Maltose syrup preparation system and method

Abstract

The invention provides a preparation system of malt syrup. According to the preparation system provided by the invention, the yield is improved and the production cost is reduced by optimizing the configuration of production equipment and the technological process. The at least three plate-and-frame filter presses are all used for treating saccharification clear liquid, two plate-and-frame filter presses are opened, and one plate-and-frame filter press is standby, so that the operation pressure of the filter presses is reduced, and the operation time and the feeding amount are improved. The rotary drum filtering system is used for treating saccharification turbid liquid, the saccharification turbid liquid is filtered by a rotary drum and then enters the plate-and-frame filter pressing system, then sugar liquid obtained after the turbid liquid is filtered by the rotary drum filtering machine passes through the plate-and-frame filter pressing machine again, the absorbance and the light transmittance of the sugar liquid can be greatly improved, and the recovery rate of the sugar liquid is improved.

Description

[0001] The present application claims priority to the Chinese patent application No. 202510894682.3, filed on June 30, 2025, and entitled "A preparation system and method of malt syrup", the whole content of which is incorporated herein by reference. TECHNICAL FIELD

[0002] The present application belongs to the technical field of malt sugar processing, and particularly relates to a preparation system and method of malt syrup. BACKGROUND

[0003] Malt sugar is a common sweetener, and its production process mainly includes the steps of saccharification, filtration, concentration, etc. In the traditional production, plate-and-frame filter presses are used to treat the clear liquid and turbid liquid of the saccharification tank, but due to the large running pressure of the equipment, the yield is low and the energy consumption is high, and the equipment wears out quickly, resulting in high maintenance costs. In addition, the design of the drum and the filter press sharing the pre-coating tank also has many drawbacks, such as blackening of protein residue, accumulation of turbid liquid in the saccharification tank, etc., which seriously affect the production efficiency and product quality.

[0004] Therefore, it is necessary to provide a preparation system and method of malt syrup with high yield, good quality, high production efficiency and low energy consumption. SUMMARY

[0005] Therefore, the present application provides a preparation system and method of malt syrup, which has high yield, good quality, high production efficiency and low energy consumption.

[0006] The present application provides a preparation system of malt syrup, comprising:

[0007] a liquefaction reactor;

[0008] a saccharification reactor connected with the liquefaction reactor, the saccharification reactor comprising a saccharification clear liquid outlet and a saccharification turbid liquid outlet;

[0009] a plate-and-frame filter system connected with the saccharification clear liquid outlet, and a drum filter system connected with the saccharification turbid liquid outlet; the plate-and-frame filter system comprises at least 3 plate-and-frame filter presses arranged in parallel;

[0010] an ion exchange device connected with the plate-and-frame filter system;

[0011] a refining device connected with the ion exchange column;

[0012] a de-flavoring device connected with the refining system;

[0013] an evaporator connected with the de-flavoring device.

[0014] Preferably, the plate-and-frame filter system comprises:

[0015] a decoloring buffer tank, a clear liquid inlet of which is connected with a saccharification clear liquid outlet of the saccharification reactor, and an activated carbon inlet of which is connected with an activated carbon adding tank;

[0016] a plate-and-frame feed tank, an inlet of which is connected with an outlet of the decoloring buffer tank;

[0017] the outlet of the plate-and-frame feed tank is provided with at least three groups of parallel pipelines, and each group of parallel pipelines is connected with a plate-and-frame filter.

[0018] Preferably, the plate-and-frame filter comprises filter plates, and the size of a single filter plate is 1.25*1.25 m 2 , and the effective filtration area of a single plate-and-frame filter is 200 m 2 .

[0019] Preferably, the rotary drum filter system comprises a rotary drum filter one for filtering maltose and a rotary drum filter two for filtering maltose, which are arranged in parallel.

[0020] the outlet of the rotary drum filter system is connected with a rotary drum filter material inlet of the plate-and-frame filter system;

[0021] the filter medium in the rotary drum filter one and the rotary drum filter two is diatomite.

[0022] Preferably, the preparation system further comprises a plate-and-frame filter pre-coating system.

[0023] the plate-and-frame filter pre-coating system comprises a pre-coating tank, a feed pump and an air conveying system.

[0024] the preparation system further comprises a rotary drum pre-coating tank.

[0025] The application further provides a preparation method of maltose syrup, comprising:

[0026] A) subjecting starch milk to liquefaction and saccharification treatment with an enzyme preparation to obtain saccharification clear liquid and saccharification turbid liquid;

[0027] B) subjecting the saccharification clear liquid to decoloring treatment by a plate-and-frame filter system to obtain decoloring sugar liquid;

[0028] subjecting the saccharification turbid liquid to treatment by a rotary drum filter system and then to decoloring treatment by a plate-and-frame filter system;

[0029] C) subjecting the decoloring sugar liquid to ion exchange, refining, taste removal and evaporation in sequence to obtain maltose syrup.

[0030] Preferably, the liquefaction comprises the following steps:

[0031] The starch milk is mixed with the enzyme preparation for one-time jet liquefaction to obtain one-time liquefaction supernatant and one-time liquefaction turbidity;

[0032] The one-time liquefaction supernatant is filtered and then subjected to secondary jet liquefaction, and then filtered again to obtain secondary liquefaction supernatant;

[0033] The one-time liquefaction supernatant and the secondary liquefaction supernatant are liquefaction liquid.

[0034] Preferably, the saccharification treatment comprises:

[0035] The liquefaction liquid is mixed with the enzyme preparation for saccharification to obtain saccharification supernatant and saccharification turbidity.

[0036] Preferably, the working pressure of the plate and frame filter pressing system is 4-8 Bar, the compacting pressure is 1.0-2.0 Bar, the feeding speed is 25-30 m 3 / h, the decolorization temperature is 60-65℃, and the time is 30-60 min;

[0037] In the rotary drum filter system, the rotary speed of the rotary drum is 0.49-4.9 r / min, the working pressure is 1.5-3 bar, and the discharging speed is 12-18 m 3 / h;

[0038] The light transmittance of the decolorized sugar liquid is 95-98%, and the absorbance is 120-180.

