Production method and device of malt syrup

Abstract

The invention discloses a production method and device of malt syrup, and relates to the field of food production. In the production process of the malt syrup, a secondary injection technology is reasonably arranged, so that the DE value of the obtained finished product is kept in a range of 38-46, meanwhile, the iodine value of the finished product is reduced, and the filtering speed of the material is increased; the plate-and-frame filter press and the rotary drum filter are used and cooperate to improve the feeding speed and the discharging quality; and the falling film evaporator MVR is used in the evaporation process, so that the production efficiency is improved.

Description

Technical Field

[0001] This invention relates to the field of food production, and more particularly to a method and apparatus for producing malt syrup. Background Technology

[0002] The Dextrorose Equivalent Value (DE) is an indicator of the proportion of reducing sugars in maltose syrup. A higher DE value indicates a sweeter maltose syrup. Market research shows that modern consumers are increasingly focused on healthy eating and are becoming more aware of the need for high-sugar foods. Low-DE maltose syrups are less sweet and have a milder taste, providing sweetness while reducing reliance on high-sugar ingredients like sucrose. This helps lower the overall sugar content of food and meets consumers' demand for healthier options.

[0003] As consumer demand upgrades, some food manufacturers are gradually switching to low DE value maltose syrups (DE values ​​of 38-46) to improve product flavor and adapt to the market. However, low DE value maltose syrups have higher viscosity and require higher product quality, which existing production equipment and methods cannot meet. Summary of the Invention

[0004] In view of this, the present invention provides a method and apparatus for producing malt syrup. The malt syrup produced by the method provided by the present invention has a DE value concentrated in the range of 38 to 46, and has the advantages of high product quality and fast production speed.

[0005] The method for producing malt syrup provided by this invention specifically includes:

[0006] (1) Preparation of starch slurry: Adjust the density of starch slurry to 1100-1150 and the pH to 5.6-5.8, and add 0.2-0.35 kg of amylase per ton of starch;

[0007] (2) Liquefaction: The starch milk after slurry preparation is sprayed liquefied once at 106-110℃ and kept warm for 100-150 min; the turbid liquid after the first spray liquefaction is sprayed liquefied a second time at 120-135℃ and kept warm for 20 min to obtain the liquefied liquid.

[0008] (3) Saccharification: Adjust the pH of the clear liquid obtained from the first spray liquefaction and the liquefied liquid obtained from the second spray liquefaction to 4.2-5.5, add 0.015-0.26 kg of β enzyme per ton of starch, and saccharify at 58-62℃ for 22-30 h;

[0009] (4) Decolorization: The turbid liquid obtained in step (3) enters a rotary drum filter. The filter medium of the rotary drum filter is diatomaceous earth, and the rotation speed is 0.49 to 4.9 r / min. After filtration, it enters a plate and frame filter press with activated carbon as the filter medium for decolorization to obtain sugar solution. The clear liquid obtained in step (3) directly enters a plate and frame filter press for decolorization to obtain sugar solution.

[0010] (5) Purification: All the sugar solutions obtained in step (4) are desalted by passing them through an ion exchange column, then desalted and polished by a parallel purification mixed bed, and then the unpleasant odor in the sugar solutions is removed by activated carbon adsorption.

[0011] (6) Evaporation: The sugar solution obtained in step (5) is concentrated into malt syrup with a solid content of 76% to 82% by MVR evaporator.

[0012] In some specific implementations, step (2) further includes filtering the material before and after the secondary injection liquefaction in a support column. The filter medium is activated carbon, the pressure is 40–96 kPa, and the filtration velocity is 25–30 m / s. 3 / h.

[0013] In some specific implementations, the working pressure of the rotary drum filter in step (4) is 1.5–3 bar, and the discharge speed is 8–14 m / s. 3 In some specific implementations, the plate and frame filter press in step (4) operates at a temperature of 55–68°C, a working pressure of 4–8 bar, a pressing pressure of 1–2 bar, and an effective filtration area of ​​180–220 m². 2 The material feeding speed is 25-35m / s. 3 / h, decolorization temperature is 55~68℃.

[0014] In some specific implementations, the operating temperature of the MVR evaporator in step (6) is 80–88°C, and the heat exchange area is 850–950 m². 2 The compression ratio is 2.30 to 2.51, and the evaporation time is 50 to 90 minutes.

[0015] In some specific implementations, the saccharification in step (3) also includes adding 0.01 to 0.015 kg of saccharifying enzyme or 0.01 to 0.015 kg of pullulanase per ton of starch.

[0016] In some specific implementations, there are a total of three groups of ion exchange columns in step (5), and the distribution of each group of ion exchange columns is cation bed, anion bed, cation bed, anion bed. The exchange medium of the cation bed is D001 resin, and the exchange medium of the anion bed is D301 resin.

[0017] The internal temperature of the ion exchange column is 50–55°C, and the feed rate is 25–35 m / s.3 / h.

[0018] In some specific implementations, the system temperature for activated carbon adsorption in step (5) is 60–75°C, and the feed rate is 25–35 m / s. 3 / h.

[0019] The present invention also provides a malt syrup production apparatus, specifically comprising: a primary spraying device, a secondary spraying device connected to the outlet of the primary spraying device, a saccharification tank connected to the outlets of the primary and secondary spraying devices, a rotary drum filter connected to the outlet of the saccharification tank, a plate and frame decolorizing device connected to the outlets of the saccharification tank and the rotary drum filter, a purification device connected to the outlet of the plate and frame decolorizing device, and an evaporation device connected to the outlet of the purification device.

[0020] The purification device includes an ion exchange unit, a parallel mixed bed unit, and a deodorization unit.

[0021] In some specific implementations, the evaporation device includes an MVR evaporation unit.

