Glucose Plants

Know-how and technology licensing.

Vogelbusch Glucose Technology

Glucose, also known as dextrose, is a starch sweetener based on starch plants such as corn, wheat, rice and cassava.

As a liquid intermediate product, glucose syrup serves as feedstock for fermentation processes and it can be further processed to gain sorbitol or fructose. When crystallized, dextrose anhydrate or monohydrate are produced, which are used in foodstuff and in medical applications.

1 blockdia glucose
Process diagram

Starch is processed into glucose a high DE (dextrose equivalent) starch sugar that can be further processed to other types of starch sugar and to biobased chemicals.

Conditioning of starch milk
RAW MATERIAL PREPARATION

The feedstock for glucose production is starch milk at a purity ranging from 98 to 99% of starch in dry substance. 

Starch mixed with process water is buffered in a starch milk vessel to allow homogenization of the starch slurry.

Starch conversion
BIOREACTION

In the liquefaction step, the starch slurry is treated with enzymes and fed to a jet cooker, where the starch is pre-liquefied. This solution is cooled down in an expansion vessel and placed in an intermediate storage tank for final liquefaction.

In the saccharification tanks, further enzymes are added to convert the dextrin into glucose and minor amounts of higher sugars (maltose, isomaltose, maltotriose etc.). By carefully selecting the process parameters, DE values of up to 98 can be reached within 30 – 60 hours of saccharification time.

View on glucose production unit
Purification
PRODUCT ISOLATION AND CONCENTRATION

For the separation of suspended particles such as fibers and proteins Vogelbusch offers a broad range of filtration technologies. State of the art polymer, sintered metal or ceramic cross flow membranes can be employed with the aim to recover the separated solids as a valuable animal fodder. Filter presses, vacuum drum or disk filters still form a cheap alternative and hence are widely used mainly for processing low DE syrups.

Deashing of the filtered solution is done in a pair of strong acidic and weak basic ion exchangers. Color bodies and foreign tastes are reduced to a minimum by activated carbon treatment. This is done either by passing through vessels filled with granular activated carbon or by suspending and subsequent filtering of the activated carbon powder.

To concentrate the solution, a finely tuned system of multiple effect plate type or falling film evaporators is deployed. It is heated by steam and/or powered by mechanical or thermal vapor re-compression, thus ensuring utmost energy efficiency in combination with minimal thermal stress for the product.

The final dry substance content is adjusted to the market demand, or to the subsequent processing steps.

1-grainprocessing
Biotechnological complexes
GRAIN PROCESSING FACILITIES

Glucose is only one of many compounds in the starch sweetener and fermentation business.

Besides starch milk and sweeteners, grain processing facilities additionally can include the production of a whole range of valuable products and by-products such as

  • Dry native starch
  • Dry protein fraction (gluten)
  • Germ fraction
  • Dried and pelletized animal fodder
  • Modified starch and other upgraded starch products
  • Fermentation products

We understand the interaction among substrate, bioconversion, recovery and purification and can assist you in developing your complete grain-processing project, from raw material selection through to the final product range. Contact us for:

  • Pre-engineering and feasibility studies including comparison of different product scenarios
  • Determination of the most suitable technical solutions and equipment for drying, filtration, evaporation, ...
  • System integration of all involved technologies (dry milling, wet milling, starch processing, product drying, ...)

More about Cross Integration Services

1 fructose 7041
Production of biobased chemicals
FURTHER PROCESSING

Besides the production of glucose syrups, dextrose, high fructose syrup and sorbitol, glucose serves as a carbohydrate source for the fermentation of biochemicals such as

  • Amino acids
  • Organic acids
  • Antibiotics
  • Polysaccharides
  • Vitamins
  • Enzymes
  • Bioplastics

We realize biochemical production plants based on our proprietary bioprocess technology, and with licensed technology from third parties.

Average consumption figures

All figures given here are typical and can vary depending on plant configuration and equipment.

