WO2013064046A1 - 一种玉米干法加工工艺及装置 - Google Patents

一种玉米干法加工工艺及装置 Download PDF

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Publication number
WO2013064046A1
WO2013064046A1 PCT/CN2012/083672 CN2012083672W WO2013064046A1 WO 2013064046 A1 WO2013064046 A1 WO 2013064046A1 CN 2012083672 W CN2012083672 W CN 2012083672W WO 2013064046 A1 WO2013064046 A1 WO 2013064046A1
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Prior art keywords
corn
peeling
machine
dry processing
agitating
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PCT/CN2012/083672
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English (en)
French (fr)
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王洪福
王毅
Original Assignee
Wang Hongfu
Wang Yi
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Application filed by Wang Hongfu, Wang Yi filed Critical Wang Hongfu
Priority to US14/355,366 priority Critical patent/US20150030739A1/en
Priority to EP12846749.5A priority patent/EP2774679A4/en
Publication of WO2013064046A1 publication Critical patent/WO2013064046A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
    • B02B—PREPARING GRAIN FOR MILLING; REFINING GRANULAR FRUIT TO COMMERCIAL PRODUCTS BY WORKING THE SURFACE
    • B02B5/00—Grain treatment not otherwise provided for
    • B02B5/02—Combined processes
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
    • A23L7/00—Cereal-derived products; Malt products; Preparation or treatment thereof
    • A23L7/10—Cereal-derived products
    • A23L7/143—Cereal granules or flakes to be cooked and eaten hot, e.g. oatmeal; Reformed rice products
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23V—INDEXING SCHEME RELATING TO FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES AND LACTIC OR PROPIONIC ACID BACTERIA USED IN FOODSTUFFS OR FOOD PREPARATION
    • A23V2002/00—Food compositions, function of food ingredients or processes for food or foodstuffs

Definitions

  • the invention relates to a corn dry processing process using agitating peeling and rolling debarking, which is suitable for the production line of corn mashing and processing corn mash, corn flour, corn germ and corn husk.
  • Corn has two processing methods: dry and wet.
  • the so-called wet processing refers to a method of producing corn starch and starch sugar product by immersing corn in water for several tens of hours. Strict classification
  • all other processing methods including the corn processing method for feed using only one pulverizing processing step are dry processing.
  • the dry processing (including the so-called semi-wet processing with a small amount of wetting water) is now generally referred to as the production of corn mash and corn flour for human consumption, the food industry and the wine industry.
  • corn processed by generalized dry processing may account for more than 80% of the world's total output, and corn processed by narrow dry processing also accounts for more than 20% of the world's total output.
  • dry processing is the main method of corn processing.
  • the existing corn processing process consists of five sections: corn cleaning, water vapor conditioning, peeling, de-embryo and smashing, and selection and extraction.
  • Corn kernels consist of four parts: the endosperm, the germ, the cortex and the root. What humans eat directly is the endosperm granules known as corn mash and corn flour.
  • the main component of the endosperm is starch, which has an average fat content of 0.8%.
  • Corn germs contain an average of 40% fat, 18% protein, and are rich in sugars, minerals and vitamins. Because the germ is mixed into corn mash and corn flour, which affects the taste of the food and is unfavorable to the winemaking industry, the fat content of not more than 1% is an important quality index of corn mash and corn flour.
  • the starch-based endosperm is mixed into the germ, the oil yield is seriously affected, so the purity of the germ is set to be not less than 80%.
  • the main component of the corn cortex and roots is cellulose, which can only be used for low-value feed or industrial raw materials. Finished corn processing includes corn bran, corn flour, corn germ, and corn husk (mixed in corn husks due to similar density). Corn mash and corn flour are the main products of the production line, and corn germ and corn husk are by-products.
  • the existing corn dry processing and peeling section uses a peeling machine similar to the rice milling machine to crush the corn partial skin layer. Because the corn cortex has high strength, poor water absorption performance, and strong binding to the endosperm, and the flat shape of the corn kernels which are approximately trapezoidal, it is difficult to invert in a small space between the roller and the sieve cylinder. Therefore, the prior art peels each skin. When the crushing rate is about 10%, the peeling rate is only about 30%. Corn and corn granules that have not been removed from the cortex are sent to a subsequent process for impact-based equipment, which inevitably produces a large number of granules that are fused together by two or three components of the cortex, germ and endosperm.
  • the object of the present invention is to provide a corn dry processing process and apparatus using agitating peeling and compacting, which is suitable for the production line of corn mashed, corn flour, corn germ and corn husk. .
  • the present invention adopts the following technical solutions:
  • the invention relates to a dry processing method of corn, which mainly comprises a process of cleaning, quenching and tempering, peeling, de-embryo and smashing, and selecting an embryo and lifting a raking process, wherein the peeling process is mainly performed by first mixing, peeling, watering and second The agitation and peeling are composed in turn.
  • the cleaning process can be composed of processes such as magnetic separation, screening and stone removal.