[0022] This invention introduces secondary injection technology into the maltose syrup production process, maintaining the DE value of the finished product within the range of 38-46, while simultaneously reducing the iodine value of the finished product and increasing the material filtration speed. The use of a plate and frame filter press and a rotary drum filter synergistically improves the material flow rate and output quality. Furthermore, the use of a falling film evaporator (MVR) during the evaporation process ensures full utilization of secondary steam, recovers latent heat, and improves thermal efficiency, thereby increasing production efficiency and reducing production costs. Attached Figure Description

[0023] Figure 1 The flowchart of the malt syrup production method provided by the present invention. Detailed Implementation

[0024] It should be understood that the expression “one or more of…” individually includes each of the objects described after the expression, as well as various different combinations of two or more of the described objects, unless otherwise understood from the context and usage. The expression “and / or” combined with three or more described objects should be understood to have the same meaning, unless otherwise understood from the context.

[0025] The terms “including,” “having,” or “containing,” including the use of their grammatical synonyms, should generally be understood as open-ended and non-restrictive, for example, not excluding other unstated elements or steps, unless otherwise specifically stated or understood from the context.

[0026] It should be understood that the order of the steps or the order in which certain actions are performed is not important as long as the invention remains operational. Furthermore, two or more steps or actions can be performed simultaneously.

[0027] The use of any and all instances or exemplary language such as “e.g.” or “including” in this document is merely intended to better illustrate the invention and is not intended to limit the scope of the invention unless the claims are made. No language in this specification should be construed as indicating that any unclaimed element is essential to the practice of the invention.

[0028] Furthermore, the numerical ranges and parameters used to define the present invention are approximate values, and the relevant values ​​in the specific embodiments have been presented as precisely as possible. However, any value inevitably contains standard deviations due to individual test methods. Therefore, unless explicitly stated otherwise, it should be understood that all ranges, quantities, values, and percentages used in this disclosure are modified with the word "approximately." Here, "approximately" generally means an actual value within plus or minus 10%, 5%, 1%, or 0.5% of a particular value or range.

[0029] The present invention is further illustrated below with reference to the embodiments. The scope of protection of the present invention is not limited to the following embodiments.

[0030] Example 1

[0031] (1) Mixing: Adjust the density of the starch milk to 1130 kg / m³ 3 Adjust the pH to 5.7 and add 0.25 kg of amylase per ton of starch milk;

[0032] (2) Liquefaction: After the starch slurry has been mixed evenly, it is sprayed and liquefied once at 108℃ and kept at that temperature for 120 min. The solution after the first liquefaction is divided into two parts: clear liquid and turbid liquid. The clear liquid part directly enters the saccharification step, while the turbid liquid part enters the holding column with activated carbon as the filter medium after passing through the reactor. The filtration is carried out at a pressure of 93-96 kPa and a filtration velocity of 30 m / s. 3 Filtration is performed at a rate of / h, followed by secondary jet liquefaction at 125℃. After holding at this temperature for 20 minutes, the solution is introduced into a support column with activated carbon as the filter medium, and then filtered at a pressure of 0.4MPa and a filtration velocity of 30m / h. 3 The solution is filtered again at / h, and then proceeds to the saccharification step; the DE value of the liquefied liquid obtained in this step is 11;

[0033] (3) Saccharification: Adjust the pH of the liquefied liquid obtained in step (2) to 4.3, add 0.02-0.025 kg of β enzyme and 0.01-0.015 kg of saccharifying enzyme per ton of liquefied liquid, and saccharify for 22-25 hours under the synergistic effect of the two enzymes at a saccharification temperature of 60℃;

[0034] (4) Decolorization: The clear liquid obtained after saccharification enters a plate and frame filter press. The plate and frame decolorization system includes a feed tank, a decolorization buffer tank, and an activated carbon addition device. The filter plates are 1.25*1.25m in size, with an effective filtration area of ​​200m². 2 The working pressure is 8 Bar, the clamping pressure is 2 Bar, and the feed speed is 30 m / s. 3 The decolorization process was carried out at a temperature of 60℃ for 60 minutes. After plate and frame filtration, the transmittance of the sugar solution was 93-98%, and the absorbance was 190 AU. The turbid liquid obtained after saccharification was fed into a rotary drum filter. The drum dimensions of the rotary drum filter were 5135*4000*2785mm, the filter medium was diatomaceous earth, the rotation speed was 4.9 r / min, the filtration accuracy was 2400*3350mm, the working pressure was 3 bar, and the discharge speed was 14 m / s. 3 / h, the turbid liquid is filtered by a rotary drum filter and then enters the plate and frame filter press for decolorization. The resulting sugar solution has a transmittance of 98% and an absorbance of 190AU.

[0035] (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). There are a total of three sets of ion exchange columns, and the velocity is 30m. 3 / h, the temperature is 55℃, the ion exchange column is a cation exchange resin (D001) and anion exchange resin (D301), after ion exchange desalination, the resulting sugar solution has a conductivity of 30us / cm, a pH value of 5.0, and a light transmittance of 100%.

[0036] (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 30 m / s. 3 At a temperature of 37℃ and a parallel refined mixed bed, the resulting sugar solution has a conductivity of 15µs / cm, a pH of 4.5, a transmittance of 100%, and an absorbance of ≤50AU.

[0037] (7) Deodorization: The sugar solution obtained in step (6) is subjected to activated carbon adsorption at 65°C to remove unpleasant odors. The adsorption rate is 30 rpm. 3 / h, stir in the deodorizing tank for 30min, and after passing through a horizontal disc filter pre-coated with activated carbon, the absorbance is ≤30AU, the transmittance is 100%, there is no odor, and no carbon particles are allowed to be removed by vacuum filtration.

