucose is converted into the fructose through isomerization.
The invention is further provided with: the storage temperature of the high fructose corn syrup in the step 14 is 27-35 ℃.
By adopting the technical scheme, the storage temperature is lower than 27 ℃, the high fructose syrup has low fluidity, and when the high fructose syrup needs to be taken out, the high fructose syrup is not easy to pour out from the storage tank; the storage temperature is higher than 35 ℃, and the color of the high fructose corn syrup gradually turns yellow along with the prolonging of the storage time, thereby influencing the quality of the high fructose corn syrup.
In conclusion, the beneficial technical effects of the invention are as follows:
1. starch is subjected to size mixing, liquefaction and saccharification to generate saccharified liquid, and starch or some small molecular oligosaccharides in sugar residues are not completely hydrolyzed and directly serve as waste residues, so that the waste of starch resources is caused. After the sugar residues are extracted, the sugar residues are further saccharified, so that starch and micromolecular oligosaccharide which are not completely hydrolyzed in the sugar residues can be continuously hydrolyzed and converted into micromolecular saccharides, and the starch conversion rate is improved. After the sugar residues are saccharified again, the finally generated solid residues can be applied to animal feed raw materials, so that the economic benefit can be improved, and waste can be converted into treasure. Sugar liquor produced after saccharification is mainly glucose, so that required fructose is generated through further isomerization, the fructose and the glucose are separated, and the separated fructose and the isomerized fructose are mixed again according to the content requirement of the fructose to produce high fructose syrup with different contents;
2. in the saccharification stage, barley β -amylase is an exo-amylase which acts on starch to cleave off the α -1, 4 glucosidic bonds of the starch from the non-reducing end in sequence, the hydrolysis product is maltose and the ultimate dextrin, fungal amylase is an endo-amylase which acts on the α -1, 4 glucosidic bonds of the dextrin, the hydrolysis product is primarily maltose and a small amount of glucose, glucoamylase hydrolyzes the dextrin from the non-reducing end, hydrolysis α -1, 4 glucosidic bonds separates one glucose unit to produce glucose, and the hydrolysis product is only glucose and no other sugars are produced.
3. The three-phase separation horizontal spiral sedimentation centrifuge can realize the three-phase separation of heavy-phase liquid, light-phase liquid and solid residue, filter aids diatomite and active carbon are not required to be added in the separation process for decolorization and filtration, the heavy-phase liquid, the light-phase liquid and saccharified liquid are reprocessed to obtain high fructose corn syrup, and the solid-phase residue can be used as an animal feed raw material because the solid-phase residue does not contain the filter aids and the active carbon.
Drawings
FIG. 1 is a flow chart of the production process of the present invention.
Detailed Description
The present invention will be described in further detail with reference to examples.
Example 1
A high fructose corn syrup production process specifically comprises the following steps:
step 1, starch size mixing, namely adding starch and water into a size mixing tank according to the mass ratio of 1: 1, fully stirring to form starch size, adjusting the pH of the starch size to be 5.4, then adding liquefying enzyme, and uniformly stirring, wherein the adding amount of the liquefying enzyme is 0.2L/t.Ds of the mass of the starch, and the liquefying enzyme is α -high-temperature amylase;
step 2, liquefaction: conveying the starch milk obtained in the step 1 into a liquefaction tank, liquefying the starch milk by steam, and injecting the starch milk into a flash tank for flash evaporation, wherein the injection temperature is controlled at 103 ℃, the injection time is controlled at 15min, the flash tank temperature is controlled at 90-100 ℃, and the flash evaporation time is 8 min;
step 3, saccharifying, namely cooling the liquefied liquid liquefied in the step 2 to 57 ℃, then transferring the liquefied liquid into a saccharifying tank, adding saccharifying enzyme into the saccharifying tank, wherein the adding amount of the saccharifying enzyme is 0.1L/t.Ds of the mass of the starch, the saccharifying time is 30h, and the saccharifying enzyme is barley β -amylase;
step 4, sugar residue extraction: after saccharification is finished, light slag floats on the upper layer of the saccharification liquid, heavy slag is precipitated to the lower layer of the saccharification liquid, the saccharification liquid is pumped out of a saccharification tank and used for preparing malt syrup, and the sugar slag is collected into the saccharification tank after extraction;
