Gluten Drying System for Starch Plant

Industry Context

In the starch production industry, optimizing drying processes is critical for ensuring product quality and operational efficiency. This case study highlights our successful implementation of a gluten drying system that not only met the efficiency requirements but also significantly reduced energy consumption.

Challenges Mitigated

1. Use of Low-Pressure Steam @ 4.0 kg/cm²(g) vs. Conventional 9.0 kg/cm²(g)

The project required the drying system to operate efficiently using lower pressure steam, which traditionally would result in lower heat transfer efficiency.
Adapting the drying process to maintain efficiency with a reduced inlet air temperature was a significant engineering challenge.

2. Ensuring Uniform Product Quality

The system had to produce a uniform gluten product without grit, despite the changes in operating conditions.
Maintaining product consistency and quality under these modified conditions was essential for the success of the project.

Key Features of the Solution

1. Use of Convective Flash Drying with In-Built Disintegrator

The system utilized convective flash drying, combined with an in-built disintegrator feature, which efficiently processed gluten without back mixing.
This approach ensured that even with lower steam pressure and inlet air temperature, the system maintained high drying efficiency.

2. Efficient Cyclone System

The incorporation of an efficient cyclone system further reduced power and steam consumption, contributing to the overall energy efficiency of the plant.
This innovative approach significantly reduces the carbon footprint and operational costs associated with traditional distillation processes.

Value Delivered

1. Lower Power & Steam Consumption

The project resulted in significant reductions in both power and steam consumption, leading to lower operational costs.
By using lower pressure steam and achieving efficient drying, the system minimized energy usage and environmental impact.

2. Uniform Product Quality

The drying system provided a uniform gluten product without grit, meeting the high-quality standards required by the starch plant.
The system’s design and implementation enhanced the overall operational efficiency of the starch plant, ensuring consistent production outputs.

Conclusion

This project showcases our ability to innovate and adapt to challenging conditions in the starch industry. By implementing a gluten drying system that operates efficiently under reduced steam pressure and delivers consistent product quality, we have set a new standard for energy-efficient drying processes in the industry.