Semi-dry Sugar Fermentation Engineering-Lushan Win Tone Engineering Technology Co., Ltd

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Semi-dry Sugar Fermentation Engineering

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Video: Producing Green Glucose Syrup from Low-Fat Corn Flour

Video on the Preparation of Green Glucose Syrup from Low-Fat Corn Flour

Research and Development Background and Significance of the Semi-Dry Sugar Production Method

Background and Significance of the Semi-Dry Sugar Production Process Technology

As is well known, in biological conversion systems, starch sugars—serving as the central carbon-source precursor for microbial metabolism—are not only the material basis driving the fermentation process but also a key source supporting cellular energy metabolism. The efficiency and quality of their supply directly affect the yield, purity, and economic viability of biosynthetic products. However, the traditionally widely used wet milling and sugar-making processes have long been plagued by inherent shortcomings, including low raw-material utilization, excessively high energy and water consumption, lengthy production cycles, and substantial costs associated with byproduct disposal. These limitations have made it increasingly difficult for these processes to meet the demands of modern bio-manufacturing industries for low-carbon and intensive production, thus becoming a bottleneck that hinders the industry’s transition toward greener and more energy-efficient practices. The sugar industry urgently needs to optimize its industrial structure and phase out outdated production capacities.

In 2022, led by Lushan Win Tone Engineering Technology Co., Ltd, and in collaboration with enterprise platforms including Beijing Yangguang Yicai, Shanghai Sidede, Hebei Tianjushi, Shandong Zhongcheng Ziran, and Hubei Meiwei Yuan, along with industry experts, we jointly initiated and developed a semi-dry sugar-making technology. Through the tireless efforts of these platforms, we have successfully built a large-scale pilot production line for low-fat corn flour, a large-scale pilot production line for three-enzyme sugar production, a pilot-scale fermentation production line for glucose syrup, and a physicochemical analysis laboratory. Upholding a spirit of scientific rigor, we have realized our vision of achieving breakthroughs in key links of the industrial chain, thereby promoting green and sustainable development of the industry and creating greater value for human society.

Current Status and Pain Points of Starch-to-Sugar Production via Wet Processing

Current Status and Pain Points of Wet-Milling Starch Sugar Production

High pollution, high energy consumption

The traditional wet-process starch-to-sugar production method consumes large amounts of water resources—2.5 tons of water per ton of corn processed—and generates wastewater containing sulfides with a COD value as high as 5,000–8,000 mg/L. Moreover, the soaking process accounts for more than 20–30% of the total energy consumption in terms of steam usage, severely contributing to water and air pollution.

Equipment investment cost

The soaking process takes 48 to 72 hours and requires a large footprint—soaking tank clusters occupy 15% to 20% of the factory’s total area. The fixed-asset investment in equipment such as wastewater treatment facilities, needle mills, hydrocyclones, centrifuges, and dryers is substantial. In contrast, the capital investment required for the semi-dry process technology equipment is only one-third of that for the conventional wet-process starch-sugar production.

Low conversion rate

In the wet-process starch extraction, the starch recovery rate ranges from 65% to 70%, while the loss of soluble proteins is about 1%. The protein recovery rate is less than 80%, and about 2% of the germ is lost due to breakage. As a result, for every 10,000 tons of corn processed, 120 to 150 tons of unusable waste residues are generated. Moreover, the wet-process starch conversion rate to sugar is only 96%. Both primary and secondary products leave chemical residues, posing risks to food safety.

Production process cost

The production cost of tonne-level starch sugar is high, encompassing energy consumption, treatment of exhaust gases and solid wastes, auxiliary materials and chemicals, environmental protection measures, and equipment maintenance. The cost of producing one tonne of starch sugar can reach as high as 500–700 yuan, whereas the semi-dry process costs only one-third of those incurred by the traditional wet process.

Corn Structure, Semi-Dry Low-Fat Corn Flour Process and Specifications

Corn structure, semi-dry process for low-fat corn flour and its indicators

The tissue structure of corn kernels

The corn kernel consists of five parts: the pericarp, aleurone layer, endosperm, embryo, and root cap.

Chemical Composition of Different Parts of Corn Kernels

Chemical composition of corn kernels (dry matter %):

Whole grain

Starch 72.4, sugar 1.94, protein 9.6, fat 4.7, ash 1.48

Endosperm

Starch 86.4, sugar 0.64, protein 9.4, fat 0.8, ash 0.31

Embryo

Starch: 8.2, Sugar: 10.8, Protein: 18.8, Fat: 45.5, Ash: 0.1

Epidermis

Starch: 7.3, Sugar: 0.34, Protein: 3.7, Fat: 1.0, Ash: 0.84

Root cap

Starch: 5.3, Sugar: 1.61, Protein: 9.1, Fat: 3.8, Ash: 1.64

Innovative Technology for Semi-Dry Extraction of Corn Germ and Bran, and Production of Low-Fat Corn Flour

Section One

Detoxify and reduce the processing stage.