step 5, sugar residue re-saccharification: keeping the temperature of the saccharifying tank at 57 ℃, continuously adding saccharifying enzyme and uniformly stirring the saccharifying enzyme and the sugar residues collected in the step (4), wherein the adding amount of the saccharifying enzyme is 0.2L/t.Ds, the saccharifying time is 20h, and the saccharifying enzyme is glucoamylase;
step 6, separation of saccharified liquid: after the saccharification of the sugar residues is finished, separating saccharified liquid and solid residues by a three-phase separation horizontal screw sedimentation centrifuge, collecting the separated saccharified liquid, and collecting the solid residues collectively as animal feed raw materials;
and 7, evaporation and concentration: evaporating and concentrating the saccharified liquid collected in the step 6 to obtain sugar liquid with the solid content of 45%;
step 8, ion exchange: conveying the sugar solution obtained after evaporation and concentration to an ion exchanger for ion exchange to remove impurity ions in the sugar solution;
step 9, glucose isomerization: the sugar solution after ion exchange enters an isomerization column, and glucose isomerization is carried out through the isomerization column to obtain the sugar solution with fructose content of 42%;
step 10, ion exchange: carrying out ion exchange on the sugar solution subjected to glucose isomerization again;
step 11, evaporation and concentration: evaporating and concentrating the sugar solution subjected to ion exchange in the step 10 to obtain sugar solution with the solid content of 58%;
step 12, chromatographic separation: separating sugar solution by chromatographic resin to obtain syrup with fructose content of 90% and syrup with glucose content of 80%;
step 13, mixing the bed: preparing fructose syrup with fructose content of 55% from syrup with fructose content of 90% and syrup with fructose content of 42% obtained in step 9;
step 14, concentrating and storing finished products: concentrating the high fructose corn syrup mixed in the step 13 to obtain the high fructose corn syrup with the solid content of 75%, and then transferring the high fructose corn syrup to a storage tank for storage, wherein the storage temperature is 27 ℃.
Example 2
A high fructose corn syrup production process specifically comprises the following steps:
step 1, starch size mixing, namely adding starch and water into a size mixing tank according to the mass ratio of 1: 1.5, fully stirring to form starch size, adjusting the pH of the starch size to be 5.7, then adding liquefying enzyme, and uniformly stirring, wherein the adding amount of the liquefying enzyme is 0.3L/t.Ds of the mass of the starch, and the liquefying enzyme is α -high-temperature amylase;
step 2, liquefaction: conveying the starch milk obtained in the step 1 into a liquefaction tank, liquefying the starch milk by steam, injecting the starch milk into a flash tank for flash evaporation, controlling the injection temperature to be 115 ℃, controlling the injection time to be 6min, controlling the flash tank temperature to be 100 ℃, and controlling the flash evaporation time to be 5 min;
step 3, saccharification: cooling the liquefied liquid liquefied in the step 2 to 60 ℃, transferring the liquefied liquid into a saccharifying tank, adding saccharifying enzyme into the saccharifying tank, wherein the adding amount of the saccharifying enzyme is 0.2L/t.Ds of the mass of the starch, the saccharifying time is 20h, and the saccharifying enzyme is fungal amylase;
step 4, sugar residue extraction: after saccharification is finished, light slag floats on the upper layer of the saccharification liquid, heavy slag is precipitated to the lower layer of the saccharification liquid, the saccharification liquid is pumped out of a saccharification tank and used for preparing malt syrup, and the sugar slag is collected into the saccharification tank after extraction;
step 5, sugar residue re-saccharification: keeping the temperature of the saccharifying tank at 60 ℃, continuously adding saccharifying enzyme and uniformly stirring the saccharifying enzyme and the sugar residues collected in the step (4), wherein the adding amount of the saccharifying enzyme is 0.5L/t.Ds, the saccharifying time is 15h, and the saccharifying enzyme is glucoamylase;
step 6, separation of saccharified liquid: after the saccharification of the sugar residues is finished, separating saccharified liquid and solid residues by a three-phase separation horizontal screw sedimentation centrifuge, collecting the separated saccharified liquid, and collecting the solid residues collectively as animal feed raw materials;
and 7, evaporation and concentration: evaporating and concentrating the saccharified liquid collected in the step 6 to obtain sugar liquid with the solid content of 50%;
step 8, ion exchange: conveying the sugar solution obtained after evaporation and concentration to an ion exchanger for ion exchange to remove impurity ions in the sugar solution;