  • the second agitating and stripping may be repeated 1-4 times according to the actual situation of the production line, and the peeled skin layer is removed by air selection or screening after repeated agitation and peeling.
  • the watering process is to add water to the corn by 0.5-5% by weight of the corn, the water temperature is 10-60 ° C (preferably 20-60 ° C), and the corn is sent within 10 min after the water is delivered.
  • the processing is carried out in the agitation and peeling process, and the height of the corn is controlled to be 0.5-3 m during the agitation and peeling process.
  • a mixer can be used to control the stirring rod line speed of the mixer to be 1-6 m/s.
  • the corn can be stirred and peeled again using a blender in the degerming and breaking process.
  • the device for realizing the corn dry processing process comprises a magnetic separator, a vibrating screen, a vertical suction duct, a stone removing machine, a hair corn silo, a water vapor adjusting machine, a corn storage bin, a first agitating and stripping Machine, watering machine, second agitating and stripping machine, suction type air sorting machine, tooth roll mill, cylindrical grading screen and flat screen; wherein one end outlet of the cylindrical sieving screen is connected with the fourth stirring and stripping machine, a stirring and peeling machine is connected to the flat screen; an upper port of the vertical suction duct is connected to the first air net device; an upper port of the suction air sorting machine is connected to the second air net device, the first and the first
  • the second air network device is composed of a fan, a centrifugal dust collector and a wind deflector.
  • the number of the second agitating and peeling machine and the suction type air sorting machine can be increased by 1-4 according to the actual situation of the production line.
  • the de-embryo and smashing process consists of one pass grinding (tooth roll mill), one pass screening (cylinder grading sieve), and one pass agitation peeling (fourth agitating and peeling machine).
  • the seed selection and lifting process can be composed of one screening and one specific gravity sorting process. If necessary, a grinding selection section consisting of at least one grinding process, one screening and one specific gravity sorting process may be added.
  • corn is subjected to quenching and tempering treatment in advance by a conventional method. For example, adding 1 to 5% of room temperature water to the corn and treating it with steam (using a water vapor regulator) can be transferred to the corn storage bin for storage and wetting for 6 to 24 hours. This can ensure that the corn cortex can fully absorb and soften, and the corn germ can be fully absorbed to improve toughness. After the quenching and tempering treatment, the corn is peeled off.
  • the watering process in the process of the present invention may employ a spray watering machine.
  • the purpose of the water is to allow moisture to enter between the corn cortex and the endosperm through the damaged area of the outer skin, so that the corn rind and the endosperm are separated.
  • Water needs to pay attention to water temperature, water addition and water time.
  • the water temperature of the water is controlled between 10 and 60 °C. Generally, the use of normal temperature water can achieve the process effect, and a slight warming can make the water penetrate into the corn epidermis more quickly, which is beneficial to the separation of the outer skin. If the temperature is too high (more than 60 degrees), it may damage and mature the protein in the corn, destroy the quality of the corn, and consume too much coal, which is not worth the loss.
  • the amount of water is controlled within 0.5-5% of the weight of the corn, because the purpose of adding water is to wet the epidermis, too much water does not produce better results, and waste water resources. After the water is taken, it is best to send the corn to the agitation and peeling process for processing within 10 minutes. Because the epidermis will separate in the short time of the water, and the time is long, the endosperm will absorb the water, so that the epidermis will be re-stained on the corn, which is not conducive to peeling. In the watering process, the corn can be sprayed with liquid water, or the corn can be treated with steam.
  • the stirring strength and the peeling effect can be controlled by adjusting the stirring bar line speed of the agitating and peeling machine and the height of the material in the container, so that each agitating and peeling process can basically produce no broken corn.
  • the stirring bar line speed of the agitating and peeling machine and the height of the material in the container, so that each agitating and peeling process can basically produce no broken corn.
  • most of the corn cortex is stripped, so that the overall process effect of the peeling section can reach the goal of stripping more than 70% of the corn cortex.
  • the agitating and stripping process uses a mixer (see patent CN200910157760.2 for details).
  • the mixer also referred to herein as agitating and peeling machine
  • the corn cortex is removed by sharp blade scraping.
  • the principle of agitating and peeling is to keep the material at a certain height, and the lower layer material is subjected to the pressure of the upper layer material to generate a holding force, which generates a relative force with the stirring force of the stirring rod, scraping or grinding the corn epidermis to break it, thereby peeling off the corn rind.
  • frictional effects are also generated between the materials, and a part of the outer skin can also be worn away.
  • the height of the corn material during agitation and peeling is preferably controlled at 0.5-3 meters.
  • the height of the corn material is too low, the holding power is not enough, and the peeling effect cannot be achieved. If the height of the corn is too high, the holding power of the material is too large, the energy consumption of the agitation and peeling is increased, and the corn is broken due to excessive application of force. .
  • the stir bar can be used to scrape the outer skin of the corn in the form of a mosaic blade on the stick, and the corn can also be polished with a polyester rod or a grinding wheel.
  • the mixing time and the stirring speed of the stir bar can be adjusted to obtain a high corn peeling rate and a low corn breaking rate, thereby achieving a better peeling effect.