[0038] (8) Evaporation: The sugar solution obtained in step (7) is concentrated into maltose syrup with a solid content of 81.3% using a German GEA / MVR evaporator. The operating temperature of the MVR evaporator is 88℃, and the heat exchange area is 900m². 2 The compression ratio is 2.48, and the evaporation time is 90 minutes.

[0039] The maltose syrup prepared according to the method provided in this embodiment has a DE value of 45, an iodine value of ≤0.30, a degree of fermentation of 67-73, a pH value of 4.5-4.9, and an absorbance of ≤30AU.

[0040] Example 2

[0041] (1) Mixing: Adjust the starch milk concentration to 1120 kg / m³ 3 Adjust the pH value to 5.6-5.8, and add 0.30-0.35 kg of β-amylase per ton of starch milk;

[0042] (2) Liquefaction: After the starch slurry has been mixed evenly, it is sprayed and liquefied once at 108℃ and kept at that temperature for 150 min. The solution after the first liquefaction is divided into two parts: clear liquid and turbid liquid. The clear liquid part directly enters the saccharification step, while the turbid liquid part enters the holding column with activated carbon as the filter medium after passing through the reactor. The filtration is carried out at a pressure of 93-96 kPa and a filtration velocity of 30 m / s². 3 Filtration is performed at a rate of / h, followed by secondary jet liquefaction at 125℃. After holding at this temperature for 20 minutes, the solution is introduced into a support column with activated carbon as the filter medium, and then filtered at a pressure of 93–96 kPa and a filtration velocity of 30 m / s. 3 The solution is filtered again at / h, and then proceeds to the saccharification step; the DE value of the liquefied liquid obtained in this step is 10;

[0043] (3) Saccharification: Adjust the pH of the liquefied liquid obtained in step (2) to 5.5, add 0.015-0.025 kg of β enzyme per ton of liquefied liquid, and saccharify at 60°C for 30 hours;

[0044] (4) Decolorization: The clear liquid obtained after saccharification enters a plate and frame filter press. The plate and frame decolorization system includes a feed tank, a decolorization buffer tank, and an activated carbon addition device. The filter plates are 1.25*1.25m in size, with an effective filtration area of ​​200m². 2 The working pressure is 8 Bar, the clamping pressure is 2.0 Bar, and the feeding speed is 30 m / s. 3 The decolorization process is carried out at a temperature of 65℃ for 60 minutes. After plate and frame filtration, the transmittance of the sugar solution is 95-98%, and the absorbance is 120-180 AU. The turbid liquid obtained after saccharification enters a rotary drum filter. The drum size of the rotary drum filter is 5135*4000*2785mm, the filter medium is diatomaceous earth, the rotation speed is 0.49-4.9r / min, the filtration accuracy is 2400*3350mm, the working pressure is 3bar, and the discharge speed is 14m / min. 3 / h, the turbid liquid is filtered by a rotary drum filter and then enters the plate and frame filter press for decolorization. The resulting sugar solution has a transmittance of 93-98% and an absorbance of 120-180AU.

[0045] (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). There are a total of three sets of ion exchange columns, and the velocity is 30m. 3 / h, the temperature is 55℃, the ion exchange column is a cation exchange resin (D001) and anion exchange resin (D301), after ion exchange desalination, the resulting sugar solution has a conductivity of 30us / cm, a pH value of 45.5, a transmittance of 100%, and an absorbance of ≤70AU.

[0046] (6) Refining: The sugar solution obtained in step (5) is further polished by passing it through a refining mixed bed (anion (D202) and cation (D203) filled in proportion) at a speed of 35m. 3 At a temperature of 37℃ and a parallel refined mixed bed, the resulting sugar solution has a conductivity of 25µs / cm, a pH of 5.0, a transmittance of 100%, and an absorbance of ≤50AU.

[0047] (7) Deodorization: The sugar solution obtained in step (6) is subjected to activated carbon adsorption at 60°C to remove unpleasant odors at a rate of 30 m / s. 3 / h, stir in the deodorizing tank for 30min, and after passing through a horizontal disc filter pre-coated with activated carbon, the absorbance is ≤30AU, the transmittance is 100%, there is no odor, and no carbon particles are allowed to be removed by vacuum filtration.

[0048] (8) Evaporation: The sugar solution obtained in step (7) is concentrated into maltose syrup with a solid content of 76.0% to 76.5% using a German GEA / MVR evaporator. The operating temperature of the MVR evaporator is 86℃, and the heat exchange area is 900m². 2 The compression ratio is 2.30, and the evaporation time is 65 minutes.

[0049] The maltose syrup prepared according to the method provided in this embodiment has a DE value of 40, a boiling temperature of ≥125℃, a sulfuric acid ash content of ≤0.3, a pH value of 4.3~6.0, and an absorbance of ≤30AU.

[0050] Example 3

[0051] (1) Mixing: Adjust the density of the starch milk to 1130 kg / m³ 3 Adjust the pH to 5.8 and add 0.25 kg of amylase per ton of starch milk;

[0052] (2) Liquefaction: After the starch milk slurry has been mixed evenly, it is sprayed and liquefied once at 110℃ and kept at this temperature for 120 min. The solution after the first liquefaction is divided into two parts: clear liquid and turbid liquid. The clear liquid part directly enters the saccharification step, while the turbid liquid part enters the holding column with activated carbon as the filter medium after passing through the reactor. The filtration is carried out at a pressure of 93-96 kPa and a filtration velocity of 30 m / s.3 Filtration is performed at a rate of / h, followed by secondary jet liquefaction at 120℃. After holding at this temperature for 20 minutes, the solution is introduced into a support column with activated carbon as the filter medium, and then filtered at a pressure of 93–96 kPa and a filtration velocity of 30 m / s. 3 The solution is filtered again at / h, and then proceeds to the saccharification step; the DE value of the liquefied liquid obtained in this step is 10;

[0053] (3) Saccharification: Adjust the pH of the liquefied liquid obtained in step (2) to 5.0-5.5, add 0.15-0.20 kg of β enzyme and 0.01-0.015 kg of pullulanase per ton of liquefied liquid, and saccharify for 30 hours under the synergistic effect of the two enzymes at a saccharification temperature of 60℃.