step 9, glucose isomerization: the sugar solution after ion exchange enters an isomerization column, and glucose isomerization is carried out through the isomerization column to obtain the sugar solution with the fructose content of 43 percent;
step 10, ion exchange: carrying out ion exchange on the sugar solution subjected to glucose isomerization again;
step 11, evaporation and concentration: evaporating and concentrating the sugar solution subjected to ion exchange in the step 10 to obtain a sugar solution with the solid content of 60%;
step 12, chromatographic separation: separating sugar solution by chromatographic resin to obtain syrup with fructose content of 90% and syrup with glucose content of 80%;
step 13, mixing the bed: mixing the syrup with fructose content of 90% and the syrup with fructose content of 43% obtained in the step 9 to obtain high fructose syrup with fructose content of 55%;
step 14, concentrating and storing finished products: concentrating the high fructose corn syrup mixed in the step 13 to obtain the high fructose corn syrup with the solid content of 80%, and then transferring the high fructose corn syrup to a storage tank for storage, wherein the storage temperature is 30 ℃.
Example 3
A high fructose corn syrup production process specifically comprises the following steps:
step 1, starch size mixing, namely adding starch and water into a size mixing tank according to the mass ratio of 1: 1.3, fully stirring to form starch size, adjusting the pH of the starch size to be 6.1, then adding liquefying enzyme, and uniformly stirring, wherein the adding amount of the liquefying enzyme is 0.5L/t.Ds of the mass of the starch, and the liquefying enzyme is α -high-temperature amylase;
step 2, liquefaction: conveying the starch milk obtained in the step 1 into a liquefaction tank, liquefying the starch milk by steam, injecting the starch milk into a flash tank for flash evaporation, controlling the injection temperature at 110 ℃, the injection time at 12min, the flash tank temperature at 95 ℃ and the flash evaporation time at 7 min;
step 3, saccharifying, namely cooling the liquefied liquid liquefied in the step 2 to 63 ℃, then transferring the liquefied liquid into a saccharifying tank, adding saccharifying enzyme into the saccharifying tank, wherein the adding amount of the saccharifying enzyme is 0.15L/t.Ds of the mass of the starch, the saccharifying time is 25h, and the saccharifying enzyme is barley β -amylase;
step 4, sugar residue extraction: after saccharification is finished, light slag floats on the upper layer of the saccharification liquid, heavy slag is precipitated to the lower layer of the saccharification liquid, the saccharification liquid is pumped out of a saccharification tank and used for preparing malt syrup, and the sugar slag is collected into the saccharification tank after extraction;
step 5, sugar residue re-saccharification: keeping the temperature of the saccharifying tank at 63 ℃, continuously adding saccharifying enzyme and uniformly stirring the saccharifying enzyme and the sugar residues collected in the step (4), wherein the adding amount of the saccharifying enzyme is 0.65L/t.Ds, the saccharifying time is 10h, and the saccharifying enzyme is glucoamylase;
step 6, separation of saccharified liquid: after the saccharification of the sugar residues is finished, separating saccharified liquid and solid residues by a three-phase separation horizontal screw sedimentation centrifuge, collecting the separated saccharified liquid, and collecting the solid residues collectively as animal feed raw materials;
and 7, evaporation and concentration: evaporating and concentrating the saccharified liquid collected in the step 6 to obtain sugar liquid with the solid content of 45%;
step 8, ion exchange: conveying the sugar solution obtained after evaporation and concentration to an ion exchanger for ion exchange to remove impurity ions in the sugar solution;
step 9, glucose isomerization: the sugar solution after ion exchange enters an isomerization column, and glucose isomerization is carried out through the isomerization column to obtain the sugar solution with fructose content of 44%;
step 10, ion exchange: carrying out ion exchange on the sugar solution subjected to glucose isomerization again;
step 11, evaporation and concentration: evaporating and concentrating the sugar solution subjected to ion exchange in the step 10 to obtain a sugar solution with the solid content of 62%;
step 12, chromatographic separation: separating sugar solution by chromatographic resin to obtain syrup with fructose content of 90% and syrup with glucose content of 80%;
step 13, mixing the bed: mixing syrup with fructose content of 90% and syrup with fructose content of 44% obtained in step 9 to obtain fructose syrup with fructose content of 56%;
step 14, concentrating and storing finished products: concentrating the high fructose corn syrup mixed in the step 13 to obtain the high fructose corn syrup with the solid content of 78%, and then transferring the high fructose corn syrup to a storage tank for storage, wherein the storage temperature is 35 ℃.