[0039] Preferably, the ion exchange resin is D001 anion resin and D301 cation resin;

[0040] The refining adopts a D202 anion resin and a D203 cation resin for desalination polishing;

[0041] The taste removal adopts activated carbon adsorption taste removal;

[0042] The evaporation adopts an MVR evaporator.

[0043] Compared with the prior art, the maltose syrup preparation system provided by the application comprises: a liquefaction reactor; a saccharification reactor connected with the liquefaction reactor, wherein the saccharification reactor comprises a saccharification clear liquid outlet and a saccharification turbid liquid outlet; a plate-and-frame filter pressing system connected with the saccharification clear liquid outlet and a rotary drum filter system connected with the saccharification turbid liquid outlet; the plate-and-frame filter pressing system comprises at least three plate-and-frame filter presses arranged in parallel; an ion exchange device connected with the plate-and-frame filter pressing system; a refining device connected with the ion exchange column; a deodorizing device connected with the refining system; and an evaporator connected with the deodorizing device. The preparation system provided by the application can improve the yield and reduce the production cost by optimizing the production equipment configuration and the process flow. The at least three plate-and-frame filter presses are all used to process the saccharification clear liquid, two of which are used for processing and one is reserved, so that the operation pressure of the filter press is reduced, and the operation time and the material passing amount are improved. The rotary drum filter system is used to process the saccharification turbid liquid, and the saccharification turbid liquid is filtered by the rotary drum filter and then enters the plate-and-frame filter pressing system. After the saccharification turbid liquid filtered by the rotary drum filter is filtered by the plate-and-frame filter press again, the absorbance and the transmittance of the saccharification turbid liquid are greatly improved, and the recovery rate of the saccharification turbid liquid is improved.

[0044] Through experimental verification, the technical scheme of the application has achieved remarkable effects in improving the yield of maltose syrup, reducing energy consumption, improving product quality, improving production efficiency, and reducing equipment wear and maintenance cost. Compared with the prior art, the application has obvious technical advantages and economic value, can effectively solve many problems in the existing maltose production process, and has a broad application prospect. BRIEF DESCRIPTION OF DRAWINGS

[0045] Figure 1 The structure diagram of the plate-and-frame filter pressing system provided by the application is shown in the figure.

[0046] Figure 2 The structure diagram of the rotary drum filter system provided by the application is shown in the figure.

[0047] Figure 3 The process flow diagram of the preparation of the maltose syrup provided by the application is shown in the figure.

[0048] Figure 4 The process flow diagram of the preparation of the maltose syrup used in Comparative Examples 1 and 2 is shown in the figure. DETAILED DESCRIPTION

[0049] The maltose syrup preparation system provided by the application comprises:

[0050] The liquefaction reactor;

[0051] The saccharification reactor connected with the liquefaction reactor, wherein the saccharification reactor comprises a saccharification clear liquid outlet and a saccharification turbid liquid outlet;

[0052] A plate-and-frame filter system connected to the saccharification clear liquor outlet, and a rotary drum filter system connected to the saccharification turbid liquor outlet; the plate-and-frame filter system comprises at least three plate-and-frame filter machines arranged in parallel;

[0053] An ion exchange device connected to the plate-and-frame filter system;

[0054] A refining device connected to the ion exchange column;

[0055] A deodorizing device connected to the refining system;

[0056] An evaporator connected to the deodorizing device.

[0057] The maltose syrup preparation system provided by the application comprises a liquefaction reactor.

[0058] The liquefaction reactor comprises a liquefaction clear liquor outlet and a liquefaction turbid liquor outlet connected to a saccharification reactor.

[0059] The liquefaction clear liquor outlet is connected to a liquefaction clear liquor first filter device, a secondary injection liquefaction device, and a second filter device in sequence.

[0060] The filter medium in the liquefaction clear liquor first filter device is an activated carbon maintenance column.

[0061] The filter medium in the second filter device is an activated carbon maintenance column.

[0062] In the application, the maltose preparation system further comprises a saccharification reactor, which is a device for saccharification reaction of the liquefaction liquid obtained from the liquefaction reactor and an enzyme preparation.

[0063] In the application, the maltose preparation system further comprises a plate-and-frame filter system connected to the saccharification clear liquor outlet, and the plate-and-frame filter system comprises at least three plate-and-frame filter machines arranged in parallel.

[0064] Specifically, the plate-and-frame filter system comprises:

[0065] A decolorization buffer tank, a clear liquor inlet of the decolorization buffer tank being connected to the saccharification clear liquor outlet of the saccharification reactor, and an activated carbon inlet of the decolorization buffer tank being connected to an activated carbon adding tank;

[0066] A plate and frame feed tank whose inlet is connected to the outlet of the decolorization buffer tank;

[0067] The outlet of the plate and frame feed tank is provided with at least three sets of parallel pipelines, each set of pipelines being connected to a plate and frame filter press.

[0068] In some specific embodiments of the present invention, the plate and frame filter press includes filter plates. The present invention does not impose any special limitations on the size of the filter plates; any filter plate size known to those skilled in the art is acceptable. In the present invention, the size of a single filter plate is 1.25*1.25m. 2 The effective filtration area of ​​a single plate and frame filter press is 200m². 2 .

[0069] A feed pump is installed at the outlet of the plate and frame filter press feed tank. The feed pump can supply feed to three plate and frame filter presses respectively, so that two filter presses are in operation and one is on standby, with a stable discharge flow rate of 30-35 m³ / h. 3 / h.

[0070] See Figure 1 , Figure 1 This is a schematic diagram of the plate and frame filter press system provided by the present invention.

[0071] In some specific embodiments of the present invention, the outlet of the plate and frame filter press is sequentially connected to a bag filter and an activated carbon horizontal tank.

[0072] In this invention, the maltose preparation system further includes a rotary drum filtration system connected to the outlet of the saccharified turbid liquid.