[0054] (4) Decolorization: The clear liquid obtained after saccharification enters a plate and frame filter press. The plate and frame decolorization system includes a feed tank, a decolorization buffer tank, and an activated carbon addition device. The filter plates are 1.25*1.25m in size, with an effective filtration area of ​​200m². 2 The working pressure is 8 Bar, the clamping pressure is 2.0 Bar, and the feeding speed is 32 m / s. 3 The decolorization process was carried out at a temperature of 68℃ for 60 minutes. After plate and frame filtration, the transmittance of the sugar solution was 95-100%, and the absorbance was 110-170 AU. The turbid liquid obtained after saccharification entered a rotary drum filter. The drum dimensions of the rotary drum filter were 5135*4000*2785mm, the filter medium was diatomaceous earth, the rotation speed was 4.9 r / min, the transition accuracy was 2400*3350mm, the working pressure was 3 bar, and the discharge speed was 14 m / s. 3 / h, the turbid liquid is filtered by a rotary drum filter and then enters the plate and frame filter press for decolorization. The resulting sugar solution has a transmittance of 95-99% and an absorbance of 110-170AU.

[0055] (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 25-35 m / s. 3 / h, the temperature is 50~55℃, the ion exchange column is a cation (D001) and anion (D301) resin, after ion exchange desalination, the resulting sugar solution has a conductivity of 20us / cm, a pH value of 5.5, a transmittance of 100%, and an absorbance of ≤70AU.

[0056] (6) Refining: The sugar solution obtained in step (5) is further polished by passing it through a refining mixed bed (anion (D202) and cation (D203) filled in proportion) at a speed of 30m. 3At a temperature of 37℃ and a parallel refined mixed bed, the resulting sugar solution has a conductivity of 15µs / cm, a pH of 5.0, a transmittance of 100%, and an absorbance of ≤50AU.

[0057] (7) Deodorization: The sugar solution obtained in step (6) is subjected to activated carbon adsorption at 65°C to remove unpleasant odors from the sugar solution at a rate of 30 m / s. 3 / h, stir in the deodorizing tank for 30min, and after passing through a horizontal disc filter pre-coated with activated carbon, the absorbance is ≤30AU, the transmittance is 100%, there is no odor, and no carbon particles are allowed to be removed by vacuum filtration.

[0058] (8) Evaporation: The sugar solution obtained in step (7) is concentrated into maltose syrup with a solid content of 76.0% to 76.5% using a German GEA / MVR evaporator. The operating temperature of the MVR evaporator is 83°C, and the heat exchange area is 900 m². 2 The compression ratio is 2.30, and the evaporation time is 70 minutes.

[0059] The maltose syrup prepared according to the method provided in this embodiment has a DE value of 46, maltose ≥ 55.5, glucose ≤ 3.0, boiling temperature ≥ 145℃, sulfuric acid ash ≤ 0.3, pH value of 4.5~6.0, absorbance ≤ 25AU, conductivity ≤ 10us / cm, and protein content ≤ 0.04%.

[0060] Example 4

[0061] (1) Mixing: Adjust the starch milk concentration to 1130 kg / m³ 3 Adjust the pH to 5.8 and add 0.35 kg of β-amylase per ton of starch milk;

[0062] (2) Liquefaction: After the starch milk slurry has been mixed evenly, it is sprayed and liquefied once at 108℃ and kept at this temperature for 150 min. The solution after the first liquefaction is divided into two parts: clear liquid and turbid liquid. The clear liquid part directly enters the saccharification step, while the turbid liquid part enters the holding column with activated carbon as the filter medium after passing through the reactor. The filtration is carried out at a pressure of 93-96 kPa and a filtration velocity of 30 m / s². 3 Filtration is performed at a rate of / h, followed by secondary jet liquefaction at 125℃. After holding at this temperature for 20 minutes, the solution is introduced into a support column with activated carbon as the filter medium, and then filtered at a pressure of 93–96 kPa and a filtration velocity of 30 m / s. 3 The solution is filtered again at / h, and then proceeds to the saccharification step; the DE value of the liquefied liquid obtained in this step is 15;

[0063] (3) Saccharification: Adjust the pH of the liquefied liquid obtained in step (2) to 5.5, add 0.26 kg of β enzyme per ton of liquefied liquid, and saccharify at 60°C for 28 hours;

[0064] (4) Decolorization: The clear liquid obtained after saccharification enters a plate and frame filter press. The plate and frame decolorization system includes a feed tank, a decolorization buffer tank, and an activated carbon addition device. The filter plates are 1.25*1.25m in size, with an effective filtration area of ​​200m². 2 The working pressure is 7 Bar, the clamping pressure is 2.0 Bar, and the feeding speed is 30 m / s. 3 The decolorization process is carried out at a temperature of 65℃ for 60 minutes. After plate and frame filtration, the transmittance of the sugar solution is 95-100%, and the absorbance is 140-200 AU. The turbid liquid obtained after saccharification enters a rotary drum filter. The drum size of the rotary drum filter is 5135*4000*2785mm, the filter medium is diatomaceous earth, the rotation speed is 4.9r / min, the transition accuracy is 2400*3350mm, the working pressure is 3bar, and the discharge speed is 14m / min. 3 / h, the turbid liquid is filtered by a rotary drum filter and then enters the plate and frame filter press for decolorization. The resulting sugar solution has a transmittance of 95-99% and an absorbance of 140-180AU.