Example 4
A high fructose corn syrup production process specifically comprises the following steps:
step 1, starch size mixing, namely adding starch and water into a size mixing tank according to the mass ratio of 1: 1.2, fully stirring to form starch size, adjusting the pH of the starch size to be 6.0, then adding liquefying enzyme, and uniformly stirring, wherein the adding amount of the liquefying enzyme is 0.3L/t.Ds of the mass of the starch, and the liquefying enzyme is α -high-temperature amylase;
step 2, liquefaction: conveying the starch milk obtained in the step 1 into a liquefaction tank, liquefying the starch milk by steam, injecting the starch milk into a flash tank for flash evaporation, controlling the injection temperature at 108 ℃, the injection time at 9min, controlling the flash tank temperature at 90 ℃ and the flash evaporation time at 6 min;
step 3, saccharifying, namely cooling the liquefied liquid liquefied in the step 2 to 62 ℃, then transferring the liquefied liquid into a saccharifying tank, adding saccharifying enzyme into the saccharifying tank, wherein the adding amount of the saccharifying enzyme is 0.1L/t.Ds of the mass of the starch, the saccharifying time is 30h, and the saccharifying enzyme is barley β -amylase;
step 4, sugar residue extraction: after saccharification is finished, light slag floats on the upper layer of the saccharification liquid, heavy slag is precipitated to the lower layer of the saccharification liquid, the saccharification liquid is pumped out of a saccharification tank and used for preparing malt syrup, and the sugar slag is collected into the saccharification tank after extraction;
step 5, sugar residue re-saccharification: keeping the temperature of the saccharifying tank at 59 ℃, continuously adding saccharifying enzyme and uniformly stirring the saccharifying enzyme and the sugar residues collected in the step (4), wherein the adding amount of the saccharifying enzyme is 0.4L/t.Ds, the saccharifying time is 15h, and the saccharifying enzyme is glucoamylase;
step 6, separation of saccharified liquid: after the saccharification of the sugar residues is finished, separating saccharified liquid and solid residues by a three-phase separation horizontal screw sedimentation centrifuge, collecting the separated saccharified liquid, and collecting the solid residues collectively as animal feed raw materials;
and 7, evaporation and concentration: evaporating and concentrating the saccharified liquid collected in the step 6 to obtain sugar liquid with the solid content of 50%;
step 8, ion exchange: conveying the sugar solution obtained after evaporation and concentration to an ion exchanger for ion exchange to remove impurity ions in the sugar solution;
step 9, glucose isomerization: the sugar solution after ion exchange enters an isomerization column, and glucose isomerization is carried out through the isomerization column to obtain the sugar solution with the fructose content of 43 percent;
step 10, ion exchange: carrying out ion exchange on the sugar solution subjected to glucose isomerization again;
step 11, evaporation and concentration: evaporating and concentrating the sugar solution subjected to ion exchange in the step 10 to obtain a sugar solution with the solid content of 61%;
step 12, chromatographic separation: separating sugar solution by chromatographic resin to obtain syrup with fructose content of 90% and syrup with glucose content of 80%;
step 13, mixing the bed: mixing syrup with fructose content of 90% and syrup with fructose content of 43% and glucose content of 80% obtained in step 9 to obtain fructose-glucose syrup with fructose content of 55%;
step 14, concentrating and storing finished products: concentrating the high fructose corn syrup mixed in the step 13 to obtain the high fructose corn syrup with the solid content of 76%, and then transferring the high fructose corn syrup to a storage tank for storage, wherein the storage temperature is 32 ℃.