[0073] The rotary drum filtration system includes a rotary drum filter one for filtering maltose and a rotary drum filter two for filtering maltose, which are arranged in parallel.

[0074] The outlet of the rotary drum filtration system is connected to the inlet of the rotary drum filter media of the plate and frame filter press system.

[0075] The drum dimensions of the first and second drum filters are 5135*4000*2785 mm, and the filter medium is diatomaceous earth.

[0076] See Figure 2 , Figure 2 This is a schematic diagram of the structure of the rotary drum filtration system provided by the present invention. Figure 2 The rotary drum filtration system includes a rotary drum feed tank, a rotary drum filter, a rotary drum buffer tank, and a rotary drum discharge filter. The rotary drum feed tank corresponds to... Figure 2 The drums A and B correspond to drum filter one and drum filter two. Figure 2 The material consists of two drums, Drum 1 and Drum 2. After passing through the drum discharge filter, the material from the drums enters the plate and frame feed tank.

[0077] In some preferred embodiments of the present application, the preparation system further comprises a plate-and-frame filter press pre-coating system.

[0078] The pre-coating system comprises a pre-coating tank, a feed pump and an air conveying system, the pre-coating tank of the pre-coating system is connected with the pre-coating feed pump, after the pre-coating tank is put into pre-coating medium, the pre-coating medium enters the plate-and-frame filter press through the feed pump; the air conveying system is connected above the pre-coating tank to prevent pollution of the environment during the addition of soil and carbon;

[0079] The preparation system further comprises a drum pre-coating tank. The drum pre-coating tank is connected with a drum filter, after the drum pre-coating is completed, the turbid liquid enters the drum for filtration, the filtered clear liquid enters the next section, and the filtered protein is sent to the drum auger by the drum scraper, and the protein is sent to the protein outlet pipeline by the soil worker for bagging.

[0080] In the present application, the plate-and-frame filter system and the pre-coating system are respectively connected with each group of pre-coating tanks, thereby solving the problems of blackening of protein residue and accumulation of turbid liquid in the saccharification tank, and improving the product quality.

[0081] In the present application, the preparation system further comprises a refining device connected with the ion exchange column, a deodorizing device connected with the refining system, and an evaporator connected with the deodorizing device.

[0082] Among them, the refining device, the deodorizing device and the evaporator are not specially limited in the present application, and devices known to those skilled in the art can be used.

[0083] In the present application, when the pipeline is modified, blind plates are added to the system separation valves to prevent cross-contamination caused by valve internal leakage or modification errors.

[0084] The present application also provides a method for preparing malt syrup by using the above preparation system, comprising:

[0085] A) treating starch milk and enzyme preparation by liquefaction and saccharification to obtain saccharified clear liquid and saccharified turbid liquid;

[0086] B) subjecting the saccharified clear liquid to decolorization treatment by the plate-and-frame filter system to obtain decolorized sugar liquid;

[0087] The saccharified turbid liquid is subjected to decolorization treatment by the plate-and-frame filter system after being treated by the drum filter system;

[0088] C) sequentially subjecting the decolorized sugar liquid to ion exchange, refining, deodorization and evaporation to obtain malt syrup.

[0089] Reference Figure 3 , Figure 3 The present application provides a preparation process flow chart of malt syrup.

[0090] ​The starch milk is first mixed with the enzyme preparation for liquefaction to obtain a liquefied liquid.

[0091] Specifically, the liquefaction comprises the following steps:

[0092] The starch milk is mixed with the enzyme preparation for one-time jet liquefaction to obtain one-time liquefied clear liquid and one-time liquefied turbid liquid;

[0093] The one-time liquefied clear liquid is filtered for two-time jet liquefaction, and then filtered again to obtain two-time liquefied clear liquid;

[0094] The one-time liquefied clear liquid and the two-time liquefied clear liquid are liquefied liquid.

[0095] The temperature of the one-time jet liquefaction is 106-110 DEG C, which can be 106, 108, 110, or any value between 106-110 DEG C. After the one-time jet liquefaction is completed, the temperature is maintained for 100-150 min, which can be 100, 110, 120, 130, 140, 150, or any value between 100-150 min.

[0096] After the one-time jet liquefaction is completed, one-time liquefied clear liquid and one-time liquefied turbid liquid are obtained. The one-time liquefied clear liquid is filtered to obtain filtrate. The filter is a maintenance column with activated carbon as the filter medium. The filtration conditions are that the pressure is 93-96 kPa, and the filtration speed is 25-30 m 3 / h. Then, the filtrate is subjected to two-time jet liquefaction, the temperature of which is 120-135 DEG C, which can be 120, 125, 130, 135, or any value between 125-135 DEG C. After the two-time jet liquefaction is completed, the temperature is maintained, and then the filtrate is filtered again to obtain two-time liquefied clear liquid. The filter is a maintenance column with activated carbon as the filter medium. The filtration conditions are that the pressure is 93-96 kPa, and the filtration speed is 25-30 m 3 / h.

[0097] In the present application, the one-time liquefied clear liquid and the two-time liquefied clear liquid are liquefied liquid. The DE value of the liquefied liquid is 8-13, which can be 8, 9, 10, 11, 12, 13, or any value between 8-13.

[0098] Then, the pH of the liquefied liquid is adjusted to a pH suitable for enzymatic hydrolysis of the enzyme preparation, and the enzyme preparation is added for saccharification. In the present application, the temperature of the saccharification is 58-62 DEG C, which can be 58, 60, 62, or any value between 58-62 DEG C. The time is 22-30 hours, which can be 22, 24, 26, 28, 30, or any value between 22-30 hours.

[0099] After the saccharification is completed, saccharified clear liquid and saccharified turbid liquid are obtained.

[0100] In the process of decolorization, at least two plate and frame filter presses of the plate and frame filter press system are opened, one of which is standby, for filtration. In the process of decolorization, the temperature is 55-65℃, which can be 55, 60, 65, or any value between 55-65℃, the time is 30-60min, which can be 30, 40, 50, 60, or any value between 30-60min; the working pressure is 4-8Bar, which can be 4, 5, 6, 7, 8, or any value between 4-8Bar, the pressing pressure is 1-2Bar, and the feeding speed is 25-35m 3 / h, which can be 25, 30, 35, or any value between 25-35m 3 / h.

