STARCH PROCESSING AND PREPARATION EQUIPMENT
Innovative Starch Processing
Many paper mills welcome the opportunity to turn over the entire process of handling starch into the hands of a professional partner and to focus entirely on the process of paper production.
This was evident to Pratt Industries from the United States. After experiencing a BVG enzymatic starch conversion system in a new green-field project, Pratt Industries upgraded all other North American paper manufacturing sites by the Super ECC Technology
FASCINATING TECHNOLOGY – ALSO PROVEN BY OUR CUSTOMERS
In 2007, Lee & Man bought four BVG „Super-ECC“ (native starch „Enzyme Continuous Conversion“) systems for their Guangdong, China paper mill (PM 8, 9, 10 and 11). They were so impressed by this equipment that they ordered three more systems (PM 4, 12, and 13) even before the first of the original four Super-ECCs was fully com-missioned.
Today, Lee & Man has 15 BVG Super-ECC machines in production. Additionally, they employ a BVG „Super-Cat“ system which enables them to cationize 20,000 tons per year of native starch using a dry process right in the paper mill. By using native starch for both wet and dry end, Lee & Man realize significant production savings.
„Compared to the existing plant from 1997 the Super-ECC plant allows a higher variance in several process parameters. It is possible to produce a degraded starch exactly for our needs. It was pos-sible to achieve the same strength properties with a lower starch consistency. The specific starch demand and the costs could be reduced significantly.“
Papierfabrik Palm GmbH & Co. KG
Super-ECC® Technology
The BVG Super-ECC system is a continuous enzymatic modification cooker for native (pearl) starch. ECC stands for E= Enzyme C= Continuous C= Conversion. The Super-ECC can modify any com-mercially available native starch (corn, wheat, potato, tapioca) to a precisely optimized final viscosity independently of temperature and solids, something impossible to do with pre-modified starch. These systems are primarily used to produce size press, film press, and coating color starch.BVG Super-ECC system provides optimized molecular weight distribution through the use of our patented high turbulence reactor, producing paper quality that meets or exceeds even modified starch (ethylated/oxidized). Super-ECC systems are fully automated and do not require any addi-tional manpower requirements over conventional cooker. Using modern secure communications technology, BVG can provide remote monitoring and troubleshooting as required. This innovation, and most importantly performance, is greatly appreciated by our customers.
Technological Advantages:
- Works with all modified starches
- Continuous system (minimal waste)
- Jet Cooking principal (optimal, efficient cooking)
- Pressure cooking at up to 130° C
- Completely dissolved starch
- Automatic regulation of starch concentration
Super-Jet Technology
BVG’s Super-Jet serves the purpose of continuous cooking of modified starch and starch derivatives. Modified starch is continuously made-down to slurry and then cooked. The Super-Jet includes post dilution to deliver cooked starch at the proper solids to your storage or run tanks. So far, more than 500 BVG Super-Jets have been sold worldwide.Technical Advantages:
- Compact design
- High production performance
- Fully automated
- Clearly laid-out mode of operation
- Highly modern DCS System
- Remote service via secure modem or internet
Super-Cat Technology
Our BVG Super-Cat system provides in situ production of cationized starch from native starch. BVG Super-Cat can employ dry (Super-D-Cat) cationization or wet cationization (Super-W-Cat). Both technologies were developed in-house by BVG. The Super-CAT system provides remarkable savings over commercially produced cationized starch and is particularly attractive to large mills that consume high volumes of wet end starch.Beyond costs savings, the Super-CAT system provides the customer with the ability to optimize the starch by adjusting the degree of substitution in the cationized starch. Here, as with all of our products, BVG’s goal is to reduce costs while improving product quality for our customers. As it does for our Super-ECC, using native starch moves the purchasing domain from specialty product to commodity, dramatically increasing opportunities for cost savings and broadening the supplier pool.