Example 5
A high fructose corn syrup production process specifically comprises the following steps:
step 1, starch size mixing, namely adding starch and water into a size mixing tank according to the mass ratio of 1: 1.4, fully stirring to form starch size, adjusting the pH of the starch size to be 5.8, then adding liquefying enzyme, and uniformly stirring, wherein the adding amount of the liquefying enzyme is 0.4L/t.Ds of the mass of the starch, and the liquefying enzyme is α -high-temperature amylase;
step 2, liquefaction: conveying the starch milk obtained in the step 1 into a liquefaction tank, liquefying the starch milk by steam, injecting the starch milk into a flash tank for flash evaporation, controlling the injection temperature at 110 ℃, the injection time at 9min, the flash tank temperature at 95 ℃ and the flash evaporation time at 7 min;
step 3, saccharifying, namely cooling the liquefied liquid liquefied in the step 2 to 60 ℃, then transferring the liquefied liquid into a saccharifying tank, adding saccharifying enzyme into the saccharifying tank, wherein the adding amount of the saccharifying enzyme is 0.18L/t.Ds of the mass of the starch, the saccharifying time is 25h, and the saccharifying enzyme is barley β -amylase;
step 4, sugar residue extraction: after saccharification is finished, light slag floats on the upper layer of the saccharification liquid, heavy slag is precipitated to the lower layer of the saccharification liquid, the saccharification liquid is pumped out of a saccharification tank and used for preparing malt syrup, and the sugar slag is collected into the saccharification tank after extraction;
step 5, sugar residue re-saccharification: keeping the temperature of the saccharifying tank at 60 ℃, continuously adding saccharifying enzyme and uniformly stirring the saccharifying enzyme and the sugar residues collected in the step (4), wherein the adding amount of the saccharifying enzyme is 0.45L/t.Ds, the saccharifying time is 15h, and the saccharifying enzyme is glucoamylase;
step 6, separation of saccharified liquid: after the saccharification of the sugar residues is finished, separating saccharified liquid and solid residues by a three-phase separation horizontal screw sedimentation centrifuge, collecting the separated saccharified liquid, and collecting the solid residues collectively as animal feed raw materials;
and 7, evaporation and concentration: evaporating and concentrating the saccharified liquid collected in the step 6 to obtain sugar liquid with the solid content of 50%;
step 8, ion exchange: conveying the sugar solution obtained after evaporation and concentration to an ion exchanger for ion exchange to remove impurity ions in the sugar solution;
step 9, glucose isomerization: the sugar solution after ion exchange enters an isomerization column, and glucose isomerization is carried out through the isomerization column to obtain the sugar solution with fructose content of 44%;
step 10, ion exchange: carrying out ion exchange on the sugar solution subjected to glucose isomerization again;
step 11, evaporation and concentration: evaporating and concentrating the sugar solution subjected to ion exchange in the step 10 to obtain a sugar solution with the solid content of 60%;
step 12, chromatographic separation: separating sugar solution by chromatographic resin to obtain syrup with fructose content of 90% and syrup with glucose content of 80%;
step 13, mixing the bed: mixing syrup with fructose content of 90% and syrup with fructose content of 44% obtained in step 9 to obtain fructose syrup with fructose content of 58%;
step 14, concentrating and storing finished products: concentrating the high fructose corn syrup mixed in the step 13 to obtain the high fructose corn syrup with the solid content of 77%, and then transferring the high fructose corn syrup to a storage tank for storage, wherein the storage temperature is 30 ℃.
The invention utilizes the compound biological saccharification technology to realize the reconversion of the sugar residues into the monomolecular sugar solution, thereby reducing the emission of the sugar residues, improving the utilization rate of starch, and realizing energy conservation, emission reduction and green production; in addition, the high-purity fructose corn syrup can be obtained in the filtering process of the high-fructose corn syrup production without adding diatomite and active carbon, and the extracted sugar residue without the diatomite and the active carbon can be used as an animal feed raw material, so that waste is changed into valuable, and the economic benefit is improved.
The present embodiment is only for explaining the present invention, and not for limiting the present invention, and those skilled in the art can make modifications without inventive contribution to the present embodiment as needed after reading the present specification, but all of which are protected by patent law within the scope of the claims of the present invention.