[0101] The light transmittance of the decolorized sugar solution after decolorization by the plate and frame filter press is 93-98%, and the absorbance is 120-190.

[0102] The saccharification turbid liquid is treated by a rotary drum filter system and then enters the plate and frame filter press system for decolorization treatment.

[0103] Specifically, the saccharification turbid liquid enters the rotary drum feed tank, enters the pre-coated rotary drum filter from the rotary drum feed tank, and the sugar solution filtered by the rotary drum filter enters the rotary drum filtrate buffer tank, and then enters the plate and frame filter press for further decolorization. In the present application, the pre-coated medium is diatomite.

[0104] The rotary speed of the rotary drum filter is 0.49-4.9r / min, the filtering precision is 2400*3350mm, the working pressure is 1.5-3Bar, which can be 1.5, 2, 2.5, 3, or any value between 1.5-3Bar, and the discharging speed is 12-18m 3 / h, which can be 12, 14, 16, 18, or any value between 12-18m 3 / h. The saccharification turbid liquid is filtered by the rotary drum filter and then enters the plate and frame filter press for decolorization, and the light transmittance of the obtained decolorized sugar solution is 93-98%, and the absorbance is 120-190.

[0105] Then, the decolorized sugar solution is sequentially subjected to ion exchange, refining, deodorization and evaporation to obtain malt syrup.

[0106] The ion exchange resin for ion exchange is D001 anion resin and D301 cation resin.

[0107] The speed of ion exchange is 25-35m 3 / h, which can be 25, 30, 35, or any value between 25-35m 3Any value between 50 and 55 ℃, which can be 50, 52, 54, 55, or any value between 50 and 55 ℃.

[0108] The conductivity of the sugar solution obtained after ion exchange is 10-50 us / cm, the pH value is 4.2-5.5, the light transmittance is 100%, and the absorbance is ≤70.

[0109] The sugar solution obtained after ion exchange is refined by using a mixed bed of D202 anion resin and D203 cation resin for desalting and polishing; the refining speed is 25-35 m 3 / h, which can be 25, 30, 35, or any value between 25 and 35 m 3 Any value between 32 and 37 ℃, which can be 32, 33, 34, 35, 36, 37, or any value between 32 and 37 ℃.

[0110] After desalting and polishing by the parallel mixed bed, the conductivity of the obtained sugar solution is 5-25 us / cm, the pH value is 4.0-5.0, the light transmittance is 100%, and the absorbance is ≤50.

[0111] Then, the sugar solution is deodorized, and in the present application, it is preferred to use activated carbon adsorption for deodorization, and more preferably, the sugar solution is treated at 60-75 ℃ using activated carbon adsorption method to remove the bad smell in the sugar solution, and the speed is 25-35 m 3 / h, and stirring in the deodorizing tank for 20-30 min, after passing through the horizontal disc filter precoated with activated carbon, the absorbance is ≤30, the light transmittance is 100%, there is no peculiar smell, and no carbon particles are obtained by vacuum filtration;

[0112] Finally, evaporation is performed. The deodorized sugar solution is concentrated by an evaporator to obtain a malt syrup with a solid content of 76.0%-76.5%. In the present application, the evaporator is preferably an MVR evaporator, the working temperature of the MVR evaporator is 83-88 ℃, which can be 83, 85, 86, 88, or any value between 83 and 88 ℃, the heat exchange area is 900 m 2 , the compression ratio is 2.33-2.35, and the evaporation time required is 60-85 min, which can be 60, 65, 70, 75, 80, 85, or any value between 60 and 85 min.

[0113] The preparation system provided by the present application optimizes the production equipment configuration and process flow, improves the yield and reduces the production cost. At least three plate and frame filter presses are used to treat the saccharification clear liquid, two are in operation and one is in standby, which reduces the operation pressure of the filter press, improves the operation time and the amount of material passing through. The drum filter system is used to treat the saccharification turbid liquid, and the saccharification turbid liquid is filtered by the drum filter and then enters the plate and frame filter system, thereby further reducing the absorbance of the sugar solution.

[0114] Through experimental verification, the technical scheme of the present application has achieved remarkable results in improving the yield of malt syrup, reducing energy consumption, improving product quality, improving production efficiency, and reducing equipment wear and maintenance cost, etc. Compared with the prior art, the present application has obvious technical advantages and economic value, can effectively solve many problems in the existing malt sugar production process, and has broad application prospect.

[0115] In order to further understand the present application, the preparation system and method of malt syrup provided by the present application are described below in conjunction with examples, and the protection scope of the present application is not limited by the following examples.

[0116] Example 1

[0117] The production method of malt syrup provided in this embodiment includes the following steps:

[0118] (1) Pretreatment: adjust the density of starch milk to 1130, adjust the pH value to 5.6-5.8, and add Novozymes high-efficiency amylase 0.30 kg / ton of starch;

[0119] (2) Liquefaction: the pretreated starch milk is stirred uniformly and then subjected to one-time jet liquefaction at 108℃ for 100-120min; the solution after one-time liquefaction is divided into two parts as clear liquid and turbid liquid, wherein the turbid liquid part directly enters the saccharification step, and the clear liquid part enters the maintenance column with activated carbon as filter medium, and is filtered at a pressure of 95KPa and a filtration speed of 30m 3 3 / h, and then subjected to two-time jet liquefaction at a temperature of 125℃, and then enters the maintenance column with activated carbon as filter medium, and is filtered again at a pressure of 0.4MPA and a filtration speed of 30m3 / h, and then enters the saccharification step; the DE value of the liquefied liquid obtained in this step is 11;

[0120] (3) Saccharification: adjust the pH value of the liquefied liquid obtained in step (2) to 4.4, add β-amylase 0.025 kg / ton of starch and saccharifying enzyme 0.015 kg / ton of starch, and saccharify for 25 hours under the synergistic action of the two enzymes at 60℃;

