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Upgrade of wheat starch production to 21T/Hr

Upgrade of wheat starch production to 21T/Hr

RB Plant’s client’s, project was to increase the capacity of the Mill & Starch manufacturing facility to 240,000 tons of wheat grind/year with an annual operating capacity of 21t/hr of flour throughput. 

RB Plants initial role was to carry out a preliminary study to encompass:

  • Detailed Process Schematics
  • Process Layout
  • Equipment & Line Capacities
  • Numerical Catalogue of Project Tasks & activities
  • Accurate Project Costs
  • Project timescale & preliminary program
  • Production Plan & Outage schedule

From the above RB plant was then tasked with the construction/installation of the plant & equipment to achieve the required processing improvement as listed in the next section.

RB Plant main challenges were the following:

Flour Mill

  • Install additional Satake Debranning Technology to increase mill capacity to 21t/Hr

Dough Preparation & Separation

  • Install Flour Water mixer to Client’s standard
  • Install Batter residence Loop
  • Install Hydrocyclone separators to the Client’s “Pate Mole” standard

Gluten Drying & Milling

  • Up rate gluten dryer feed system
  • Install additional gluten dewatering equipment
  • Up rate gluten milling system with standard Client’s Freres Mill
  • Up rate existing dryers
  • Install intermediate Starch slurry storage
  • Upgrade Finished Product Storage & out load

Starch Refining Process

  • Install additional fibre removal equipment to Client’s standard
  • Replace current refining hydrocyclone system with Client’s standard
  • Install QX separator equipment on secondary starch (A-) stream

Soluble Process

  • Pipe work to be reviewed
  • De-Bottleneck solubles evaporation stage

Utilities

  • Replace the starch Provox system with Foxboro system
  • Upgrade compressed air system
  • Upgrade electrical distribution system
  • Install additional boiler water treatment capacity
  • Upgrade buildings & roads

All other work identified & defined by Pre-Project study

RB Group’s end result of all the works above was beneficial operation on time and within budget . Allowing for increase production capacity to begin on schedule.

RB Group’s main benefits to the client were through their increased processing capacity & plant throughput increase. Also, by updating their electrical & control systems better process control was achieved & reduced loses through better overall control of the plant