The manufacturing process of corn germ oil production line is a complex and refined technology, mainly involving extracting oil from corn germ and obtaining the final product corn oil through a series of processing steps
The extraction process of corn germ can be divided into dry extraction, wet extraction, and semi wet extraction. If oil factories find it troublesome, they can directly cooperate with corn starch factories. Directly collecting corn germ can reduce the operational difficulty of oil factories, but the collected corn germ needs to undergo processes such as cleaning, drying, and softening to achieve a convenient oil production state.
Corn oil can be extracted through pressing or leaching processes, but considering the difficulty of extracting corn germ and the relatively low oil content, leaching processes are often used in industrial production to extract corn germ oil in order to achieve good production results. The extraction process of corn oil involves transporting processed oilseeds to the extraction system to obtain corn germ wool oil.
Raw oil can be processed through processes such as water washing, alkali stripping, acid removal, vacuum dehydration, adsorption decolorization, and vacuum deodorization to obtain healthy and nutritious finished corn oil. It is an indispensable part of mechanical equipment in the extraction and processing of corn oil. With the widespread application of mechanization and automation, mechanical production can replace most manual operations in the oil processing process, reducing the production intensity of workers.
Corn oil extraction plant extracts corn germ from corn and produces corn germ oil by solvent extraction method. The corn oil production line includes corn germ extraction process, corn germ pretreatment and prepressing process, corn germ cake solvent extraction process and crude corn germ oil refining process. Corn oil extraction plant is suitable for large-scale corn oil production. Adopt prepressing extraction technology, this corn oil plant has a large capacity and short extraction time. The crude oil obtained has few impurities, shallow color, and high quality. For small and medium scale production, corn oil processing plant by the pressing method is provided.
The Processing Process of Corn Oil Production Line
Corn Germ Extraction
Dry Method
The dry method extracts corn germ mechanically without moisture adjusting. This method has a simple process, low power consumption and no pollution. It is mainly used for producing corn flour.
Half-wet Method
Half-wet method is suitable for fermentation industry. The cleaned corn is moistened and crushed. Adopt winnowing equipment, the bran is separated. Adopt gravity separator, the endosperm is separated from the mixture of corn germ and endosperm. The mixture enters the roller-crushing mill. The germ is flattened while the endosperm is crushed. Then by using plansifter, the germ and endosperm are separated. The corn germ is dried by pipe bundle drier and then enters the oil pressing workshop in the corn oil plant. High efficiency above 85%, low power consumption, no pollution, low cost.
Wet Method
Wet method is used in starch industry. The cleaned corn is soaked in sulfurous acid solution and then crushed. Adopt hydrocyclone the corn germ is separated. The corn germ has high moisture content and is dried before storage. This method has high efficiency of 85%-95%and high corn germ purity above 70%.
Corn Germ Pretreatment & Prepressing
corn germ→cleaning→softening→flaking→cooking→prepressing→pressed crude corn germ oil
Major Equipment: vibrating screen, magnetic separator, softening equipment, flaking roll, vertical cooker, screw oil press.
Pretreatment process involves screening the corn germs and ensuring that they have minimal impurities, starch, and corn husks before entering the oil production workshop, as these factors can affect the oil extraction rate.
The corn germs are heated in a steam cooker to fully denature and solidify proteins, reduce the viscosity of the oil, and promote further aggregation of oil droplets. This facilitates the flow of oil from the cells and provides favorable conditions for the oil press.
Cleaning
The corn germ extracted contains starch which can affect the oil yield and oil quality. Corn oil processing plant adopts vibration screen to remove the starch and bran in the corn germ to improve the purity. Adopts magnetic separator to remove the metal impurities to protect the equipment.
Softening
The cleaned corn germ enters the softening equipment to adjust the moisture content and temperature to increase the plasticity.
Flaking
The softened corn germ enters the flaking roll in the corn oil processing plant to be made into 0.3-0.4 mm flakes. Flaking is to destroy the cell wall, which is good for oil yielding.
Cooking
The corn germ flakes enter the vertical cooker for the cooking process. Cooking can denature the protein and make it solidify, agglutinate the oil and reduce the viscosity, which is good for oil pressing.
Prepressing
The cooked corn germ flakes enter the screw oil press which integrates adjusting cooker to adjust the moisture content and temperature of the cooked materials. The crude oil is filtered to remove the impurities and then enters the refining workshop. The pre-pressed cake is sent to the solvent extraction workshop for oil extraction.
Cake Solvent Extraction
The solvent extraction process involves further soaking the processed corn germ cake in a solvent, typically hexane, to dissolve the corn oil present in the cake. This is followed by a series of steps, such as mixing oil processing, where the oil is separated from the solvent through evaporation and distillation based on their different boiling points, resulting in crude corn oil.