  • a watering process can be added before the start of the agitation and stripping process, the purpose of which is to increase the toughness of the corn cortex, so that the corn skin can be better scraped during the first agitation and peeling process.
  • the whole or part of the agitation stripping process step can be repeated to increase the stripping ratio and obtain a better process effect.
  • 2 to 4 steps of agitation and stripping are provided.
  • the stirring strength of the agitating and peeling machine can be adjusted to a higher level in each process to ensure that the overall process effect of the agitation and stripping process reaches 70% of the skin layer of the corn kernels. (The cortical scraper on the top of the corn kernel and the pit at the germ can't be touched, the whole grain state is difficult to peel off), and the corn kernel breakage rate should be controlled within 3%.
  • the process of the invention breaks the whole corn by grinding in a deburring and breaking process by a tooth roll mill. Because the thickness of corn germ is only about 1/3 of the thickness of corn, the corn germ contains more fat, is malleable, and is not easy to be broken. The corn germ absorbs water quickly, and the binding force between the endosperm and the cortex is weakened after water swelling, so it is ground with a tooth roller. When grinding the machine, adjust the rolling distance to 2mm It is easy to achieve the purpose of basically not damaging the corn germ when milling the corn kernels.
  • the material after grinding and crushing is filtered out to send the fine sifting material within 1 mm to the cylindrical sieving sieve for sorting and lifting, and the large granules are sent to the third stirring and peeling machine for re-baking and peeling.
  • the purpose of setting the agitation and stripping process here is to scrape off the cortex and small germ granules adhering to the large endosperm and the cortex and small endosperm granules adhering to the large granules by using a scraper blade with a blade stirrer to maximize the pure large endosperm. And the content of germ granules.
  • the first screening process of the embryo selection and lifting process of the present invention is to divide the materials sent from the de-embryo and break-break sections into several grades by using a flat sieve, and the second screening process uses a gravity classifier and a powder-cleaning machine respectively.
  • the size materials separated in the first screening process are further screened and classified according to the difference in density and suspension speed.
  • the heavy material selected by the gravity classifier and the powder clearing machine is the finished corn meal, the light material is the germ, and between the two is a mixture of substandard endosperm, germ and cortex (hereinafter referred to as the mixture) . If the quality of the mixture is poor, it can be used directly for feed.
  • the modern production line generally consists of at least one grinding process and at least one screening process consisting of a grinding selection section. After separating a small amount of pure germ and endosperm, the remaining mixture is used as feed.
  • the process of the present invention peels off more than 70% of the skin layer of corn while keeping the corn kernels substantially intact.
  • the peeled cortex is almost entirely large and easily separated.
  • the unpeeled skin layer is also mostly peeled off from the corn endosperm (meaning that part of it adheres to the endosperm and the other part has peeled off the sheet-like skin layer of the endosperm) and is easily separated in subsequent processes. Stripping at least 70% of the corn cortex and separating them in large pieces means that the technical problems of corn peeling that have plagued the world's corn processing industry for thousands of years have been overcome. On this basis, corn de-emergence has been further solved. Difficult problem, this will become a qualitative leap in the field of corn dry processing.
  • the process of degerming and breaking blast in the process of the invention can make the yield of corn mash and corn flour having a fat content of not more than 1% as high as 60% or more (the prior art is only 30-40%), and the purity The germ yield of about 80% can be increased to more than 10% (the current technology is only about 7%), and the comprehensive economic production efficiency is significantly improved.
  • the water vapor regulating machine is used to moisten the corn, and the dust, dirt and the like adhered to the corn cortex can be removed, so that the sand content of the finished corn product is reduced.
  • the cleanliness and food quality are significantly improved.
  • FIG. 1 is a schematic flow chart of a dry corn processing process according to the present invention.
  • a dry process of corn the main process of which is: magnetic separation ⁇ screening ⁇ going stone ⁇ into corn storage ⁇ tempering ⁇ running corn ⁇ first mixing and peeling ⁇ watering ⁇ second mixing and peeling ⁇ first Road wind selection ⁇ third mixing and peeling ⁇ second air selection ⁇ degerming and breaking ⁇ ⁇ selection of embryos and lifting.
  • a device for realizing the corn dry processing process (as shown in FIG. 1), the device comprising a magnetic separator 1, a vibrating screen 2, a vertical suction duct 3, a stone removing machine 4 (a stone removing machine 4)
  • the first screw conveyor 33 is connected to the wool corn bin 5, the wool corn bin 5 (the wool corn bin 5 is connected to the water vapor regulating machine 6 via the second screw conveyor 34, the second elevator 35), and the water vapor regulating machine 6 (
  • the water vapor regulating machine 6 is connected to the corn storage bin 7 via the third screw conveyor 36, and the corn storage bin 7 (the run corn bin 7 is connected to the first agitating and peeling machine 8 via the fourth screw conveyor 37 and the third elevator 38) , the first agitating and peeling machine 8, the spray watering machine 9, the second agitating and peeling machine 10, the first suction type air sorting machine 11, the third agitating and peeling machine 12, and the second suction type air sorting machine 13 (second suction type)
  • the air sorting machine 13 is connected
  • the first wind net device 40 is used for collecting the light impurities sucked out by the corn cleaning section; the second wind net device 41 is used for collecting the corn cortex, roots, fine endosperm and germ granules produced by the agitation stripping, the embryo selection and the lifting work section. By-products.