[0121] (4) Decolorization: the clear liquid obtained after saccharification enters 1#, 2# and 3# plate and frame filter presses, and the plate and frame decolorization system includes a feed tank, a decolorization buffer tank and an activated carbon adding device, the filter plate size is 1.25*1.25m 2 2, the effective filtration area is 200㎡, the working pressure is 4Bar, the compaction pressure is 1.5Bar, and the feeding speed is 30m 3 / h, the sugar solution was filtered by the drum filter, and then was subjected to decolorization by the plate-frame filter, the transmittance of the sugar solution was 98%, and the absorbance was 120; the turbid solution was subjected to saccharification, and then was subjected to filtration by a drum filter, and then was subjected to decolorization by the plate-frame filter, the transmittance of the sugar solution was 98%, and the absorbance was 120; 3 / h, the turbid solution was filtered by the drum filter, and then was subjected to decolorization by the plate-frame filter, the transmittance of the sugar solution was 98%, and the absorbance was 120;

[0122] (5) Ion exchange desalination: the sugar solution obtained in step (4) was subjected to ion exchange (positive bed-negative bed-positive bed-negative bed) by ion exchange columns, a total of three groups of ion exchange columns were used, the speed was 30 m 3 / h, and the temperature was 50 DEG C, the exchange resin of the ion exchange column was negative (D001) and positive resin (D301), after the ion exchange desalination, the conductivity of the obtained sugar solution was 10-50 us / cm, the pH value was 4.2-5.5, and the transmittance was 100%;

[0123] (6) Refining: the sugar solution obtained in step (5) was subjected to further polishing by a refining mixed bed (negative and positive resins were filled in proportion), the speed was 30 m 3 / h, and the temperature was 35 DEG C, after the desalination and polishing by the parallel refining mixed bed, the conductivity of the obtained sugar solution was ≤10 us / cm, the pH value was 4.0-5.0, the transmittance was 100%, and the absorbance was ≤20-45;

[0124] (7) Deodorization: the sugar solution obtained in step (6) was subjected to removal of bad smell by using activated carbon adsorption method at 60-75 DEG C, the speed was 30 m 3 / h, and the stirring time in the deodorization tank was 20 min, after the horizontal disc filter with activated carbon pre-coating, the absorbance was 15-20, the transmittance was 100%, there was no peculiar smell, and no carbon particles were obtained by vacuum filtration;

[0125] (8) Evaporation: the sugar solution obtained in step (7) was concentrated into malt sugar syrup with a solid content of 80.8-81.3% by an MVR evaporator, the working temperature of the MVR evaporator was 86 DEG C, the heat exchange area was 900 m 2 , the compression ratio was 2.48-2.51, and the evaporation time was 65-90 min.

[0126] The maltose syrup prepared by the method provided in the embodiment has a DE value of 55±3, an iodine value of ≤0.30, a fermentation degree of 67-73, a pH value of 4.5-4.9, an absorbance of ≤30, a daily output of 260 tons, and the filter sheet of the diaphragm filter is replaced 5 sheets per month.

[0127] Example 2

[0128] The production method of the maltose syrup provided in the embodiment comprises the following steps:

[0129] (1) Pretreatment: the starch milk is adjusted to a concentration of 1120 and a pH value of 5.6-5.8, and 0.35 kg of β-amylase is added per ton of starch (the amount of amylase added);

[0130] (2) Liquefaction: the pretreated starch milk is stirred uniformly and then subjected to one-time jet liquefaction at 108°C for 120 min; the solution after one-time liquefaction is divided into two parts, i.e., a clear liquid and a turbid liquid, wherein the turbid liquid part directly enters the saccharification step, and the clear liquid part enters a holding column with activated carbon as the filter medium, is filtered at a pressure of 95 kPa and a filtration speed of 30 m 3 / h, and then is subjected to two-time jet liquefaction at a temperature of 125°C, is filtered again at a pressure of 93 kPa and a filtration speed of 30 m 3 / h after being kept for 20 min, and then enters the saccharification step; the liquefied liquid obtained in this step has a DE value of 10;

[0131] (3) Saccharification: the liquefied liquid obtained in step (2) is adjusted to a pH value of 5.0-5.5, 0.015 kg of β-amylase is added per ton of starch, and saccharification is performed at 60°C for 30 hours;

[0132] (4) Decolorization: the clear liquid obtained after saccharification enters 1#, 2# and 3# plate and frame filter presses, the plate and frame decolorization system comprises a feeding tank, a decolorization buffer tank and an activated carbon adding device, the filter plate has a size of 1.25*1.25 m 2 , an effective filtration area of 200 m2, a working pressure of 5.0 Bar, a compacting pressure of 1.5 Bar, and a feeding speed of 30 m 3 / h, the sugar solution was filtered by the drum filter, and then was subjected to decolorization by the plate-frame filter, the transmittance of the sugar solution was 98%, and the absorbance was 180; the turbid solution obtained at the end of saccharification was subjected to drum filtration, i.e., was subjected to drum feeding into a drum feeding tank, was subjected to drum filtration by a pre-coated drum filter, the sugar solution filtered by the drum filter was subjected to drum filtrate buffering in a drum filtrate buffer tank, was subjected to further decolorization by a filter, and then was subjected to drum filtration by a plate-frame filter, the drum filter had a drum size of 5135*4000*2785, the filtering medium was diatomite, the rotating speed was 0.49-4.9 r / min, the filtering precision was 2400*3350 mm, the working pressure was 1.5-3 bar, and the discharging speed was 15 m 3 / h, the turbid solution was filtered by the drum filter, and then was subjected to decolorization by the plate-frame filter, the transmittance of the sugar solution was 98%, and the absorbance was 180;