The crude corn oil obtained after extraction contains some impurities, such as free fatty acids, phospholipids, pigments, and small amounts of protein colloids. These impurities are not suitable for consumption or storage of corn oil. Therefore, further refining processes are carried out to remove these impurities and produce refined corn oil that meets national standards. Refined corn oil can then be sold in the market.
Corn germ cake solvent extraction workshop uses the organic solvent to extract oil from the corn germ cake through soaking or spraying methods. There is only less 1% oil content in the meal after solvent extraction. This section includes corn germ oil extraction, wet meal desolventizing, miscella evaporation and stripping, solvent condensation and vent gas recovery.
Major Equipment
oil extractor, D.T.D.C desolventizer-toaster, evaporator, stripping tower, condenser, mineral oil system.
1.The corn germ cake from the prepressing workshop enters the oil extractor, where the solvent is used to extract oil from the cake. The wet meal discharged from the oil extractor is sent into the desolventizer to remove the solvent. The dried meal obtained is sent to the meal warehouse for packaging. The mixed vapor discharged from the desolventizer enters the shell pass of the first evaporator as the heat source.
2.The miscella from the oil extractor is pumped into the first evaporator, the second evaporator and the disk stripping tower in the corn oil extraction plant to remove the solvent. The crude extracted oil obtained enters the refining workshop.
3.The solvent vapor in the corn oil plant enters the condenser. The condensate enters the water separator. The solvent separated enters the solvent holding tank. The water separated is boiled to recover the solvent.
4.The vent gas in the extraction workshop enters the last condenser. The vent gas from the last condenser enters the mineral oil system in the corn oil extraction plant to recycle the solvent.
Crude Corn Oil Refinery
To obtain refined corn oil, it needs to undergo various processing steps such as degumming, deacidification, decolorization, deodorization, and dewaxing. Degumming or alkali refining is used to remove phospholipids from the corn oil. Alkali refining also helps neutralize free fatty acids and remove color through bleaching. The final steps of the refining process include winterization and steam distillation under high vacuum at temperatures ranging from 232–260 °C for deodorization.
Refining processes involve innovative combinations of different techniques and aim to efficiently coordinate with other parts of the production line. This improves overall refining efficiency, ensures the quality and food safety of corn oil, and extends the storage time of the oil.
Corn oil refinery is to remove the unneeded and hazardous substances such as phospholipids, free fatty acids, wax, pigment and unpleasant smell in the crude corn germ oil to obtain qualified refined oil.
Corn Germ Oil Refining Process
crude corn germ oil→degumming→deacidification→decolorization→dewaxing→deodorization→finished oil
Major Equipment
degumming tank, nentralizing tank, decolorizing tank, crystalizer, deodorization tower, centrifuge, filter, vacuum pump, heat conducting oil furnace.
1.The filtered crude corn germ oil is preheated and mixed with phosphoric acid in the corn oil refinery. The colloids such as phospholipids absorb water and expand to form the emicelle which are precipitated to be removed.
2.The degummed oil enters the alkali refining tank and alkali liquid is added which reacts with free fatty acid to form soapstocks. The soapstocks are precipitated to be removed. Part of the impurities like pigment, phospholipids, protein and mucus are also adsorbed on the soapstocks to be removed.
3.The neutral oil is heated and soft water is added for water washing. Then the oil is centrifuged to remove the wastewater.
4.The water washed oil enters the decolorizing tank and is heated and dried under vacuum. The oil is then fully mixed with bleaching clay.After bleaching, the mixture is filtered to remove the waste clay. The decolorized oil enters the crystalizer in the corn oil processing plant and filter aid is added. Then the oil is cooled rapidly for crystallization. The mixture is filtered to remove the wax.
The dewaxed oil enters the deaerator to remove the air and then enters the deodorization tower for deodorization.The deodorized oil is filtered to obtain the refined corn germ oil.
We also provide the complete sets of automatic filling production line equipment, including automatic bottle blowing machine, automatic filling machine, conveyor belt, stainless steel inspection light box, automatic labeling machine, laser engraving machine, automatic capping machine, and carton sealing machine.
Technology Feature
Corn Germ oil cake solvent extraction process, negative pressure evaporation technology, help to improve energy efficiency and heat recovery, and reduce steam consumption.
Corn Germ oil refining, innovative continuous deacidification and deodorization process, help improve the overall refining efficiency, ensure the quality and food safety of Corn Germ oil, and also prolong the storage time.
Corn oil filling production line utilizes a PLC control system. It offers fast operation speed, stable performance, and flexible configuration options for both manual and unmanned operations.