  • the corn When the production line is used, the corn is first placed in the lowering pit 31, and sequentially enters the magnetic separator 1 (removing ferromagnetic impurities), the vibrating screen 2 (removing large and small impurities and light impurities), and the vertical suction duct through the first hoist 32.
  • the second hoisting machine 35 enters the water vapor regulating machine 6 to be wetted by water, and then is sent into the corn hopper 7 for about 15 hours, and then enters the first agitating and peeling machine 8 through the fourth screw conveyor 37 and the third hoisting machine 38 first.
  • the corn which has been stripped of more than 70% of the skin layer is crushed by the toothed roller mill 26 under the premise of ensuring that all the corn kernels are broken and substantially does not damage the germ, and the fine sieve is sieved out by the cylindrical sieve 27
  • the sieved large particles of coarse material are sent to the fourth agitating and peeling machine 15 for agitation and peeling again, and the material after being agitated and peeled again is still sent to the flat sieve 14 for sieving and grading.
  • the flat screen 14 divides the material into five kinds of materials: large material, medium material, small material, coarse powder and fine powder (usually used as feed, recorded as SL) according to the particle size requirements of the finished product, wherein the large material is sent to the first
  • the gravity classifier 16 further screens and fractionates to obtain the extremely high purity of the large scorpion (DS), the germ (PY) and the mixture; the medium sputum is sent to the second gravity classifier 17 for further screening and classification to obtain the highly pure scorpion ( ZS), germ (PY) and mix.
  • Both the first gravity classifier 16 and the upper end outlet of the second gravity classifier 17 are connected to the second air mesh device 41.
  • the small mash is sent to the first pulverizer 18 for further screening and classification to obtain very small purity (XS), germ (PY) and mixture.