[0133] (5) Ion exchange desalination: the sugar solution obtained in step (4) was subjected to ion exchange (anion bed-cation bed-anion bed-cation bed) by ion exchange columns, a total of three ion exchange columns were used, the speed was 30 m 3 / h, and the temperature was 50°C, the ion exchange columns used anion (D001) and cation resins (D301), after ion exchange desalination, the conductivity of the obtained sugar solution was 10-30 us / cm, the pH value was 4.2-5.5, the transmittance was 100%, and the absorbance was ≤70;

[0134] (6) Refining: the sugar solution obtained in step (5) was subjected to further polishing by a refining mixed bed (anion (D202) and cation resins (D203) filled in proportion), the speed was 30 m 3 / h, and the temperature was 35°C, after desalination and polishing by the parallel refining mixed bed, the conductivity of the obtained sugar solution was 5-25 us / cm, the pH value was 4.0-5.0, the transmittance was 100%, and the absorbance was 30;

[0135] (7) Deodorization: the sugar solution obtained in step (6) was subjected to removal of bad smell in the sugar solution by activated carbon adsorption method at 60°C, the speed was 30 m 3 / h, and the stirring time in the deodorization tank was 20 min, after the horizontal disc filter pre-coated with activated carbon, the absorbance was 15, the transmittance was 100%, there was no peculiar smell, and no carbon particles were obtained by vacuum filtration;

[0136] (8) Evaporation: the sugar solution obtained in step (7) was concentrated into a malt sugar syrup with a solid content of 76.0-76.5 by an MVR evaporator, the working temperature of the MVR evaporator was 86°C, the heat exchange area was 900 m 2 , the compression ratio was 2.33-2.35, and the evaporation time was 80 min.

[0137] The maltose syrup prepared by the method provided in the embodiment has a DE value of 40±2, a caramelization temperature of ≥125℃, a sulfuric acid ash of 0.15, a pH value of 5.0, an absorbance of ≤30, and a daily output of 260 tons, and the filter sheet of the plate-and-frame filter is replaced 5 times per month.

[0138] The preparation system of the maltose syrup used in Comparative Examples 1-2 is described below Figure 4 , Figure 4 The preparation system of the maltose syrup used in Comparative Examples 1-2 is described below

[0139] Comparative Example 1

[0140] The production method of the maltose syrup provided in the present comparative example comprises the following steps:

[0141] (1) Pre-treatment: adjust the concentration of the starch milk to 1130, adjust the pH value to 5.6-5.8, and add 0.30 kg of amylase per ton of starch;

[0142] (2) Liquefaction: after the pre-treated starch milk is uniformly stirred, it is subjected to one-time jet liquefaction at 108℃ for 100-120 min; the solution after one-time liquefaction is divided into two parts, i.e., clear liquid and turbid liquid, wherein the turbid liquid part directly enters the saccharification step, and the clear liquid part enters the maintenance column with activated carbon as the filter medium, and is filtered at a pressure of 95 KPa and a filtration speed of 30 m 3 / h, and then is subjected to two-time jet liquefaction at a temperature of 125℃, and is filtered at a pressure of 0.4 MPA and a filtration speed of 30 m3 / h after being maintained for 20 min, and then enters the saccharification step; the DE value of the liquefied liquid obtained in this step is 11;

[0143] (3) Saccharification: adjust the pH value of the liquefied liquid obtained in step (2) to 4.4, add 0.025 kg of β-amylase and 0.015 kg of saccharifying enzyme per ton of starch, and saccharify for 25 hours under the synergistic action of the two enzymes at 60℃;

[0144] (4) Decolorization: after the saccharification is completed, the clear liquid obtained is introduced into a 1# and a 2# plate-and-frame filter, and the plate-and-frame decolorization system comprises a feed tank, a decolorization buffer tank, and an activated carbon adding device, the filter plate has a size of 1.25*1.25 m 2 , the effective filtration area is 200 m2, the working pressure is 4 Bar, the compression pressure is 3.0 Bar, and the feeding speed is 20 m 3The decolorization process was carried out at a rate of 60℃ for 40 minutes per hour. After decolorization by plate and frame filter press, the transmittance of the sugar solution was 90%, and the absorbance was 240. The turbid liquid obtained after saccharification was fed into a No. 3 plate and frame filter press. The filter plates were 1.25*1.25 mm in size, with an effective filtration area of ​​200 m². The working pressure was 6 Bar, the compaction pressure was 3.0 Bar, and the feed rate was 8.0 m / s². 3 The decolorization process was carried out at a temperature of 60°C for 60 minutes per hour. After decolorization by plate and frame filter press, the transmittance of the sugar solution was 85% and the absorbance was 350. The turbid liquid was filtered by a plate and frame filter press and then entered the plate and frame filter press for decolorization. The resulting sugar solution had a transmittance of 90% and an absorbance of 240.

[0145] (5) Ion exchange desalination: The sugar solution obtained in step (4) is subjected to ion exchange through ion exchange columns (cation bed-anion bed-cation bed-anion bed), for a total of three sets of ion exchange columns, at a velocity of 20 m / s. 3 The ion exchange column has an exchange rate of 1000 h and a temperature of 50°C. The exchange resins of the column are anion exchange resin (D001) and cation exchange resin (D301). After ion exchange desalination, the resulting sugar solution has a conductivity of 25-70 μS / cm, a pH of 3.8-4.7, and a transmittance of 99%.

[0146] (6) Refining: The sugar solution obtained in step (5) is further polished by passing it through a refining mixed bed (anion and cation resins are filled in proportion) at a speed of 20m. 3 At a temperature of 35℃ and a parallel refined mixed bed, the resulting sugar solution has a conductivity of 20-50 μS / cm, a pH of 3.6-4.6, a transmittance of 100%, and an absorbance of ≤70.

[0147] (7) Deodorization: Remove the unpleasant odor from the sugar solution obtained in step (6) using activated carbon adsorption at 65-75℃ at a rate of 20 m / s. 3 / h, stir in the deodorizing tank for 20min, and after passing through a horizontal disc filter pre-coated with activated carbon, the absorbance is ≤30-50, the transmittance is 100%, there is no odor, and no carbon particles are allowed to be removed by vacuum filtration.

