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 Benefits of Gravity-Fed DSM Screens
Washing s No maintenance necessary as
Economical corn wet milling practice screen media is rugged stainless
requires dewatering of the supply stream steel and there are no moving parts.
ahead of the degerminating mills. Also s Space needed is minimal since
the separated germ must be washed to units are compact and handle high
get a high purity germ product free of throughputs. Cascade mounting
starch. arrangement of three screens also
makes effective use of available
space.
Gravity-Fed DSM® Screens s Operation is trouble free due to
Dewatering and germ washing are non-blinding, wedge wire screen
done more effectively with Dorr-Oliver surface.
DSM screens. The DSM screens for s No fumes and spillage as screens
these applications are gravity fed over are totally enclosed.
a weir. A single stage screen is used for
dewatering. For germ washing, however, Pressure-Fed DSM Screen
three stages of DSM screens are used. Fiber Washing
The wash water flows countercurrently To get maximum starch recovery, while
and removes the starch quite efficiently keeping any fiber in the final product Benefits of Pressure-Fed 120 DSM
as the germ moves forward from stage to an absolute minimum, it is necessary Screens
to stage. 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.
Gravity-Fed DSM Screen

3
 Germ Separation and Starch
Washing Systems
Germ Separation Benefits of Germ Separation
After the corn kernels are steeped for DorrClones
softening, they are cracked open to s Maximum germ oil recovery (very low
release the germ. The germ contains the loss of the valuable process fraction).
valuable corn oil. The germ is separated s Easy maintenance and quick
from the heavier density mixture of replacement of individual cyclone
starch, hulls and fiber essentially by units because of the quick opening
“floating” the germ segments free of the couplings.
other substances under closely controlled s Rapid response to process changes
conditions. This method serves to through single instrument control.
eliminate any adverse effects of traces of s Totally enclosed design assures
corn oil in later processing steps. clean and fume-free operating area. Starch Washing Hydrocyclone System
s Lightweight construction and
overflow wash water stream. The multi-
Manifolded DorrClone shipment as a complete factory
stage systems provide easy and precise
Systems assembled package means low cost
control of the process, resulting in the
To accomplish this critical separation installation.
uniform, high quality starch required in
most efficiently, most plants today s Modular system design allows
today’s highly demanding marketplace.
use Dorr-Oliver’s compact manifolded easy expansion when production
The latest in starch washing technology
two-stage Germ Separation System. demands dictate.
incorporates recently developed high-
Specially sized DorrClone cyclones
efficiency 10mm cyclones for the
and engineered flow distributions are Starch washing
Starch Washing System. These high
specifically designed for the magma/ The starch slurry from the primary
capacity units incorporate advanced
germ separation. Because of the high separation contains some insoluble
flow channeling with superior materials
centrifugal forces employed, germ is protein and much of the solubles. They
and layout to save money in installed
separated instantly. The first pass makes have to be removed before a top quality
cost and operating power. Varying plant
a selective separation for optimum starch can be made. Modern plants
capacities can be handled.
purity and the second pass increases are using Dorr-Oliver Starch Washing
germ recovery by capturing any germ Systems for this important task.
Benefits of Starch Washing
that may have been bypassed in the first
Hydrocyclones
stage. This system has given processors Hydrocyclone Starch Washing
s Easy operation because simplified
a new standard of process control and System
control system uses self regulation
sanitation. A typical Dorr-Clone or Hydrocyclone
of intermediate stages.
Starch Washing System consists
Germ Separation s Improved sanitation since system is
DorrClone System 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

Gluten Dewatering Its reliable filtration enhances product

Before the gluten moves on to drying it is recovery minimizing protein loss.
good practice to dewater the gluten slurry
from the gluten thickener, which obviously Benefits of E-Belt Drum Filters
saves on the energy required to thermally s No more blinding problems and greatly
dry a high moisture product. This is usually improved washing and cloth tracking
accomplished economically on a rotary drum with the revolutionary swivel roll
filter with belt discharge. concept that doesn’t require filter cloth
rubber edges.
Dorr-Oliver Eimco s Delivers high rates of filtration and
E-Belt Drum Filter high hydraulic capacity for cake dryness
Dorr-Oliver Eimco E-Belt Drum Filters for enhancement.
corn wet milling applications have been s Hi Hydraulic capacity
adapted to meet the industry’s specific s Food design for cleaning and sanitation
needs for corrosion resistance and sanitation s Innovative cloth alignment design
Filters are of stainless steel construction s Low installation costs and clean working
and are equipped with streamlined internal environment due to compact design.
piping and valves, snap-in plastic supporting s No operator attention required.
media and easily adaptable discharge s Minimal maintenance
mechanisms.
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 Cake discharge from filter Filter enclosed in sanitary housing
starches processed on the Pneumapress
include corn, wheat, potato and tapioca The most common throughput sizes for The Pneumapress filter can be
starches – including modified, industrial single filters on native starches are in the totally enclosed to prevent product
and food grade varieties. Pneumapress range of 6 to 25 metric tons per hour contamination and provide increased
filters are installed in starch plants the dry solids and for modified starch are safety for those working in the vicinity.
USA, Germany, Thailand, Korea, France in the range of 4 to 20 metric tons per This enclosure may be designed in 316
and Italy. hour dry solids. stainless steel to provide the ultimate in
sanitary design and safety.
The design focus of Pneumapress
for the starch industry is to provide
Benefits of Pneumapress Filters
a mechanically simple, sanitary
s Very dry filter cakes with highly
and efficient filter. Pneumapress
effective cake washing when
filters do not require rubber seals or
required
diaphragms, simplifying the operation
s Highest throughput per unit area
and maintenance of the equipment.
of any filter, which minimizes the
Significant repeat business and referral
required filter area, equipment
sales are indicative of the success of the
size, number of moving parts and
Pneumapress design.
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
Pneumapress Sanitary Multi-Module Filter
from 316 stainless steel
The cleaning and hygiene requirements s An isolatable plate design provides
at food starch plants are becoming more very high equipment availability
stringent. Pneumapress has recognized s Sanitary or industrial design with
this need and created a patented optional filter housing, structure
sanitary design option to enable ease cladding, and CIP systems
of cleaning and sanitization. This option s Single-sided cake discharge
incorporates a fully automatic clean in s Low installation costs
place (CIP) system.

6
 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 Dorr-Oliver Eimco Indexing Belt Filter (IBF)

Precoat Filter
features a slow and precise knife Benefits of Pre-Coat Filters IBF, Indexing Belt Filter
advance system that assures the lowest Consistently clear and better Dorr-Oliver Eimco IBF is one of the many
precoat expense without affecting the quality syrup. products in our portfolio for vacuum
machine’s high throughput rates. The s Longer operating cycles and filtration of a wide range of hydrogenated
precoat material can be applied to the equipment life. compounds. The continuous operation
filter in varying thicknesses and users s Can be readily adapted to meet together with a simple mechanical design
get longer processing cycles between varying process needs. reduce maintenance offering steady and
filter medium replacements. The unit’s s Effective use of precoat, without reliable operation.
exclusive scraper design enables the waste, lowers operating costs.
operator to better control removal of s Revolutionary precoat discharge Benefits of IBF Filters
impurities with minimum loss of precoat system electronically control for s Food design, FDA validated.
material, and this also keeps operating reduced precoat consumption and s Totally enclosed execution for
costs down. longer filtration cycle. 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

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