After cleaning and separation, the equipment removes organic impurities from the raw grains as well as various mycotoxins adhering to the surface of the grains, thereby ensuring food safety.

Section Two

Homogeneous De-embryonation Screening Section

Using the double-cone rubbing and embryo-removal screening equipment, corn kernels are rubbed into four-, six-, or eight-lobed segments, ensuring that the germ remains undamaged and its integrity is fully preserved.

Section Three

Optoelectronic Technology – Grading and Embryo Extraction Section

AI-optoelectronic technology equipment is used to effectively separate pure germ and pure endosperm.

Section Four

Tippy Selected Work Section

Equipped with adjustable micro-negative-pressure suspension technology, this system achieves a gentle separation of the skin from the endosperm granules based on their differing densities.

Section Five

Light R&D Powder Section

The graded endosperm is processed through advanced light milling and fine grinding technologies to produce yellow, low-fat corn flour. All physicochemical indicators meet the requirements for application in sugar fermentation processes.

The Role of Special Enzymes in Liquid Saccharification Using the Innovative Three-Enzyme Method

Degradation

The starch and protein cell walls in coarse cornmeal are broken down into small molecules, releasing the bioactive substances contained within the cell walls. This increases the contact area with water, accelerates the extraction rate, and enhances the utilization efficiency of the active ingredients.

Reduce ash content

It can remove insoluble impurities from low-fat corn flour, thereby reducing the ash content.

Reduce the viscosity of the feed liquid

Reduce the viscosity of the feed liquid, increase the filtration rate, improve the clarity of the liquefied liquid, and enhance filtration performance.

A Comparison Between the Innovative Semi-Dry Process for Glucose Production and the Traditional Wet Process

Project	Name	Unit	Dry-process unit	Wet-process unit	Positive and negative values
Ingredients	Commodity corn	t/t	1.503	1.51	-0.007/t (less than one ton of starch) Using 7 kg of corn as raw material
Excipients	Special enzyme	t/t	0.0002	0
	Liquefying enzyme	t/t	0.0002	0.00021
	Glycogenase	t/t	0.0004	0.00039
	98% sulfuric acid	t/t	0.001	0.0008
Energy consumption	Water	t/t	2.5	3.5	-1/t (1 ton of starch used less) ton of water)
	Electricity	kW·h/t	130	230	-100 kWh/t (per ton of starch) Use 100 fewer kilowatt-hours of electricity)
	Steam	t/t	0.55	1.10	-0.55/t (reduce starch usage by 1 ton) 0.55 tons of steam)
Product	Glucose yield	t/t	720	710	+10 kg (crystalline glucose)
Byproduct	Embryo	t/t	0.121	0.102	+0.019/t (per ton produced) The starch yield can be increased by up to 19 kilograms. Embryo)
	Fiber	t/t	0.145	0.145
	Protein powder	t/t	0.102	0.081	+0.021/t (per ton produced) The starch yield can be increased by up to 21 kilograms. Corn protein powder)
	Corn syrup	t/t	None	0.131
Environmental protection	Exhaust gas	t/t	None	Large amounts of acidic waste gas	One ton of glucose saves approximately 357. Yuan
Environmental protection	Wastewater	t/t	None	1.2	One ton of glucose saves approximately 357. Yuan

Revolutionary breakthrough in costs

Using the semi-dry process, each ton of starch sugar produced can save approximately 357 yuan, fundamentally overturning the traditional wet-process model that is characterized by high costs.

Excellent Environmental Performance

The semi-dry process achieves minimal wastewater discharge while reducing sulfide pollution, thereby overcoming the challenges of environmental impact assessments in the industry and realizing green and environmentally friendly practices.

Key to a Leap in Energy Efficiency

The semi-dry process, through the use of specialized enzymes, antibacterial agents, and micronization treatment, significantly improves the conversion rate of grain into sugar, thereby reducing grain consumption and minimizing losses.

Quality Dimension Upgrade

The DE value is greater than 98 and the transmittance is ≥98%, meeting the specifications of various syrups produced by traditional processes.

Potential for industrial chain extension

The semi-dry process simultaneously produces protein powder with a purity of 60%, enhancing the value of byproducts.

Innovative Semi-Dry Process for Converting Low-Fat Corn Flour into Commercial Starch

Process characteristics:

1. The raw grains do not need to be soaked in sulfurous acid, resulting in minimal wastewater discharge and ensuring an environmentally friendly process.
2. Reduce process costs by lowering water consumption, electricity consumption, and steam consumption.
3. Increase the yield of starch and protein.
4. The comprehensive cost can be reduced by approximately 160 yuan per ton of starch.
5. This process is applicable to medical-grade sugar, F55, and F75 fructose-glucose syrup.

Characteristics of Low-Fat Corn Flour Converted into Glucose Syrup

Properties of Syrup Converted from Low-Fat Corn Flour

Low-fat, high-starch characteristics

The low-fat corn flour has a strictly controlled fat content of less than 0.85% and an starch content exceeding 87%, providing an ideal raw material base for syrup conversion and fermentation products while minimizing the impact of lipid oxidation on syrup quality.