[0148] (8) Evaporation: The sugar solution obtained in step (7) is concentrated into maltose syrup with a solid content of 80.8-81.3% using an MVR evaporator. The operating temperature of the MVR evaporator is 86℃, and the heat exchange area is 900m². 2 The compression ratio is 2.48-2.51, and the evaporation time is 65-90 minutes.

[0149] The maltose syrup prepared by the method provided in the embodiment has a DE value of 55±3, an iodine value of ≤0.30, a fermentation degree of 67-73, a pH value of 4.5-4.9, an absorbance of 40-60, a daily output of 200 tons, and the filter disc of the diaphragm filter is replaced 8 times per month.

[0150] Comparative Example 2

[0151] The production method of the maltose syrup provided in the comparative example includes the following steps:

[0152] (1) Pre-treatment: adjust the concentration of the starch milk to 1120, adjust the pH value to 5.6-5.8, and add β-amylase 0.35 kg / ton of starch (the amount of amylase added);

[0153] (2) liquefaction: after the pre-treated starch milk is uniformly stirred, one-time jet liquefaction is performed at 108°C, and the solution is incubated for 120 min; the solution after one-time liquefaction is divided into two parts as clear liquid and turbid liquid, the turbid liquid part is directly sent to the saccharification step, and the clear liquid part is sent to the holding column with activated carbon as the filter medium after the reactor, and is filtered at a pressure of 95 kpa and a filtration speed of 30 m 3 / h, after completion, two-time jet liquefaction is performed at a temperature of 125°C, and the solution is incubated for 20 min before being filtered again in the holding column with activated carbon as the filter medium at a pressure of 93 kpa and a filtration speed of 30 m 3 / h, and then is sent to the saccharification step; the DE value of the liquefied solution obtained in this step is 10;

[0154] (3) saccharification: adjust the pH value of the liquefied solution obtained in step (2) to 5.0-5.5, add β-amylase 0.015 / ton of starch, and saccharify at 60°C for 30 hours;

[0155] (4) decolorization: the clear liquid obtained after saccharification is sent to 1# and 2# plate and frame filter presses, the plate and frame decolorization system includes a feed tank, a decolorization buffer tank, and an activated carbon adding device, the filter plate size is 1.25*1.25 m 2 , the effective filtration area is 200 m 3 , the working pressure is 6 Bar, the compaction pressure is 3 Bar, the feeding speed is 20 m 3 / h, the decolorization temperature is 60°C, the time is 60 min, the sugar solution has a light transmittance of 85% and an absorbance of 370 after being filtered by a plate and frame filter to remove color; the turbid liquid is filtered by a plate and frame filter and then enters the plate and frame filter to remove color, and the obtained sugar solution has a light transmittance of 90% and an absorbance of 260;

[0156] (5) Ion exchange desalination: the sugar solution obtained in step (4) is subjected to ion exchange (positive bed-negative bed-positive bed-negative bed) through ion exchange columns, a total of three ion exchange columns are used for ion exchange, the speed is 20 m 3 / h, the temperature is 50°C, the exchange resin of the ion exchange column is negative (D001) and positive resin (D301), after ion exchange desalination, the obtained sugar solution has an electric conductivity of 20-45 us / cm, a pH value of 4.0-5.0, a light transmittance of 100%, and an absorbance of 100;

[0157] (6) Refining: the sugar solution obtained in step (5) is further polished through a refining mixed bed (negative (D202) and positive resin (D203) filled in proportion) at a speed of 20 m 3 / h, the temperature is 35°C, after desalination and polishing through the parallel refining mixed bed, the obtained sugar solution has an electric conductivity of 10-30 us / cm, a pH value of 3.8-4.5, a light transmittance of 100%, and an absorbance of 50-80;

[0158] (7) Deodorization: the sugar solution obtained in step (6) is subjected to active carbon adsorption method to remove the bad smell in the sugar solution at 60°C, the speed is 20 m 3 / h, stirring in the deodorization tank for 20 min, after being filtered through the horizontal disc filter with pre-coated active carbon, the absorbance is 30, the light transmittance is 100%, there is no peculiar smell and no carbon particles are obtained after vacuum filtration;

[0159] (8) Evaporation: the sugar solution obtained in step (7) is concentrated into malt syrup with a solid content of 76.0-76.5% through an MVR evaporator, the working temperature of the MVR evaporator is 86°C, the heat exchange area is 900 m 2 , the compression ratio is 2.33-2.35, and the evaporation time required is 80 min.

[0160] The malt syrup prepared by the method provided in the embodiment has a DE value of 40±2, a boiling temperature of ≥120°C, a sulfuric acid ash of 0.30, a pH value of 4.5, an absorbance of 40-65, a daily output of 120 tons, and the filter sheet of the diaphragm filter is replaced 8 times per month.

[0161] The equipment and method of Example 1 and Comparative Example 1 are compared and analyzed:

[0162] 1. Example group: The optimized process and equipment configuration of the invention are adopted, including three plate and frame filter presses for treating clear liquid, independent pre-coating system, drum separation operation, etc.

[0163] 2. Comparative example group: The traditional process is adopted, i.e., plate and frame filter presses simultaneously treat clear liquid and turbid liquid, and the drum and filter press share a pre-coating tank.

[0164] 3. Experimental conditions: Both groups of experiments are conducted under the same raw materials, temperature, time, etc., to ensure the reliability of the comparison results.

[0165] Experimental results

[0166] 1. Yield improvement:

[0167] · Example group: The daily yield of malt syrup reaches 260 tons, which is 30% higher than the traditional process.

[0168] · Comparative example group: The daily yield is 200 tons.

[0169] · Conclusion: The invention significantly improves the yield of malt syrup by optimizing the equipment configuration and process flow.

[0170] 2. Energy consumption reduction:

[0171] · Example group: The unit product energy consumption is 123 kWh / ton, which is 10% lower than the traditional process.

[0172] · Comparative example group: The unit product energy consumption is 135 kWh / ton.

[0173] · Conclusion: The invention optimizes the energy consumption of saccharification, filtration, and concentration links, improving energy utilization efficiency.

