Continuous Martin Process

1 Dough Preparation
The process begins by mixing wheat flour with water in a precise ratio using an industrial mixer. This forms a cohesive dough, which is then transferred to a dough tank. Here, the dough is allowed to rest for a predetermined period, enabling proper hydration and gluten development. After resting, the dough is fed into a rotating watering drum for the next stage.

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2 Dough Washing (Starch Extraction)
Inside the rotary drum, the dough is subjected to a vigorous washing process. High-pressure water streams and mechanical agitation from rotating blades help break down the dough, separating the starch granules from the gluten matrix. This step ensures maximum starch extraction, leaving behind a gluten-rich residue.

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3 Gluten and Starch Separation
The resulting slurry—a mixture of starch, water, and gluten—flows onto a flat screen (vibrating sieve). Here, the gluten agglomerates are retained on the screen, while the starch-water suspension (starch milk) passes through. This effectively separates gluten from starch, directing them into different processing streams.

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4 Gluten Processing (Drying & Milling)
The wet gluten collected on the screen undergoes thorough rinsing to remove residual starch. It is then mechanically dewatered to reduce moisture content before entering a dryer. After drying, the gluten is finely ground into a powder, yielding vital wheat gluten, a high-protein product used in baking and meat alternatives.

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5 A-Starch and B-Starch Separation
The starch milk (from Step 3) is first pumped through a centrifuge conical sieve to remove any remaining fibrous impurities. The purified starch slurry is then fed into a nozzle separator, which fractionates it into two distinct components:

• A-Starch Milk: Contains larger, purer starch granules (prime quality).

• B-Starch Milk: Comprises smaller starch granules and some soluble proteins.

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6 A-Starch Refining
The A-starch milk is concentrated using a cyclone separator to increase starch density. It is then dewatered via centrifugation or filtration and finally dried in a hot-air dryer. The end product is high-quality A-starch, used in food, paper, and textile industries.

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7 B-Starch Refining
The B-starch milk undergoes further purification in a nozzle separator and a decanter centrifuge to remove residual proteins and fine fibers. The concentrated starch is dried in a gas dryer, resulting in B-starch, a secondary-grade product often used in adhesives or as a fermentation feedstock.

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8 Fiber Processing (Byproduct Utilization)
The fibrous material extracted during centrifugation is collected, dewatered, and dried. This nutrient-rich byproduct is repurposed as animal feed, contributing to zero-waste production.

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Tri-Canter Process

1. Flour Conveying and Dough Preparation

• Flour Extraction: Wheat flour is drawn from storage silos using a vibrating extractor, ensuring a steady and controlled feed.

• Precision Dosing: A rotary valve meters the flour into the system, maintaining consistent flow rates.

• Sifting for Purity: The flour passes through a sifter to remove any foreign particles or residual impurities before processing.

• Mixing & Homogenization: The sifted flour is combined with water in a high-shear dough mixer, forming a uniform slurry. This slurry is then pumped into a homogenizer, where mechanical forces further break down particles for optimal starch-gluten separation.

2. Separation of Gluten, A-Starch, B-Starch, and Pentosan

• Tri-Phase Decanter Separation: The homogenized slurry enters a three-phase decanter centrifuge, which separates components based on density differences:

  • Heavy Phase (A-Starch & Fiber): Sent to a rotary screen for further refinement.

  • Middle Phase (Gluten & B-Starch): Directed to a two-stage rotary screen for gluten extraction.

  • Light Phase (Pentosan & Solubles): Collected in a dedicated pentosan storage tank for later use.

• Gluten Recirculation: To maximize yield, the gluten-rich stream is recirculated through the system, ensuring minimal loss and higher purity.

3. Concentrating and Drying of A-Starch

• Primary Separation: The A-starch milk from the centrifugal sieve splits into:

  • Pure A-Starch Milk (for further refining).

  • Wet Fiber (sent to the pentosan tank).

• Refining Process:

  • The A-starch milk undergoes washing and refining in a decanter to remove residual proteins.

  • A second decanter concentrates the starch slurry, increasing solids content.

• Final Processing: The thickened A-starch is dewatered in a peeler centrifuge and then dried in a hot-air dryer, producing high-purity A-starch for food and industrial applications.

4. Refining of B-Starch

• Initial Separation: The A/B-starch mixture from the rotary screen is processed in a decanter, isolating:

  • A-Starch (returned to the A-starch refining line).

  • B-Starch Milk (proceeds to further treatment).

• Fiber Removal: The B-starch milk passes through a centrifugal sieve, separating:

  • Fine Fiber (diverted to byproduct processing).

  • Purified B-Starch Milk.

• Concentration & Drying: The B-starch milk is concentrated in a second decanter and dried in a dedicated B-starch dryer, yielding B-starch, commonly used in adhesives or fermentation.

5. Water Management System

• Fresh & Process Water: The system utilizes both fresh and recycled water for:

  • Slurry dilution, equipment cleaning, and process adjustments.

• Chemical Treatment: pH adjustment and anti-microbial agents are applied as needed to maintain water quality.

• Wastewater Handling: Contaminated water is treated before discharge or reuse.

• Safety Water Tank: An emergency water supply ensures continuous operation in case of interruptions.

6. Gluten Drying Process

• Mechanical Dewatering: Wet gluten from the screens is pressed in a gluten press, reducing moisture content significantly.

• Final Drying: The partially dewatered gluten enters a ring flow dryer, where controlled heat and airflow produce vital wheat gluten with less than 9% moisture—ideal for bakery and meat analogue applications.