Claims (6)
1. A high fructose corn syrup production process is characterized in that: the method specifically comprises the following steps:
step 1, starch size mixing: the starch and the water are mixed according to the mass ratio of 1: 1-1.5, adding the starch slurry into a slurry mixing tank, fully stirring to form starch slurry, adjusting the pH of the starch slurry to 5.4-6.1, adding liquefying enzyme, and uniformly stirring, wherein the adding amount of the liquefying enzyme is 0.2-0.5L/t.Ds of the mass of the starch;
step 2, liquefaction: conveying the starch milk obtained in the step 1 into a liquefaction tank, liquefying the starch milk by steam, injecting the starch milk into a flash tank for flash evaporation, controlling the injection temperature to be 103-115 ℃, controlling the injection time to be 6-15 min, controlling the temperature of the flash tank to be 90-100 ℃, and controlling the flash evaporation time to be 5-8 min;
step 3, saccharification: cooling the liquefied liquid liquefied in the step 2 to 57-63 ℃, transferring the liquefied liquid into a saccharification tank, adding saccharifying enzyme into the saccharification tank, wherein the adding amount of the saccharifying enzyme is 0.1-0.2L/t.Ds of the mass of starch, and the saccharification time is 20-30 h;
step 4, sugar residue extraction: after saccharification is finished, light slag floats on the upper layer of the saccharification liquid, heavy slag is precipitated to the lower layer of the saccharification liquid, the upper layer of the saccharification liquid is pumped out from a saccharification tank and used for preparing maltose syrup, and the sugar slag is collected into the saccharification tank after extraction;
step 5, sugar residue re-saccharification: keeping the temperature of the saccharifying tank at 57-63 ℃, continuously adding saccharifying enzyme and uniformly stirring the saccharifying enzyme and the sugar residues collected in the step (4), wherein the adding amount of the saccharifying enzyme is 0.3-0.65L/t.Ds, and the saccharifying time is 10-20 h;
step 6, separation of saccharified liquid: separating saccharified liquid and solid residues generated in the re-saccharification step after the re-saccharification of the sugar residues is finished;
and 7, evaporation and concentration: evaporating and concentrating the saccharified liquid separated in the step 6 into a sugar liquid with the solid content of 45-50%;
step 8, ion exchange: conveying the sugar solution obtained after evaporation and concentration to an ion exchanger for ion exchange to remove impurity ions in the sugar solution;
step 9, glucose isomerization: enabling the sugar solution after ion exchange to enter an isomerization column, and carrying out glucose isomerization through the isomerization column to obtain the sugar solution with fructose content of 42-44%;
step 10, ion exchange: carrying out ion exchange on the sugar solution subjected to glucose isomerization again;
step 11, evaporation and concentration: evaporating and concentrating the sugar solution subjected to ion exchange in the step 10 to obtain sugar solution with the solid content of 58-62%;
step 12, chromatographic separation: separating sugar solution by chromatographic resin to obtain syrup with fructose content of 90% and syrup with glucose content of 80%;
step 13, mixing the bed: mixing syrup with fructose content of 90% and syrup with fructose content of 42-44% obtained in the step (9) to prepare high fructose corn syrup with fructose content of 55-58%;
step 14, concentrating and storing finished products: concentrating the high fructose corn syrup mixed in the step 13 into high fructose corn syrup with the solid content of 75-80%, and then transferring the high fructose corn syrup into a storage tank for storage.
2. The process for producing high fructose corn syrup according to claim 1, wherein the liquefying enzyme in step 1 is α -high temperature amylase.
3. The process for producing high fructose corn syrup according to claim 1, wherein the saccharifying enzyme in step 3 comprises at least one of barley β -amylase and fungal amylase, and the saccharifying enzyme in step 4 is glucoamylase.
4. The high fructose corn syrup production process according to claim 1, wherein: and (3) the content of glucose in the saccharified liquid obtained in the step (5) is not less than 95%.
5. The high fructose corn syrup production process according to claim 1, wherein: and 6, separating saccharified liquid and solid residues by adopting a three-phase separation horizontal screw sedimentation centrifuge.
6. The high fructose corn syrup production process according to claim 1, wherein: the storage temperature of the high fructose corn syrup in the step 14 is 27-35 ℃.
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