  • the coarse powder is sent to the second powder removing machine 19 for further screening and classification to obtain a very high purity coarse powder (CF), a germ (PY), and a fine material (SL) which can be used as a feed.
  • the mixture of different large-sized corn mash, middle hoe and small mash coarse powder can be used again by light roller mill 20, 21, 22, and screened by flat sieve 23, 24, 25
  • the second screening is carried out by using a powder cleaning machine; the sifting material of the anterior segment of the sifting machine is corn mash or corn flour, the upper sifting material is the germ, and the rest is a mixture.
  • the mixture selected by the powder cleaning machine is mostly used as feed, and no need to repeat the selection.
  • the regulated gravity classifiers 16, 17 and the powder removing machines 18, 19 can make the selected heavy materials reach the quality standard of corn mash, and can also make the selected germ purity reach or exceed the existing level of 80%.
  • This embodiment can be used to produce a variety of products for large, medium and small corn bran and coarse corn flour. If the production line wants to reduce the variety of corn products, you only need to grind and break the large-grain corn grits.

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Abstract

公开了一种玉米干法加工工艺，主要由清理、调质、脱皮、脱胚与破糁、选胚与提糁工序组成。脱皮工序由第一道搅拌脱皮、着水和第二道搅拌脱皮依次组成。着水时，用着水机（9）向玉米中添加占玉米重量0.5-5%的水，水温为10-60°C，着水后在10min内进行搅拌脱皮工序。搅拌脱皮工序中将玉米高度控制在0.5-3m，采用搅拌机（8，1，12，15），并控制搅拌棒线速度为1-6m/s。该工艺可以提高脂肪含量低于1%的玉米糁、玉米粉及纯度达80%以上胚芽的产出率。

Description

一种玉米干法加工工艺及装置
技术领域
本发明涉及一种采用搅拌脱皮和碾压脱坯的玉米干法加工工艺，它适用于把玉米粉碎加工产出玉米糁、玉米粉、玉米胚芽和玉米皮的生产线。
背景技术
玉米有干湿两种加工方法。所谓湿法加工是指用水把玉米浸渍数十小时以后再粉碎后生产淀粉和淀粉糖产品的方法。严格分类除上述湿法加工者外，包括只有一道粉碎加工工序的饲料用玉米加工方法在内其它所有加工方法都属干法加工范畴。但现在人们通常所述干法加工（包括加少量润湿水的所谓半湿法加工）都是特指生产供人食用、食品工业和酿酒工业等用的玉米糁和玉米粉的加工方法。权威资料记载：广义干法加工的玉米可能占世界总产量80%以上，狭义干法加工的玉米也要占世界总产量20%以上。显然，干法加工是主要的玉米加工方法。
现有的玉米加工工艺流程主要由玉米清理、水汽调质、脱皮、脱胚与破糁和选胚与提糁五个工段组成。玉米籽粒由胚乳、胚芽、皮层和根冒四部分组成。人类直接食用的是被称为玉米糁和玉米粉的胚乳碎粒。胚乳主要成分是淀粉，其脂肪平均含量为0.8%。玉米胚芽平均含脂肪40%，含蛋白质18%，其糖类、矿物质和维生素的含量也很丰富。因胚芽混入玉米糁和玉米粉中影响食用口感并对酿酒等行业不利，所以脂肪含量不大于1%是玉米糁和玉米粉的一个重要的质量指标。又因以淀粉为主的胚乳混入胚芽会严重影响出油率，所以胚芽的纯度被定为不低于80%。玉米皮层和根冒的主要成分是纤维素，它只能做低价值的饲料或工业原料用。玉米加工的成品包括玉米糁、玉米粉、玉米胚芽和玉米皮（因密度相近根冒都混在玉米皮中）。其中玉米糁和玉米粉是生产线的主产品，玉米胚芽和玉米皮是副产品。因玉米糁和玉米粉的质量是由所含玉米胚乳的纯度决定的，而玉米胚芽含大量营养和经济价值都很高的脂肪和蛋白质，深加工的经济和社会效益巨大，所以，把胚乳与皮层和胚芽分离开（以下均简称脱皮和脱胚），并提取最大数量的纯净胚乳和胚芽是玉米加工的关键指标。
