Native & Modified Starch Drying System for 160 TPD Equivalent Maize Plant

  • Region : India

Industry Context

In the agricultural and food processing industry, efficient drying systems are essential for maintaining the quality and shelf-life of starch products. The maize-based starch production process demands high efficiency and energy optimization to remain competitive. This case study highlights our successful implementation of a drying system tailored for a 160 Tons Per Day (TPD) equivalent maize plant, focusing on both native and modified starch production.

Challenges Mitigated

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

  • Energy Efficiency Challenge
Traditional drying systems operate at higher steam pressures, leading to increased energy consumption and higher operational costs. The project required the design of a drying system that could maintain high efficiency using significantly lower steam pressure.
  • Technical Adaptation
Ensuring that the drying process remains effective with reduced steam pressure involved overcoming technical hurdles related to heat transfer and drying rates.

2. Providing Same Efficiency with Lower Inlet Air Temperature

  • Process Optimization Challenge
Achieving the same level of drying efficiency with a lower inlet air temperature was crucial to reduce energy usage and improve overall system sustainability.
  • Product Quality Maintenance
Maintaining the quality and consistency of both native and modified starch products despite the lower drying temperatures required precise engineering and process control.

Key Features of the Solution

1. Convective Flash Drying with In-Built Disintegrator

  • Advanced Drying Technology
The system utilizes convective flash drying, which rapidly removes moisture from the starch, ensuring quick and efficient drying.
  • Integrated Disintegrator
An in-built disintegrator feature eliminates back mixing, ensuring uniform drying and preventing product clumping or inconsistency.

2. Efficient Cyclone System

  • Enhanced Separation Efficiency
The cyclone system effectively separates dry starch particles from the air stream, minimizing product loss and ensuring a clean final product.
  • Energy and Resource Optimization
The cyclone system contributes to lower power and steam consumption by efficiently managing the airflow and particulate matter within the drying system.

Value Delivered

1. Lower Power & Steam Consumption

  • Energy Savings
By operating at a reduced steam pressure of 4.0 kg/cm²(g) compared to the conventional 9.0 kg/cm²(g), the drying system significantly lowers energy consumption, leading to cost savings and improved operational efficiency.
  • Sustainability
The reduced steam and power usage align with sustainable practices, decreasing the environmental footprint of the starch production process.

2. Uniform Product Quality Without Grit

  • Consistent Product Standards
The integrated disintegrator and efficient cyclone system ensure that the dried starch is uniform and free from grit, meeting high-quality standards required by the maize plant.
  • Enhanced Operational Reliability
The reliable and consistent drying process minimizes product defects and enhances overall production reliability.

Conclusion

The implementation of the Native & Modified Starch Drying System for the 160 TPD equivalent maize plant exemplifies our expertise in delivering innovative and energy-efficient solutions tailored to the specific needs of the agricultural and food processing industry. By addressing the challenges of lower steam pressure and maintaining drying efficiency with reduced inlet air temperatures, we have successfully enhanced the operational efficiency and sustainability of the starch production process. This project sets a new benchmark for energy-efficient drying systems in the industry, demonstrating our commitment to quality, innovation, and environmental responsibility.

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  • A/1108, Mahaavir icon, Plot 89, Sector 15, CBD Belapur, Navi Mumbai 400614

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  • Unit 204, I-Thum Tower B. Sector - 62, Gautam Budha Nagar Nodia, UP - 201301, India

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About Us

Industry

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Core Sectors

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Head Office

  • A/1108, Mahaavir icon, Plot 89, Sector 15, CBD Belapur, Navi Mumbai 400614

North Office

  • Unit 204, I-Thum Tower B. Sector - 62, Gautam Budha Nagar Nodia, UP - 201301, India

Need Support

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