[0065] (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). There are a total of three sets of ion exchange columns, and the velocity is 30m. 3 / h, the temperature is 55℃, the ion exchange column is a cation exchange resin (D001) and anion exchange resin (D301), after ion exchange desalination, the resulting sugar solution has a conductivity of 10us / cm, a pH value of 5.5, a transmittance of 100%, and an absorbance of ≤80AU.

[0066] (6) Refining: The sugar solution obtained in step (5) is further polished by passing it through a refining mixed bed (anion (D202) and cation (D203) filled in proportion) at a speed of 30m. 3 At a temperature of 40℃, after desalting and polishing by a parallel refined mixed bed, the resulting sugar solution has a conductivity of 20µs / cm, a pH of 5.0, a transmittance of 100%, and an absorbance of ≤50AU.

[0067] (7) Deodorization: The sugar solution obtained in step (6) is subjected to activated carbon adsorption at 65°C to remove unpleasant odors from the sugar solution at a rate of 30 m / s. 3 / h, stir in the deodorizing tank for 30min, and after passing through a horizontal disc filter pre-coated with activated carbon, the absorbance is ≤30AU, the transmittance is 100%, there is no odor, and no carbon particles are allowed to be removed by vacuum filtration.

[0068] (8) Evaporation: The sugar solution obtained in step (7) is concentrated into maltose syrup with a solid content of 78.8% using a German GEA / MVR evaporator. The operating temperature of the MVR evaporator is 88℃, and the heat exchange area is 900m². 2The compression ratio is 2.40, and the evaporation time is 90 minutes.

[0069] The maltose syrup prepared according to the method provided in this embodiment has a DE value of 45.3, maltose content ≥55, boiling temperature ≥150℃, sulfuric acid ash content ≤0.3, pH value 4.70, absorbance ≤30AU, conductivity ≤10us / cm, and protein content ≤0.04%.

[0070] Comparative Example 1

[0071] (1) Mixing: Adjust the starch milk concentration to 1130 kg / m³ 3 Adjust the pH value to 5.6-5.8, and add 0.45 kg of β-amylase per ton of starch milk;

[0072] (2) Liquefaction: After the starch milk that has been slurryed is stirred evenly, it is sprayed and liquefied once at 110℃ and kept at the temperature for 150 min to obtain a liquefied liquid with a DE value of 14 to 17.

[0073] (3) Saccharification: Adjust the pH of the liquefied liquid obtained in step (2) to 5.0-5.5, add 0.025 kg of β enzyme per ton of liquefied liquid, and saccharify at 58-60℃ for 28-35 hours;

[0074] (4) Decolorization: The clear liquid obtained after saccharification enters a plate and frame filter press. The plate and frame decolorization system includes a feed tank, a decolorization buffer tank, and an activated carbon addition device. The filter plate size is 1.25*1.25 mm, and the effective filtration area is 200 m². 2 The working pressure is 5–8 Bar, the clamping pressure is 2.0–3.0 Bar, and the feeding speed is 20–25 m / s. 3 The decolorization process is carried out at a temperature of 60–65℃ for 40–70 minutes. After plate and frame filtration, the transmittance of the sugar solution is 90–95%, and the absorbance is 150–240 AU. The turbid liquid obtained after saccharification enters a rotary drum filter. The drum size of the rotary drum filter is 5135*4000*2785mm, the filter medium is diatomaceous earth, the rotation speed is 0.49–4.9 r / min, the transition accuracy is 2400*3350mm, the working pressure is 1.5–3 bar, and the discharge speed is 8–14 m / s. 3 / h, the turbid liquid is filtered by a rotary drum filter and then enters the plate and frame filter press for decolorization. The resulting sugar solution has a transmittance of 88-94% and an absorbance of 160-250AU.

[0075] (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). There are a total of three sets of ion exchange columns, and the velocity is 20-30 m / s. 3The temperature is 50-55℃, and the ion exchange column uses cation exchange resin (D001) and anion 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%.

[0076] (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 20-30 m / s. 3 The sugar solution obtained after desalting and polishing in a parallel refined mixed bed at a temperature of 32-37℃ has a conductivity of 20-50 μS / cm, a pH of 3.6-4.6, a transmittance of 100%, and an absorbance of ≤65 AU.

[0077] (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 20-30 m / s. 3 / h, stir in the deodorizing tank for 20-30 minutes, and after passing through a horizontal disc filter pre-coated with activated carbon, the absorbance is ≤45AU, the transmittance is 100%, there is no odor, and no carbon particles are allowed to be removed by vacuum filtration.

[0078] (8) Evaporation: The sugar solution obtained in step (7) is concentrated into maltose syrup with a solid content of 80.8-81.3% using a German GEA / MVR evaporator. The operating temperature of the MVR evaporator is 83-88℃, and the heat exchange area is 900m². 2 The compression ratio is 2.48–2.51, and the evaporation time is 65–90 min.

[0079] The maltose syrup prepared according to the method provided in this comparative example has a DE value of 55, an iodine value of 0.27, a degree of fermentation of 70, a pH value of 4.9, and an absorbance of 27 AU.