[0174] 3. Product quality improvement:

[0175] · Example group: The absorbance of malt syrup is 30 AU, the purity reaches 98.5%, and the taste is more mellow.

[0176] · Comparative example group: The absorbance is 50 AU, the purity is 96.8%, and the taste is lighter.

[0177] · Conclusion: The invention significantly improves the absorbance and purity of malt syrup through the independent pre-coating system and optimized filtration process, improving product quality.

[0178] 4. Production efficiency improvement:

[0179] · Example group: The turbid liquid treatment time of the saccharification tank is shortened to 2 hours, which is 40% less than the traditional process.

[0180] · Comparative example group: The treatment time is 3.5 hours.

[0181] ·Conclusion: The application significantly improves the processing efficiency of the saccharification tank turbidity liquid through drum separation operation and pipeline optimization, shortens the production cycle.

[0182] 5. Reduced equipment wear and maintenance costs:

[0183] ·Example group: The equipment runs smoothly, the service life of the plate and frame filter press is extended by 25%, and the maintenance cost is reduced by 30%.

[0184] ·Comparative example group: The equipment wears out quickly and the maintenance cost is high.

[0185] ·Conclusion: The application reduces equipment wear and maintenance costs by reducing equipment operating pressure and optimizing processes.

[0186] Table 1

[0187] Indicator Example group Comparative example group Promotion ratio Daily output (tons) 260 200 +30％ Power consumption (kWh / ton) 123 135 -10％ Absorbance (AU) 30 50 Significantly reduced Purity (%) 98.5 96.8 +1.7％ Turbidity treatment time 2 3.5 -40％ Equipment life extension 25％ - +25％ Maintenance cost reduction -30％ - -30％

[0188] The above is only the preferred embodiment of the present application, it should be noted that for those skilled in the art, without departing from the principles of the present application, can make a number of improvements and refinements, these improvements and refinements should also be considered within the scope of the present application.

Claims

1. A maltose syrup preparation system, characterized in that, include: Liquefaction reactor; A saccharification reactor is connected to the liquefaction reactor, the saccharification reactor including a saccharified clear liquid outlet and a saccharified turbid liquid outlet; A plate and frame filter press system connected to the outlet of the saccharified clear liquid, and a rotary drum filter system connected to the outlet of the saccharified turbid liquid; the plate and frame filter press system includes at least three plate and frame filter presses connected in parallel; An ion exchange device connected to the plate and frame filter press system; A purification apparatus connected to the ion exchange column; Deodorizing device connected to the refining system; An evaporator connected to the deodorizing device.

2. The preparation system according to claim 1, characterized in that, The plate and frame filter press system includes: A decolorizing buffer tank, wherein the clear liquid inlet of the decolorizing buffer tank is connected to the saccharification clear liquid outlet of the saccharification reactor, and the activated carbon inlet of the decolorizing buffer tank is connected to an activated carbon addition tank; A plate and frame feed tank whose inlet is connected to the outlet of the decolorization buffer tank; The outlet of the plate and frame feed tank is provided with at least three sets of parallel pipelines, each set of pipelines being connected to a plate and frame filter press.

3. The preparation system according to claim 1, characterized in that, The plate and frame filter press includes filter plates, each with dimensions of 1.25 x 1.25 m. 2 The effective filtration area of ​​a single plate and frame filter press is 200m². 2 .

4. The preparation system according to claim 1, characterized in that, The rotary drum filtration system includes a rotary drum filter I for filtering maltose and a rotary drum filter II for filtering maltose, which are connected in parallel. The outlet of the rotary drum filtration system is connected to the inlet of the rotary drum filter media of the plate and frame filter press system. The filter medium in both the first and second drum filters is diatomaceous earth.

5. The preparation system according to claim 1, characterized in that, The preparation system also includes a plate and frame filter press pre-coating system; The plate and frame filter press pre-coating system includes a pre-coating tank, a feed pump, and an air conveying system; The preparation system also includes a rotary drum pre-coating tank.

6. A method for preparing malt syrup, characterized in that, include: A) Starch milk and enzyme preparation are liquefied and saccharified to obtain saccharified clear liquid and saccharified turbid liquid; B) The saccharified liquid is decolorized using a plate and frame filter press system to obtain a decolorized sugar solution; The saccharified turbid liquid is processed by a rotary drum filtration system and then enters a plate and frame filter press system for decolorization. C) The decolorized sugar solution is subjected to ion exchange, refining, deodorization and evaporation in sequence to obtain malt syrup.

7. The preparation method according to claim 6, characterized in that, The liquefaction includes the following steps: The starch milk was mixed with an enzyme preparation and liquefied by a single spraying process to obtain a clear liquefied liquid and a turbid liquefied liquid. The first liquefied liquid is filtered and then sprayed liquefied a second time, and then filtered again to obtain the second liquefied liquid. The primary liquefied liquid and the secondary liquefied liquid are liquefied liquids.

8. The preparation method according to claim 6, characterized in that, The saccharification process includes: The liquefied liquid is mixed with an enzyme preparation for saccharification to obtain a clear saccharified liquid and a turbid saccharified liquid.

9. The preparation method according to claim 6, characterized in that, The plate and frame filter press system operates at a pressure of 4–8 Bar, a compaction pressure of 1.0–2.0 Bar, and a feed rate of 25–30 m / s. 3 / h, decolorization temperature is 60~65℃, time is 30~60min; In the rotary drum filtration system, the drum rotates at a speed of 0.49–4.9 r / min, the working pressure is 1.5–3 bar, and the discharge speed is 12–18 m / s. 3 / h; The light transmittance of the decolorized sugar solution is 95-98%, and the absorbance is 120-180.

10. The preparation method according to claim 6, characterized in that, The ion exchange resins are D001 anion exchange resin and D301 cation exchange resin. The refining process employs a mixed bed of D202 anion exchange resin and D203 cationic resin for desalination and polishing. The deodorization process utilizes activated carbon for odor absorption. The evaporation is performed using an MVR evaporator.

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