Micronutrient retention

The semi-dry process avoids the loss of water-soluble vitamins caused by wet soaking, preserving B vitamins, zinc, magnesium, and other minerals naturally present in corn, thereby enhancing the nutritional value of the syrup.

Protein component optimization

The corn protein extracted via the semi-dry method maintains its intact structure and can generate functional peptide fragments during the saccharification process, enabling the finished syrup to serve dual functions—providing energy and supplementing protein.

The Impact of Innovative Process Technologies on the Sugar Industry

The Impact of Innovative Process Technologies on the Sugar Manufacturing Industry

Industrial Chain Structural Transformation

Raw material substitution effect

In the semi-dry process, low-fat corn flour combined with invert sugar syrup significantly enhances fermentation efficiency compared to traditional fermentation methods. 1. The syrup’s ash content (≤0.3%) reduces co-extraction of impurities; 2. Glucose syrup enables rapid fermentation initiation, shortening the lag phase; 3. Maltose syrup maintains stable metabolism, extending the window for product synthesis.

Process Chain Integration and Innovation

This technology integrates the entire process—from corn germ removal to syrup production—compressing the traditional 12-step sugar-making process down to just 7 steps and reducing overall energy consumption by 40%. The glucose conversion rate has been increased to 99.2%.

Reconstructing Value Distribution

The gross profit margin for traditional fermentation processing typically ranges from 15% to 20%. In the production of bulk commodities, where semi-dry processing is used to convert low-fat corn flour into invert sugar syrup and then incorporate it into fermentation, companies can achieve gross profit margins as high as 25% to 35%. In the pharmaceutical and high-value products sectors, technological barriers support premium pricing, enabling gross profit margins of up to 50% to 75%. As a result, capital is increasingly converging on the field of semi-dry bioconversion technology.

Reconfiguration of the competitive landscape

Breaking through cost barriers

Key process control points for sugar fermentation using low-fat corn flour: 1. Maintain residual sugar levels between 2-5 g/L; 2. Accurately control dissolved oxygen during the mycelial phase at 30-50% to promote biomass accumulation, and during the synthesis phase at 20-30% (to induce metabolism); 3. Avoid potential toxin risks in the early stage.

Technical standard upgrade

The controllable range of the DE value (dextrose equivalent) for green syrup has been expanded to 20–99, meeting diverse food industry needs and breaking the long-term dominance of international brands in the syrup sector.

Economic efficiency and environmental friendliness

Low-fat corn flour produced via a semi-dry process is used in fermentation: The cost of carbon source is reduced by 30% compared to the traditional lactose-based process, and the wastewater is easier to treat with no residual lactose. Antibiotic consumption per unit is reduced by 18%. The syrup undergoes deep purification (ash content ≤ 0.3%), ensuring high extraction purity and enhancing sugar conversion efficiency.

Sustainable Development Potential

Improved resource utilization

The semi-dry low-fat corn flour sugar-making technology yields 720 kg of crystalline glucose, 25 kg of germ oil, and 10 kg of protein powder per ton of corn. This represents a 20% increase in the utilization rate of traditional sugar-making raw materials, and the water treatment system achieves a wastewater reuse rate of 90%.

Significant carbon emission advantages

In the wet-process production method that uses corn starch as a raw material, approximately 0.77 m³ of carbon dioxide is emitted per ton of starch (calculated based on coal as the energy source). In the semi-dry process, which directly uses corn flour to produce starch sugars, each ton of glucose can reduce carbon dioxide emissions by about 0.7 m³.

Downstream scenario extension

Thanks to its low-carbon characteristics, starch sugars produced via the semi-dry process can be used as a “low-carbon raw material” in markets such as infant and young-child foods and functional beverages, aligning with consumers’ demand for “green products” and enhancing the added value of these products.

Driven by market demand

The downstream food and pharmaceutical industries are gradually refining their procurement standards for “low-carbon raw materials” (e.g., the EU’s “carbon border tax” is driving supply chains toward decarbonization). The market penetration rate of semi-dry starch sugars is expected to rise from the current 15% to over 40% by 2030. Once economies of scale are achieved, costs will further decline, setting off a positive cycle of “technology promotion—scale expansion—cost reduction.”

Lushan County Huayu Wantong Engineering Technology Co., Ltd.

E-MAlL:info@wintonemachinery.com

Whatsapp :+86 199 3949 7332

Lushan Win Tone Engineering Technology Co., Ltd

Phone:+86-371-86159555

Whatsapp :+86 199 3949 7332

WeChat:+86-199 3739 2058

info@wintonemachinery.com

Address: East of the intersection of Xinggong Road and Central Road, Northern Area, Lu Shan Industrial Cluster Zone, Pingdingshan City, Henan Province, China

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Semi-dry Sugar Fermentation Engineering

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