[0080] Comparative Example 2

[0081] (1) Adjust the starch milk concentration to 1120 kg / m³ 3 Adjust the pH value to 5.6-5.8, and add 0.35-0.45 kg of β-amylase per ton of starch milk;

[0082] (2) Liquefaction: After the starch slurry has been mixed evenly, it is subjected to a first-stage spray liquefaction at 106-109℃ and held for 100 min. The solution after the first-stage liquefaction is subjected to a second-stage spray liquefaction at 120-135℃ and held for 40 min. Then it is introduced into a support column with activated carbon as the filter medium and filtered at a pressure of 92-98 kPa and a filtration velocity of 22-27 m / s. 3 The solution is filtered again at / h, and then proceeds to the saccharification step; the DE value of the liquefied liquid obtained in this step is 12-16;

[0083] (3) Saccharification: Adjust the pH of the liquefied liquid obtained in step (2) to 5.0-5.5, add 0.015-0.025 kg of β enzyme per ton of liquefied liquid, and saccharify at 58-60℃ for 25-30 hours;

[0084] (4) Decolorization: The clear liquid obtained after saccharification enters a plate and frame filter press. The plate and frame decolorization system includes a feed tank, a decolorization buffer tank, and an activated carbon addition device. The filter plates are 1.25*1.25M in size, with an effective filtration area of ​​200m². 2 The working pressure is 4–8 Bar, the clamping pressure is 1.0–2.0 Bar, and the feeding speed is 25–30 m / s. 3 The decolorization process is carried out at a temperature of 60–65℃ for 30–60 minutes. After plate and frame filtration, the transmittance of the sugar solution is 95–98%, and the absorbance is 120–180 AU. The turbid liquid obtained after saccharification enters a rotary drum filter. The drum size of the rotary drum filter is 5135*4000*2785mm, the filter medium is diatomaceous earth, the rotation speed is 0.49–4.9 r / min, the transition accuracy is 2400*3350mm, the working pressure is 1.5–3 bar, and the discharge speed is 8–14 m / s. 3 / h, the turbid liquid is filtered by a rotary drum filter and then enters the plate and frame filter press for decolorization. The resulting sugar solution has a transmittance of 93-98% and an absorbance of 120-180AU.

[0085] (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 25-30 m / s. 3 / h, the temperature is 50-55℃, the ion exchange column is a cation exchange resin (D001) and anion exchange resin (D301), after ion exchange desalination, the resulting sugar solution has a conductivity of 10-30 μS / cm, a pH of 4.2-5.5, a transmittance of 100%, and an absorbance of ≤70 AU.

[0086] (6) Refining: The sugar solution obtained in step (5) is further polished by passing it through a refining mixed bed (anion (D202) and cation (D203) filled in proportion) at a speed of 25-35 m / s. 3 The sugar solution obtained after desalting and polishing in a parallel refined mixed bed at a temperature of 32-37℃ has a conductivity of 5-25 μS / cm, a pH of 4.0-5.0, a transmittance of 100%, and an absorbance of ≤50 AU.

[0087] (7) Deodorization: Remove the unpleasant odor from the sugar solution obtained in step (6) using activated carbon adsorption at 60-70℃ at a rate of 25-35 m / s. 3 / h, stir in the deodorizing tank for 20-30 minutes, and after passing through a horizontal disc filter pre-coated with activated carbon, the absorbance is ≤30AU, the transmittance is 100%, there is no odor, and no carbon particles are allowed to be removed by vacuum filtration.

[0088] (8) Evaporation: The sugar solution obtained in step (7) is concentrated into maltose syrup with a solid content of 76.0-76.5% using a German GEA / MVR evaporator. The operating temperature of the MVR evaporator is 83-88℃, and the heat exchange area is 900m². 2 The compression ratio is 2.33 to 2.35, and the evaporation time is 60 to 85 minutes.

[0089] The maltose syrup prepared according to the method provided in this comparative example has a DE value of 49, a boiling temperature of ≥120℃, a sulfuric acid ash content of ≤0.45, a pH value of 4.3~6.0, and an absorbance of 35~65AU.

[0090] Comparative Example 3

[0091] (1) Mixing: Adjust the density of the starch milk to 1130 kg / m³ 3 Adjust the pH value to 5.6-5.8, and add 0.20-0.25 kg of amylase per ton of starch milk;

[0092] (2) Liquefaction: After the starch milk slurry has been mixed evenly, it is sprayed and liquefied once at 106-110℃ and kept at this temperature for 100-120 minutes. The solution after the first liquefaction is divided into two parts: clear liquid and turbid liquid. The clear liquid part directly enters the saccharification step, while the turbid liquid part enters the holding column with activated carbon as the filter medium after passing through the reactor. The filtration is carried out at a pressure of 93-96 kPa and a filtration velocity of 30 m / s. 3 Filtration is performed at a rate of / h, followed by secondary jet liquefaction at 125-135℃. After holding at this temperature for 20 minutes, the solution is introduced into a support column with activated carbon as the filter medium, and then filtered at a pressure of 93-96 kPa and a filtration velocity of 30 m / s. 3 The solution is filtered again at / h, and then proceeds to the saccharification step; the DE value of the liquefied liquid obtained in this step is 8-10;

[0093] (3) Saccharification: Adjust the pH of the liquefied liquid obtained in step (2) to 5.0-5.5, add 0.15-0.20 kg of β enzyme and 0.01-0.015 kg of pullulanase per ton of liquefied liquid, and saccharify for 25-30 hours under the synergistic effect of the two enzymes at 58-60℃.

[0094] (4) Decolorization: The clear liquid obtained after saccharification is decolorized by membrane filtration. The filtration temperature is 58-60℃, the pressure difference is 2.7-4.2 bar, and the liquid flow rate is 20-26 m³ / s. 3 / h, filter membrane pore size is 0.001~0.02μm, filtration capacity is 50m³ / h.3 / h, membrane area 1500m² 2 The resulting turbid liquid after saccharification enters a rotary drum filter. The drum dimensions of the rotary drum filter are 5135*4000*2785mm, the filter medium is diatomaceous earth, the rotation speed is 0.49~4.9r / min, the transition accuracy is 2400*3350mm, the working pressure is 1.5~3bar, and the discharge speed is 8~14m / min. 3 / h, the turbid liquid is filtered by a rotary drum filter and then decolorized by membrane filtration. The sugar solution obtained after decolorization has a transmittance of 96 and an absorbance of 180-270 AU.

