Malt extract plant from Barley
Raw barley is cleaned & soaked in water and then put to humidified condition to germinate which is further dried & milled. This acts as a good source of diastase enzyme. This milled barley (using roller mill) is passed through mashing process mashing & liquid so extracted is called wort (14-18% T.S).This is filtered using press filter & concentrated to 83% or as the requirement may be. Other ingredients including milk powder are added to make solid to 83% which is directly tray dried. However if milk is to be used then malt extract and other ingredients say sugar, chocolate powder minerals, vitamins are added to give 28-30 % T.S. which is concentrated to 55 % solid using four or five effect falling film evaporator and finally it is concentrated to 83-85 % solid. It is then led to tray or vacuum band dryer. Once material is dried it is taken to scrapping machine for tray dryer and cooled before final granulation or milling and is then packed in dehumidified condition.
Step by Step process:
- Dry Blending Section
- Mashing and Mixing of Ingredients
- 1st stage- Evaporating Plant for 55% concentration
- 2nd stage –Scrapped Surface evaporating plant for 83 % concentration
- Dosing section
- Drying (Either vacuum band dryer OR Vacuum tray dryer)
- Packing Section
Glucose and Maltodextrine plant from Brocken Rice
Broken Rice is pulverized to the required specification and the slurry is made of 25 – 30 (D.S). Alternatively bought out Starch can also be used for making slurry. This process is based on broken or full rice only. PH of slurry is adjusted to 6.5 – 6.8 and the required doses of enzyme is given in the slurry feed tank. Enzyme treated slurry is fed to the thermal hydro-heater where starch is broken to thinning stage. Thereafter it is passed through retention & Dextrine nozzle column to get the malto-Dextrine of required DE (Dextrose Content). For liquid glucose the Malto dextrine slurry is further treated with another enzyme to convert dextrine to height degree of glucose i.e. 42-43 DE. Further process is of separation of protein by filtration and refining with carbon treatment. Liquid Glucose is given De-ashing treatment by using Ion-Exchange refined syrup of 25-30% is evaporated in calandria type/Batch Evaporator to concentrate Malto Dextrine/Liquid Glucose syrup to the solid content of 45%, 75% & 86% depending on end use of maltodextrine & liquid Glucose.
For manufacturing Malto Dextrine powder M.D concentrate of 45% is fed to the Spray Dryer to get product of 3-3.5% moisture.