Sorbitol Production Process
Biochem
Turnkey
Sorbitol
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Blending: The production process begins by adjusting the concentration of dextrose syrup to approximately 45-50% using Reverse Osmosis (R.O) water. Once the desired concentration is achieved, an alkaline solution is added to regulate and stabilize the pH value within the required range. Following pH adjustment, a specific catalyst is introduced into the mixture to facilitate the upcoming hydrogenation reaction.
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Hydrogenation: The pretreated dextrose syrup is then pumped into a high-pressure hydrogenation reactor. Under controlled conditions — involving suitable temperature, pressure, and continuous feeding of hydrogen gas — the dextrose molecules undergo a catalytic hydrogenation reaction. During this stage, dextrose is converted into sorbitol over a predetermined reaction time.
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Sedimentation: After the hydrogenation reaction is complete, the crude sorbitol solution — which contains suspended catalyst particles — is transferred to a settling tank. Here, the catalyst is allowed to settle and separate from the sorbitol solution, enabling recovery and potential reuse of the catalyst material.
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Filtration: The partially purified sorbitol solution is then subjected to a filtration process. This step removes any residual catalyst particles or impurities that remain suspended in the solution after sedimentation.
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Decolorization: To improve the appearance and purity of the product, the sorbitol solution undergoes a decolorization process using activated carbon. This step effectively removes colored substances and organic impurities.
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Ion Exchange: The decolorized sorbitol solution is passed through ion exchange resins. This treatment eliminates dissolved salts, metallic ions, and residual organic compounds, significantly enhancing the chemical purity and quality of the final product.
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Evaporation: Finally, the purified sorbitol solution is concentrated by evaporating excess water. This evaporation process increases the sorbitol content to the desired concentration level, making it suitable for packaging, storage, or further processing according to product specifications.
Description of Investment Components:
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Machinery:
The machinery investment includes the essential equipment required for sorbitol production, such as starch slurry preparation systems, enzymatic hydrolysis reactors, vacuum evaporators, crystallizers, dryers, filtration systems, blending units, CIP (Cleaning-In-Place) systems, and all related process lines and automation systems. These machines ensure efficient conversion of starch or glucose into sorbitol and the subsequent drying, refining, and packaging of the final product. -
Land & Construction:
The land and construction costs cover industrial-zoned land and all necessary physical infrastructure, including production buildings, administrative offices, raw material and finished product storage areas, laboratory units, social facilities, and landscaping areas. These facilities are designed to support the full operation of the sorbitol production plant, ensuring that the production process from raw material intake to final product storage and distribution is seamless and efficient. -
Total Investment:
The total investment estimate includes all essential components such as detailed process engineering, mechanical and electrical installation, infrastructure setup, environmental protection units (e.g., wastewater treatment), product handling systems, licensing, and utility connections (electricity, water, gas). These components are vital for establishing a continuous, large-scale sorbitol production facility that can operate efficiently and in compliance with industry standards. -
Auxiliary Equipment:
Auxiliary systems such as steam boilers, cooling towers, air compressors, water purification systems (e.g., reverse osmosis), control panels, backup power generators, and utility monitoring systems are not included in the machinery prices listed above. These systems must be quoted separately based on the specific capacity and operational needs of the facility. -
Project Design:
Project planning, feasibility studies, and factory layout design services are provided independently and are not part of the above investment figures. These services can be customized according to local regulations, raw material availability, and market targets. They are essential for ensuring that the facility is designed for optimal efficiency, regulatory compliance, and cost-effectiveness. -
Technical Service & Consulting:
Turnkey installation is included within the investment scope. After commissioning, remote monitoring, process optimization, and technical support services will be provided free of charge for a period of 700 days following plant handover. This ensures that the plant operates at peak efficiency and that any technical issues are promptly addressed to maintain continuous operations.
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