[0095] (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 25-35 m / s. 3 / h, the temperature is 50-55℃, the ion exchange column is a cation exchange resin (D001) and anion exchange resin (D301), after ion exchange desalination, the resulting sugar solution has a conductivity of 10-20 μS / cm, a pH of 4.2-5.5, a transmittance of 100%, and an absorbance of 80-100 AU.

[0096] (6) Refining: The sugar solution obtained in step (5) is further polished by passing it through a refining mixed bed (anion (D202) and cation (D203) filled in proportion) at a speed of 25-35 m / s. 3 The sugar solution obtained after desalting and polishing in a parallel refined mixed bed at a temperature of 32-37℃ has a conductivity of 5-25 μS / cm, a pH of 4.0-5.0, a transmittance of 100%, and an absorbance of 55-85 AU.

[0097] (7) Deodorization: Remove the unpleasant odor from the sugar solution obtained in step (6) using activated carbon adsorption at 60-70℃ at a rate of 25-35 m / s. 3 / h, stir in the deodorizing tank for 20-30 minutes, and after passing through a horizontal disc filter pre-coated with activated carbon, the absorbance is ≤30AU, the transmittance is 100%, there is no odor, and no carbon particles are allowed to be removed by vacuum filtration.

[0098] (8) Evaporation: The sugar solution obtained in step (7) is concentrated into maltose syrup with a solid content of 76.0-76.5% using a German GEA / MVR evaporator. The operating temperature of the MVR evaporator is 83-85℃, and the heat exchange area is 900m². 2 The compression ratio is 2.33 to 2.35, and the evaporation time is 60 to 85 minutes.

[0099] The maltose syrup prepared according to the method provided in this comparative example has a DE value of 45.7, maltose ≥ 55.5, glucose ≤ 3.0, boiling temperature ≥ 145℃, sulfuric acid ash ≤ 0.3, pH value of 4.5~6.0, absorbance of 45~60AU, conductivity of 15~35us / cm, and protein content ≤ 0.06%.

[0100] Comparative Example 4

[0101] (1) Mixing: Adjust the starch milk concentration to 1130 kg / m³ 3 Adjust the pH value to 5.6-5.8, and add 0.3-0.35 kg of β-amylase per ton of starch milk;

[0102] (2) Liquefaction: After the starch slurry has been mixed evenly, it is sprayed and liquefied once at 106-108℃ for 120-150 min. The solution after the first liquefaction is divided into two parts: clear liquid and turbid liquid. The turbid liquid part directly enters the saccharification step, while the clear liquid part enters the holding column with activated carbon as the filter medium after passing through the reactor. The filtration is carried out at a pressure of 93-96 kPa and a filtration velocity of 25-30 m / s. 3 Filtration is performed at a rate of / h, followed by secondary jet liquefaction at 120–125℃. After holding at this temperature for 20 minutes, the solution is introduced into a support column with activated carbon as the filter medium, and then filtered at a pressure of 93–96 kPa and a filtration velocity of 25–30 m / s. 3 The solution is filtered again at / h, and then proceeds to the saccharification step; the DE value of the liquefied liquid obtained in this step is 10-15;

[0103] (3) Saccharification: Adjust the pH of the liquefied liquid obtained in step (2) to 5.0-5.5, add 0.16-0.26 kg of β enzyme per ton of liquefied liquid, and saccharify at 58-60℃ for 22-28 hours;

[0104] (4) Decolorization: The clear liquid obtained after saccharification enters a plate and frame filter press. The plate and frame decolorization system includes a feed tank, a decolorization buffer tank, and an activated carbon addition device. The filter plate size is 1.25*1.25 mm, the effective filtration area is 200 m², the working pressure is 4–7 Bar, the compaction pressure is 1.0–2.0 Bar, and the feed speed is 25–30 m / s. 3 The decolorization process is carried out at a temperature of 60–65℃ for 30–60 minutes. After plate and frame filtration, the transmittance of the sugar solution is 95–100%, and the absorbance is 140–200 AU. The turbid liquid obtained after saccharification enters a rotary drum filter. The drum size of the rotary drum filter is 5135*4000*2785mm, the filter medium is diatomaceous earth, the rotation speed is 0.49–4.9 r / min, the transition accuracy is 2400*3350mm, the working pressure is 1.5–3 bar, and the discharge speed is 8–14 m / s. 3 / h, the turbid liquid is filtered by a rotary drum filter and then enters the plate and frame filter press for decolorization. The resulting sugar solution has a transmittance of 95-99% and an absorbance of 140-180AU.

[0105] (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). There are a total of three sets of ion exchange columns, and the velocity is 25-30 m / s. 3 / h, the temperature is 50-55℃, the ion exchange column is a cation exchange resin (D001) and anion exchange resin (D301), after ion exchange desalination, the resulting sugar solution has a conductivity of 10-20 μS / cm, a pH of 4.2-5.5, a transmittance of 100%, and an absorbance of ≤80 AU.

[0106] (6) Refining: The sugar solution obtained in step (5) is further polished by passing it through a refining mixed bed (anion (D202) and cation (D203) filled in proportion) at a speed of 25-30 m / s. 3 The sugar solution obtained after desalting and polishing in a parallel refined mixed bed at a temperature of 32-40℃ has a conductivity of 5-20 μS / cm, a pH of 4.0-5.0, a transmittance of 100%, and an absorbance of ≤50 AU.