现有的玉米干法加工脱皮工段用结构和工作原理都与碾米机类似的脱皮机碾掉玉米部分皮层。因为玉米皮层强度高，吸水性能差，且与胚乳结合牢固，再加上近似梯形的扁平形状的玉米籽粒在碾辊与筛筒之间狭小的空间内翻转困难，所以，现有技术每道脱皮工序在破碎率达10%左右时，脱皮率却只有30%左右。皮层未脱掉的玉米和玉米碎粒被送到后续工序用以撞击为主的设备加工，这样必然产出大量由皮层、胚芽和胚乳中的两种或三种成分混成一体的颗粒。因粘附少量皮层和胚芽的胚乳粒与同等粒度的纯胚乳粒及粘附少量皮层和胚乳的胚芽粒与同等粒度的纯胚芽粒的密度和悬浮速度都相近，很难分离，所以目前中国乃至全世界玉米干法加工业高标准产品成品率都很低（资料记载中国脂肪含量低于1%的玉米糁和玉米粉的平均出率只有30%，发达国家最高也只能达到45%，但玉米籽粒中脂肪含量平均值为0.8的胚乳的平均含量却是83%！）。脱皮工段脱皮率低和脱皮时产出碎粒多是现有技术存在上述弊端的根源。因脱皮脱胚技术不过关，中国和世界上许多国家都把整粒玉米粉碎用作饲料，这样每年浪费的可供人食用的优质食用油和优质植物蛋白质资源达数百万或数千万吨，而这些数百或数千万吨脂肪用作饲料，对饲养业的危害也不容忽视。
发明内容
根据上述情况，本发明目的在于提供一种采用搅拌脱皮和碾压脱坯的玉米干法加工工艺及装置，它适用于把玉米粉碎加工产出玉米糁、玉米粉、玉米胚芽和玉米皮的生产线。
为实现上述目的，本发明采用如下技术方案：
一种玉米干法加工工艺，主要由清理、调质、脱皮、脱胚与破糁及选胚与提糁工序组成，其中，所述脱皮工序主要由第一道搅拌剥皮、着水和第二道搅拌剥皮依次组成。其中清理工序可以由磁选、筛选和去石等工序组成。
具体的，所述第二道搅拌剥皮可根据生产线实际情况重复1－4次，重复搅拌剥皮时每次搅拌剥皮后用风选或筛选除去已剥除的皮层。
进一步的，所述着水工序为用着水机向玉米中添加占玉米重量0.5－5%的水，水温为10－60℃（优选20－60℃），着水后在10min内将玉米送至搅拌剥皮工序进行加工，搅拌剥皮过程中将玉米高度控制在0.5－3m。搅拌剥皮时可采用搅拌机，控制搅拌机的搅拌棒线速度为1－6m/S。
较好的，在脱胚与破糁工序中可以使用搅拌机对玉米再次进行搅拌剥皮。
一种实现所述玉米干法加工工艺的装置，其包括依次连接的磁选器、振动筛、垂直吸风道、去石机、毛玉米仓、水汽调节机、润玉米仓、第一搅拌剥皮机、着水机、第二搅拌剥皮机、吸式风选机、齿辊磨粉机、圆筒分级筛和平筛；其中所述圆筒分级筛的一端出口与第四搅拌剥皮机连接，第四搅拌剥皮机与平筛连接；所述垂直吸风道的上端口与第一风网装置连接；所述吸式风选机的上端口与第二风网装置连接，所述第一和第二风网装置由风机、离心集尘器和闭风器组成。
具体的，所述第二搅拌剥皮机和吸式风选机的数量可根据生产线的实际情况增加1－4台。
所述脱胚与破糁工序由1道研磨（齿辊磨粉机）、1道筛选（圆筒分级筛）和1道搅拌剥皮（第四搅拌剥皮机）工序组成。所述选胚与提糁工序可以由1道筛选和1道比重分选工序组成。必要时可增设由至少1道研磨工序、1道筛选和1道比重分选工序组成研磨精选工段。
本发明工艺中采用常规的方法预先对玉米进行调质处理。如向玉米中添加1～5%的室温水同时用蒸汽进行处理（使用水汽调节机即可实现），处理后转移至润玉米仓存储润湿6～24h。这样既可以保证玉米皮层能够充分吸水软化，又可以使玉米胚芽充分吸水提高韧性。调质处理后再对玉米进行脱皮处理。
本发明工艺中的着水工序可以采用喷雾着水机。着水的目的在于使水分通过外皮破损的地方进入玉米皮层与胚乳之间，使玉米外皮和胚乳分离开。着水需要注意水温、加水量及着水时间等。着水的水温控制在10～60℃之间。一般使用常温水就可以达到工艺效果，略微加温可使水更快的渗入到玉米表皮内，有利于外皮分离。温度若过高（超过60度），可能使玉米内的蛋白质受损、熟化，破坏玉米的品质，而且过多消耗煤电，得不偿失。着水量控制在玉米重量的0.5－5%以内，因为加水的目的在于润湿表皮，过多的加水并不能起到更好的效果，而且浪费水资源。着水后最好在10min内将玉米送至搅拌剥皮工序进行加工。因为表皮会在着水短时间分离，而时间长了，胚乳会吸收水分，使表皮重新沾到玉米上，不利于剥皮。着水工序可用液态水对玉米进行喷洒，也可以用水蒸气对玉米进行处理。
所述脱皮工序的每道搅拌剥皮工序都可通过调节搅拌剥皮机的搅拌棒线速度和容器内料位高度来控制搅拌强度和剥皮效果，保证每道搅拌剥皮工序能在基本不产出碎玉米粒的前提下剥除大部分玉米皮层，使剥皮工段的整体工艺效果达到剥除70%以上玉米皮层的目标。