Our glucose showcase projects

4 donbiotech
Glucose Plant for Processing Complex in Volgodonsk
DONBIOTECH - Volgodonsk, Rostov Region, Russia

OOO «DonBioTech», a joint venture of Russian Varshavsky group and German industrial group Evonik, sets up a grain processing facility for the production of L-lysine from wheat. VOGELBUSCH has been awarded with the detailed design and the supply of the process plant for the conversion of starch milk to glucose solution...

4-rosva
Biotechnological Complex in Kaluga
BIOTECH ROSVA - Kaluga, Russia

The biotechnological complex put up by JSC «Biotech Rosva» uses wheat as a feedstock to produce speciality goods such as starch, gluten and various starch sugars, which are intended as ingredients for the food industry. A by-product will be used as animal feed. VOGELBUSCH is responsible for the planning and delivery...

4 ishim0
Glucose plant for processing compex in Ishim
AMINOSIB - Ishim, Tyumen Region, Russia

ZAO Agroholding «Yubileinii» sets up a wheat processing complex -  AminoSib - in Ishim in the Tyumen Region. VOGELBUSCH has been assigned by the general contractor, Talmax Engineering s.r.o., with the supply of a glucose plant to produce a fermentation substrate. The order includes the process design as well as the supply of...

Process units

Find out more about the processes used in glucose production:

Enzymatic conversion of starch into sugar.
Hydrolysis
Separating solid-liquid and liquid-liquid media.
Centrifugation
Concentrating products and treating effluents.
Evaporation
Removing of ionic impurities and colors.
Ion exchange
Separating suspended particles.
Filtration
Cleaning and product formulation.
Crystallization
Finishing of products and co-products.
Drying

News

Russia: Project progress at Rosva
12 Dec 2016

Installation works are ongoing in Kaluga.

FAQ

All information given here is typical and can vary depending on plant configuration. For particular information please send us a message with your project details.

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  • What’s the difference between glucose and fructose syrups?

    Glucose syrups are produced in a two stage enzymatic process containing mainly glucose and higher sugars, but virtually no fructose. Fructose syrups are produced by enzymatic conversion of glucose (see HFS).

  • What is the difference between maltose syrups, low and high DE syrups?

     Again, those syrups differ in their share of higher sugars, maltose and glucose:

    • Low DE syrups are ranging from DE 20 - 40 and contain mainly higher sugars
    • In maltose syrups, ranging from DE 45 - 60, maltose has the biggest portion
    • High DE syrups with a DE value of > 96 contain mainly glucose
  • How many different products can be made in a high DE plant?

    Since the composition (sugar profile) of the final product is solely defined by the enzymatic conversion mode, a broad range of products from DE 32 to DE 98 can be achieved by variation of types of enzymes and process parameter. 

  • Which minimum capacity is recommended?

    Owing to rather low profit margins of glucose syrups the minimum economic capacity is rather high, normally starting at 25,000 tpa. However, if the glucose syrup is used as an intermediate for more profitable products, considerably lower capacities may be commercially interesting.

  • Can I combine several feedstocks?

    Glucose plants connected to grain processing facilities are run with one type of feedstock, which is the starch milk available there.

    However, plants can also be designed to run on dry starch and in such case different types of native starch (e.g. wheat, corn, cassaca) can be processed with only minor adjustments of process parameter.

  • Which location is favorable?

    Decisive factors for the location of the glucose plant are the same as for grain processing:

    • Short transport routes for raw material & the final product
    • Availability of energy and water

    The most suitable location is therefore next to a grain processing facility.

     

  • How much space do I need?

    A small glucose plant excluding utilities can be placed in a building of approximately 50m x 36m x 18m (L x W x H). Additionally, space for product storage according to ruling logistics has to be foreseen.

  • And the investment for such plant?

    Capital expenditure always depends on plant capacity and configuration as well as local conditions. Costs for the process plant (excluding building, auxiliaries, infrastructure) are from euro 5 million upwards.

    This figure is for general reference only since each project has its own particularities that need consideration. 

  • How long does it take to set up the plant?

    With permits on hand the engineering, delivery of equipment and construction takes 12 - 18 months depending on capacity and complexity of the plant.

  • How can I get more information for my glucose plant project?

    Complete our design questionnaire (check Links & Downloads section above) and send it back to us to get a professional opinion on your project.