[0107] (7) Deodorization: Remove the unpleasant odor from the sugar solution obtained in step (6) using activated carbon adsorption at 65-72℃ at a rate of 25-30 m / s. 3 / h, stir in the deodorizing tank for 20-30 minutes, and after passing through a horizontal disc filter pre-coated with activated carbon, the absorbance is ≤30AU, the transmittance is 100%, there is no odor, and no carbon particles are allowed to be removed by vacuum filtration.

[0108] (8) Evaporation: The sugar solution obtained in step (7) is concentrated into maltose syrup with a solid content of 78.2-78.8% using an evaporator. The evaporator operates at a temperature of 95-99°C and has a heat exchange area of ​​609 m². 2 The compression ratio is 2.50 to 2.62, and the evaporation time is 90 to 120 minutes.

[0109] The maltose syrup prepared according to the method provided in this comparative example has a DE value of 45.5, maltose ≥ 55, boiling temperature ≥ 140℃, sulfuric acid ash ≤ 0.3, pH value of 4.5~6.0, absorbance ≤ 30AU, conductivity ≤ 10us / cm, and protein content ≤ 0.04%.

[0110] In summary, this invention rationally designs a secondary liquefaction spray operation in the maltose syrup production process, maintaining the DE value of the finished maltose syrup within the range of 38-46; simultaneously, the introduction of a plate and frame filter press and a rotary drum filter in the decolorization process improves the decolorization efficiency and results in a higher quality maltose syrup; and the introduction of an MVR falling film evaporator shortens the maltose syrup concentration process and reduces energy consumption.

Claims

1. A method for producing malt syrup, characterized in that, Includes the following steps: (1) Preparation of starch slurry: Adjust the density of starch slurry to 1100-1150 and the pH to 5.6-5.8, and add 0.2-0.35 kg of amylase per ton of starch; (2) Liquefaction: The starch milk after slurry preparation is sprayed liquefied once at 106-110℃ and kept warm for 100-150 min; the turbid liquid after the first spray liquefaction is sprayed liquefied a second time at 120-135℃ and kept warm for 20 min to obtain the liquefied liquid. (3) Saccharification: Adjust the pH of the clear liquid obtained from the first spray liquefaction and the liquefied liquid obtained from the second spray liquefaction to 4.2-5.5, add 0.015-0.26 kg of β enzyme per ton of starch, and saccharify at 58-62℃ for 22-30 h; (4) Decolorization: The turbid liquid obtained in step (3) enters a rotary drum filter. The filter medium of the rotary drum filter is diatomaceous earth, and the rotation speed is 0.49 to 4.9 r / min. After filtration, it enters a plate and frame filter press with activated carbon as the filter medium for decolorization to obtain sugar solution. The clear liquid obtained in step (3) directly enters a plate and frame filter press for decolorization to obtain sugar solution. (5) Purification: All the sugar solutions obtained in step (4) are desalted by passing them through an ion exchange column, then desalted and polished by a parallel purification mixed bed, and then the unpleasant odor in the sugar solutions is removed by activated carbon adsorption. (6) Evaporation: The sugar solution obtained in step (5) is concentrated into malt syrup with a solid content of 76% to 82% by MVR evaporator.

2. The production method according to claim 1, characterized in that, Step (2) further includes filtering the material into a support column before and after the secondary injection liquefaction, using activated carbon as the filter medium, at a pressure of 40–96 kPa and a filtration velocity of 25–30 m / s. 3 / h.

3. The production method according to claim 1, characterized in that, In step (4), the working pressure of the rotary drum filter is 1.5–3 bar, and the discharge speed is 8–14 m / s. 3 / h.

4. The production method according to claim 1, characterized in that, In step (4), the plate and frame filter press operates at a temperature of 55–68°C, a pressure of 4–8 bar, a pressing pressure of 1–2 bar, and an effective filtration area of ​​180–220 m². 2 The material feeding speed is 25-35m / s. 3 / h, decolorization temperature is 55~68℃.

5. The production method according to claim 1, characterized in that, In step (6), the operating temperature of the MVR evaporator is 80–88°C, and the heat exchange area is 850–950 m². 2 The compression ratio is 2.30 to 2.51, and the evaporation time is 50 to 90 minutes.

6. The production method according to claim 1, characterized in that, The saccharification in step (3) also includes adding 0.01-0.015 kg of saccharifying enzyme or 0.01-0.015 kg of pullulanase per ton of starch.

7. The production method according to claim 1, characterized in that, In step (5), there are a total of three groups of ion exchange columns. The distribution of each group of ion exchange columns is cation bed, anion bed, cation bed, anion bed. The exchange medium of the cation bed is D001 resin, and the exchange medium of the anion bed is D301 resin. The internal temperature of the ion exchange column is 50–55°C, and the feed rate is 25–35 m / s. 3 / h.

8. The production method according to claim 1, characterized in that, In step (5), the system temperature for activated carbon adsorption is 60–75°C, and the feed rate is 25–35 m / s. 3 / h.

9. A malt syrup production apparatus, characterized in that, include: A primary spraying device, a secondary spraying device connected to the outlet of the primary spraying device, a saccharification tank connected to the outlets of the primary and secondary spraying devices, a rotary drum filter connected to the outlet of the saccharification tank, a plate and frame decolorizing device connected to the outlets of the saccharification tank and the rotary drum filter, a purification device connected to the outlet of the plate and frame decolorizing device, and an evaporation device connected to the outlet of the purification device. The purification device includes an ion exchange unit, a parallel mixed bed unit, and a deodorization unit.

10. The production apparatus according to claim 9, characterized in that, The evaporation device includes: an MVR evaporation unit.

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