Super-Shear and Super-C-Shear
When it comes to the production of coating colors, there are two primary processes. BVG Super-Shear is a conventional batch system in which coating color is produced discontinuously. The different components of coating color are measured by weight or through flow measurement and mixed according to a batch recipe.BVG Super-C-Shear is a continuous make down system. Metered addition and mixing of singular coating color components is done continuously. In 2010, the largest coating kitchen in the world went into production at JHPP in Hainan, China. BVG provided the turnkey engineering, manufacturing, DCS, installation, and commissioning of this system. This paper machine outperforms all benchmarks yet set in the paper industry. 6000 t/d of high value coated papers are produced on one machine. Per sheet, starch and 4 pigment coatings are used, adding up to 10 layers in total. So far, this has been the largest order in BVG’s history. The coating kitchen’s current capacity is 3000 t/d of coating color, however the mill could produce significantly more using the same equipment.
In comparison to the originally proposed batch process, this BVG continuous coating kitchen offers manifold advantages which are crucial in a technical, technological and economic manner, such as:
- Constant solids and viscosity of coating color
- Solids concentrations as high as 72%
- Highly energy efficient extraction of coating color (approximately 90% reduction in power usage over similar batch coating kitchens)
- Gentle mixing of single components leads to reduced demand in shear-sensitive ingredients (binders)
- High flexibility of the equipment that can be reconfigured to expand capacity
- Minimum Space demand
In packaging paper, the continuous coating kitchen BVG Super-C-Shear mixer also offers many advantages. When changing from uncoated grades such as testliners or corrugated material to coated materials, such as CWT-Liner, high flexibility is needed in order to keep loss of coating color as low as possible and to reduce energy costs. The BVG C-Super-Shear offers the highest possible reduction potential in this field.
Technical Advantages:
- High solid processing
- Regaining of rinsing water and coating color effluent
- No rinsing water necessary
- Maximum shear rate up to 30 m/s
- Forced mixing via inline aggregation
- Highest flexibility
- Minimum space demand (smaller footprint of continuous system)
- High production performance
- Online measurement of slurry concentration
- Fully automated operation mode
- Minimal maintenance effort
- Remote service
Dispergator CHS
In today‘s changing paper making environment the trend of pigments is also moving to continuous dispersing and grinding. China is a leading consumer of these on-site technologies. With BVG‘s Dispergator CHS technology, pigments can be dispersed fully automatically, continuously, and very energy efficiently. Reference projects of BVG are in the area of 50-20.000 kg/h extraction capacity of the following products:
- Aluminium hydroxide
- Barium sulfate
- Bentonite
- Chalk
- Clay
- Earth colors
- Fly ash
- Kaolin
- Pigments with fibers or blends
- Silicic acid
- Special polysaccharides
- Talcum
- Titanium dioxide
- and many others
Chemical preparation plants
BVG provides equipment to process and disburse a large variety of products, including but not limited to the following:
- Acids and bases
- Adhesives
- Aluminium sulfite
- ASA /AKD glue
- Binders
- Biocide
- Blackening
- Bleaching agents
- Carboxymethylcellulose
- Chemical additives
- Coagulant
- Coating additives
- Coating pigments
- Coatings
- Coloring pigments
- Enzymes
- Fatty acid
- Felt cleaning agent
- Fixing agents
- Flour
- Glues
- Guar
- Hydro sulfite
- Hydrogen peroxide
- Inhibitors
- Minerals
- Optical bleach
- Polyelectrolytes
- Polysaccharides
- Polyacrylamides
- Polyvinylalcohole
- Process water
- Salt
- Sizing agent
- Soap
- Sodium silicate
- Surfactants
- Synthetics
BVG Super Glue
Starch is a crucial component for adhesives in the paper corrugating and converting industry. A challenging field with large starch volume requirements is the production of corrugated paper.
To serve this customer need, BVG developed the Super-Glue process, which makes it possible to produce corrugated paper glue with very precise solids and final viscosities. The viscosity of the glue is produced, measured and fine-tuned during the production by an online viscometer at ad-dition of alkali.
Advantages of the Super Glue technology:
- Automatic regulation of carrier viscosity
- Automatic regulation of final viscosity
- Reproducable quality of the glue
- Amount of glue is freely determinable
- Suitable for native maize, wheat, potato and tapioca starch
- Better apanage through less insertion of moist
- Mix of different recipes possible
- References of corrugated paper machines with v = 400m/min
- Fully-automated operation mode
- Easy to use
- Remote service
- Recipe manager
- Qualified plant construction
- Use of native starch
- Minimal use of glue