本发明工艺中搅拌剥皮工序采用搅拌机（详见专利CN200910157760.2）。搅拌机（本文中也可称为搅拌剥皮机）工作时，靠刃口锋利的刮刀刮削去除玉米皮层。搅拌剥皮的原理是：让物料保持一定高度，下层物料承受上层物料的压力从而产生握持力，与搅棒搅拌力产生相对的力，刮或磨玉米表皮，使之破损，从而剥除玉米外皮，搅拌过程中，物料之间也会产生摩擦效应，也能磨掉一部分外皮。搅拌应注意物料的搅拌深度、搅棒的形式和材质、搅拌的时间及搅棒运动速度等参数。搅拌剥皮时玉米物料高度以控制在0.5－3米为宜。玉米物料高度过低，握持力不够，无法达到较好的剥皮效果；玉米高度过高则物料的握持力过大，加大搅拌剥皮的能耗，并且因施力过大使玉米破碎产生副作用。搅棒可使用在棒上镶嵌刀片的形式，将玉米的外皮刮下来，也可用聚酯棒或者砂轮对玉米进行抛光。可依据玉米性质的不同，来调整搅拌时间和搅棒搅速，从而获取高的玉米表皮剥除率和低的玉米破碎率，达到较好的剥皮效果。可在整个搅拌剥皮工序开始前增加一道着水工序，其目的在于增加玉米皮层韧性，从而在第一次搅拌剥皮过程中能更好的刮掉玉米表皮。可重复整个或部分搅拌剥皮工艺步骤，从而提高剥皮比例，获取较好的工艺效果。本发明工艺中设置2～4道搅拌剥皮工序工序。实际操作时，只要基本搅拌不产出碎玉米粒，每道工序都可把搅拌剥皮机的搅拌强度调到较高水平，以保证搅拌剥皮工序的整体工艺效果达到剥除玉米籽粒70%以上皮层（玉米籽粒顶端和胚芽处的凹坑上的皮层刮刀碰不到，整粒状态很难剥掉），同时玉米籽粒破碎率应控制在3%以内的目标。
本发明工艺在脱胚与破糁工序通过齿辊磨粉机研磨来破碎整粒玉米。因玉米胚芽厚度只有玉米整粒厚度的1/3左右，玉米胚芽含脂肪多，有延展性，不易破碎，玉米胚芽吸水迅速、吸水膨胀后与胚乳和皮层的结合力减弱，所以用齿辊磨粉机研磨时，把磨辊轧距调到2mm 左右就能很容易达到在碾碎玉米籽粒时基本不伤及玉米胚芽的目的。研磨破碎后的物料筛选出1mm以内的细料送圆筒分级筛进行选胚与提糁，大颗粒送第三搅拌剥皮机重新进行搅拌剥皮。这里设置搅拌剥皮工序的目的在于用安装刮刀搅棒的刮刀刮掉粘附在大胚乳粒上的皮层和小胚芽粒及粘附在大粒胚芽上的皮层和小胚乳粒，尽量增加纯净的大胚乳和胚芽粒的含量。
本发明选胚与提糁工序的第一道筛选工序是用平筛把脱胚与破糁工段送来的物料按粒度大小分成若干等级，第二道筛选工序采用重力分级机和清粉机分别对第一道筛选工序分离出的大小物料按照密度和悬浮速度的不同进一步筛选分级。重力分级机和清粉机筛选出的重质物料是成品玉米糁，轻质物料是胚芽，而介于两者之间的是未达标的胚乳、胚芽和皮层的混合物（以下均简称混合物料）。混合物料品质较差者可直接做饲料用。现代化生产线一般增设由至少1道研磨工序和至少1道筛选工序组成研磨精选工段，在分离出少量纯净胚芽和胚乳后，剩余混合料做饲料用。
和现有技术相比，本发明工艺的有益效果：
（1）本发明工艺在保持玉米籽粒基本完整的前提下，剥掉玉米70%以上的皮层。剥下的皮层几乎全部呈大片状，很容易分离。未剥掉的皮层也大多从玉米胚乳上剥开（指一部分粘附在胚乳上，另一部分已剥离胚乳的片状皮层），在后续工序很容易被分离。剥下至少70%以上的玉米皮层，并让它们呈大片状被分离出去意味着一举攻克了困扰世界玉米加工业上千年的玉米脱皮难的技术难题，在此基础上进一步解决了玉米脱胚难的问题，这必将成为玉米干法加工领域一次质的飞跃。玉米脱皮脱胚难问题的攻破，使得仅在中国每年就可开发出高达数百万吨的优质食用油和植物蛋白质资源（在全世界范围则可能是数千万吨），显然其经济和社会效益都是异常巨大的。
（2）本发明工艺中采用脱胚与破糁的工序可以使脂肪含量不大于1%的玉米糁和玉米粉的产出率高达60%以上（现有技术仅30－40%），而纯度达80%左右的胚芽出率可以提高到10%以上（现有技术仅为7%左右），综合经济生产效益显著提高。
（3）本发明工艺中搅拌剥皮工段使用水汽调节机在给玉米着水湿润的同时，还能清除粘附在玉米皮层上的粉尘、污物等杂质，使生产线上的玉米成品含砂量降低，洁净度和食用品质明显提高。
附图说明
图1为本发明所述玉米干法加工工艺的流程示意图。
具体实施方式
以下结合优选实施例对本发明的技术方案作进一步地详细介绍，但本发明的保护范围并不局限于此。
实施例1
一种玉米干法加工工艺，其工艺流程主要为：磁选→筛选→去石→入毛玉米仓→调质→润玉米→第一道搅拌剥皮→着水→第二道搅拌剥皮→第一道风选→第三道搅拌剥皮→第二道风选→脱胚与破糁→选胚与提糁。
一种实现所述玉米干法加工工艺的装置（如图1所示），该装置包括依次连接的磁选器1、振动筛2、垂直吸风道3、去石机4（去石机4经第一螺旋输送机33与毛玉米仓5连接）、毛玉米仓5（毛玉米仓5经第二螺旋输送机34、第二提升机35与水汽调节机6连接）、水汽调节机6（水汽调节机6经第三螺旋输送机36与润玉米仓7连接）、润玉米仓7（润玉米仓7经第四螺旋输送机37、第三提升机38与第一搅拌剥皮机8连接）、第一搅拌剥皮机8、喷雾着水机9、第二搅拌剥皮机10、第一吸式风选机11、第三搅拌剥皮机12、第二吸式风选机13（第二吸式风选机13经第四提升机39与齿辊磨粉机26连接）、齿辊磨粉机26、圆筒分级筛27和平筛14；其中所述圆筒分级筛27的一端出口与第四搅拌剥皮机15连接；所述垂直吸风道3的上端口与第一风网装置40连接；所述第一吸式风选机11和第二吸式风选机13的上端口均与第二风网装置41连接，所述风网装置40、41由风机、离心集尘器和闭风器组成。第一风网装置40用于收集玉米清理工段吸出的轻杂质；第二风网装置41用于收集搅拌剥皮、选胚与提糁工工段产出的玉米皮层、根冒、细小胚乳和胚芽粒等副产品。
