Glucose from Starch

Glucose Production :

There are several methods of producing Glucose syrup from starch:

1. Acid conversion method

2. Enzymatic process
3. Carbon free method

First method is the most economic and traditional process, Enzymatic is the most common one and
Carbon free method is the most advanced one which is economic for high capacity processing line.

Depends on the applicatios, Glucose syrup has verities DE ranging form around 30 to around 95. Higher
DE required for acting as a aweeteners mainly. Glucose syrups can be divided into 4 groups based on the
degree of conversion, Low conversion 20-35 DE, Intermediate Conversion 35-55 DE, High Conversion 55-
70 DE and Very High Conversion 70-98 DE.

Glucose Production Process Description:

Here is a brief description Glucose syrup production based on carbon free method.

1. Slurry preparation
Starch slurry is pumped into the slurry preparation tank. By adding water concentration is
adjusted to about 18-21 degree C, and then pH value isadjusted to about 6.0, finally liquefying
amylase is added.
2. Liquefaction
The aim o the liquefaction process is to convert the starch slurry into liqueur by breaking the
starch molecules with enzyme under determined temperature, pressure and reaction time. The
prepared starch slurry is pump into the feeding tank in which it is pre-heated to about 50 degree
C. Then it is pumped into an ejector for cooking. After ejection its temperature is controlled at
110 degree C for 5-10 minutes, and then it is cooled down to 100 degree C in a very short time
and insulated for about 2 hours. After killing amylase it is cooled down again to 58-60 degree c
in a very short time.
3. Saccharification
In this step, Glucoamylase enzyme or another type of enzyme is used to complete the
breakdown of starch into dextrose. The amylase is added immediately and the slurry is pumped
into Saccharification tank. It takes about 40 hours for Saccharification. When the
Saccharification liquid reaches the required DE value, it is heated to 70 degree immediately.
4. Preliminary and Membrane filtration
Before entering to Membrane System, glucose is filtered from slags created during liquefaction
and saccharification process. Saccharified solution containing several organic compounds (for
example: proteins, fatty substances, not liquefied starch, long chain polysaccharides, fatty acids,
protein and fiber). The traditional method for removing these impurities was using activated
 carbon and diatomaceous earth and filtrating them using filter press and rotary vacuum filter.
But new technology is using Membrane Filtration. This system has a a lot advantages including
the following but not limited to:
a. Better quality of starch sugar
b. Very low weigh in comparison with other systems and can significantlydecease building load
c. Flexibility for layout design at it can be palced wherever even on the floor
d. High efficiency
e. As it works in a closed system, the bacteria growth is very low in cmparison with other
ethods
f. Reduces number of labors for operation
5. Demineralization (Ion Exchanging)
When the liquid is cooled down to below 50 degree C, it is fed to the ion exchange system. Ion
exchangers are cation and anion ion exchanger.
6. Evaporation
The refined liquid form ion exchanging section comes to the evaporator to be concentrated to
the required value. Three main common evaporators are used for glucose concentration to
equired DE, falling film, plate and MVR evaporator; each one has its own advanages and
disadvantages.

The liquefied starch at 8-12 DE is suitable for saccaharification to produce syrups with DE values
of from 45 to 98 or more. The greatest quantities produced are the syrups with DE values of
about 97. At these are produced using exoamylase, glucan 1,4 alpha glucosidase (1,4 alpha D
glucan glucohydrolase, commonly called glucoamylase but also called amyloglucosidase an
gamma amylase), which is releases beta glucose from 1,4 alpha 1,6 alpha and 1,3 alpha linked
glucans. In theory, carefully liquefied starch at 8-12 DE can be hydrolysed completely to produce
a final glucoamylase reaction mixture with DE of 100 but, in practice, this can be achieved only
at comparatively low substrate concentrations. The cost of concentrating the product by
evaporation decrees that a substrate concentration of 30% is used. It follows that he maximum
DE attainable is 96-98 with syrup composition 95-97% glucose, 1-2% maltose and 0,5-2% (w/w)
isomaltose (alpha D glucopyranosyl (1,6) D glucose). This material is used after concentration,
directly for the production of high fructose syrups or for the production of crystalline glucose.

Whereas liquefaction is usually a continuous process, saccharification is most often conducted

as a batch process. The glucoamylase most often used is produced by Aspergillus niger strains.
This has a pH optimum of 4.0-4.5 and operates most effectively at 60 degree C, so liquefied
starch must be cooled and its pH adjusted before addition of the glucoamylase. The cooling
must be rapid, to avoid retrogradation (the formation of intractable insoluble aggregatesof
amylose; the process that gives rises rise to the skin on custard). Any remaining bacterial alpha
amylase will be inactivated when the pH is lowered; however, this may be replaced later by
some acid-stable alpha amylase which is normally present in the glucoamylase preparations.
When conditions are correct the glucoamylase is added, usually at the dosageof 0,65-0,80 litre
enzyme preparation/tonne starch (200 U/kg). Saccharification is normally conducted in vast
stirred tanks, which may take several hours to fill (and empty), so time will be wasted if the
enzyme is added only when the reactors are full. The alternatives are to meter the enzyme at a
fixed ratio or to add the whole dose of enzyme at the commencement of the filling stage. The
latter should give the most economical use of the enzyme.

The saccaharification process takes about 72 h to complete but may, of course, be speeded up
by the use of more enzyme. Continous saccharification is possible and practicable if at least six
tanks are used in series. It is necessary to stop the reaction, by heating to 85 degree C for 5 min
when a maximum DE has been attained. Further incubation will result in a fail in the DE, to
about 90 DE eventually, caused by the formation of isomaltose as accumulated glucose re-
polymerises with the approach of thermodynamic equilibrium.

The saccharified ssyrup is filtered to remove fat and denaturated protein released from the
starch granules and may then be purified by passage through activated charcoal andion-
exchange resins. It should be remembered that the dry substance concentration increases by
about 11% during saccharification, because one molecule of water is taken up for each
glycosidic bond hydrolysed (molecule of glucose produced).