生产线使用时，先将玉米放入下料坑31中，经第一提升机32依次进入磁选器1（除去铁磁性杂质）、振动筛2（除去大小杂质和轻杂质）、垂直吸风道3（除去轻杂质）、去石机4（除去石子等重杂质）中清理除杂，除杂后经第一螺旋输送机33送入毛玉米仓5中，再通过第二螺旋输送机34、第二提升机35进入水汽调节机6内着水润湿，然后送入润玉米仓7中放置15h左右，接着经第四螺旋输送机37、第三提升机38先进入第一搅拌剥皮机8中进行初步搅拌剥皮（用以让部分玉米皮破损或剥离，利于在下一步的着水工序中水能更好的进入玉米内部），然后用喷雾着水机9进行喷雾着水（着水量约3%，水温35度左右），玉米着水后8min左右依次进入第二搅拌剥皮机10、第一吸式风选机11、第三搅拌剥皮机12和第二吸式风选机13中进行连续两道搅拌剥皮分离工序去除玉米皮层，可以剥除70%以上的玉米皮层（剥除的皮层用风选机11和13清除剥下的玉米皮和其它杂质，然后进入第二风网装置41进行后续的分离处理）。已剥除70%以上皮层的玉米在确保所有玉米籽粒破碎和基本不损伤胚芽的前提下，用齿辊磨粉机26碾碎后，用圆筒分级筛27筛出细料送平筛14中进行筛理，筛出的大颗粒粗料送入第四搅拌剥皮机15中进行再次搅拌剥皮，再次搅拌剥皮后的物料仍然送人平筛14中进行筛理分级。平筛14按成品粒度要求把物料分成大糁料、中糁料、小糁料、粗粉料和细粉料（常用作饲料，记为SL）五种物料，其中大糁料送入第一重力分级机16中进一步筛选分级得到纯度极高的大糁（DS）、胚芽（PY）和混合料；中糁料送入第二重力分级机17中进一步筛选分级得到纯度极高的中糁（ZS）、胚芽（PY）和混合料。第一重力分级机16和第二重力分级机17的上端出口均与第二风网装置41连接。小糁料送入第一清粉机18中进一步筛选分级得到纯度极高的小糁（XS）、胚芽（PY）和混合料。粗粉料送入第二清粉机19中进一步筛选分级得到纯度极高的粗粉（CF）、胚芽（PY）及可用作饲料的细料（SL）。各不同粒度的玉米大糁料、中糁料和小糁料粗粉料分离得到的混合料可以相应再次用光辊磨粉机20、21、22轻研，用平筛23、24、25筛选出胚芽（PY）后，再用清粉机进行二次筛选；清粉机二次筛选出的前段筛下物为玉米糁或玉米粉，上层筛上物为胚芽，其余为混合料。为降低生产成本，清粉机二次筛选出的混合料大多用作饲料，不需再重复精选。调控重力分级机16、17和清粉机18、19可使其筛选出的重质物料达到玉米糁的质量标准，也可使其筛选出的胚芽纯度达到甚至超过80%这一现有水平。该实施例可用于生产大、中、小玉米糁和粗细玉米粉等多种产品的生产线。如果生产线要减少玉米成品的品种，只需将大颗粒玉米糁研磨破碎即可。
采用本发明工艺和装置对玉米进行加工，玉米糁和玉米粉的产出率高，经济效益十分显著。最后所应说明的是：上述实施例仅用于说明而非限制本发明的技术方案，任何对本发明进行的等同替换及不脱离本发明精神和范围的修改或局部替换，其均应涵盖在本发明权利要求保护的范围之内。

Claims (7)

  1. 一种玉米干法加工工艺，主要由清理、调质、脱皮、脱胚与破糁及选胚与提糁工序组成，其特征在于，所述脱皮工序主要由第一道搅拌剥皮、着水和第二道搅拌剥皮依次组成。
  2. 如权利要求1所述的玉米干法加工工艺，其特征在于，所述着水工序为用着水机向玉米中添加占玉米重量0.5－5%的水，水温为10－60℃，着水后在10min内将玉米送至搅拌剥皮工序进行加工，搅拌剥皮过程中将玉米高度控制在0.5－3m。
  3. 如权利要求1或2所述的玉米干法加工工艺，其特征在于，搅拌剥皮时采用搅拌机，控制搅拌机的搅拌棒线速度为1－6m/S。
  4. 如权利要求3所述的玉米干法加工工艺，其特征在于，所述第二道搅拌剥皮为1－4次，重复搅拌剥皮时每次搅拌剥皮后用风选或筛选除去已剥除的皮层。
  5. 如权利要求3所述的玉米干法加工工艺，其特征在于，在脱胚与破糁工序中使用搅拌机对玉米进行搅拌剥皮。
  6. 实现权利要求1所述玉米干法加工工艺的装置，其特征在于，该装置包括依次连接的磁选器、振动筛、垂直吸风道、去石机、毛玉米仓、水汽调节机、润玉米仓、第一搅拌剥皮机、着水机、第二搅拌剥皮机、吸式风选机、齿辊磨粉机、圆筒分级筛和平筛；其中所述圆筒分级筛的一端出口与第四搅拌剥皮机连接，第四搅拌剥皮机与平筛连接；所述垂直吸风道的上端口与第一风网装置连接；所述吸式风选机的上端口与第二风网装置连接，所述第一和第二风网装置均由风机、离心集尘器和闭风器组成。
  7. 如权利要求6所述用于玉米干法加工工艺的装置，其特征在于，所述第二搅拌剥皮机和吸式风选机的数量可根据生产线的实际情况增加1－4台。
PCT/CN2012/083672 2011-10-31 2012-10-29 一种玉米干法加工工艺及装置 WO2013064046A1 (zh)

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