Emsland Group optimizes starch production processes in Emlichheim

In 2008, the Emsland Group - Germany's largest potato starch manufacturer - decided to optimise the entire production process in their main Emlichheim potato starch production plant.

In the preliminary planning stage, great value was placed on the quality, hygiene and energy consumption of the systems which were to be newly designed.

This implicated the core removal of the wet starch, dismantling outdated machines, complete renovation of piping and electrical wiring as well as the redesign of the control system and the entire pulp dehydration system.

Due to the campaign operation, there were only around 4 months available for the renovation, thus the renovation measures were divided over a 2 year period.

Fine Fibre System:

Business year 2009/10 New construction of the fine fibre system and modification of the control system.

The new construction of the fine fibre system could in the first instance enable an additional yield of around 2000 to/a of starch. By bringing forward the changes to the control system, the staff could be trained in the new conditions in order to ensure a smooth start in the second phase of system reconstruction.

Optimisation of wet starch:

Business year 2010/2011 Core removal of wet starch;reconstruction of extraction facilities;reconstruction of sand separation in the extraction system feed;re-piping throughout all systems and renovation of the pulp dehydration system.

In the course of the reconstruction, all old plumbing was removed. The entire concrete surface on which the machines had stood previously was raised up by approximately 80 cm. The machine processes can now be brought together, freeing up various pumps. As a result of the new plumbing, which has been implemented entirely in stainless steel, it is now possible to reduce system pressure and thus save energy, as well as improving hygiene conditions.

Today, the Emlichheim potato starch plant processes approx. 5,500 - 6,000 tonnes of potatoes per day.  Yield has increased, the qualitative and hygiene conditions in the plant have been improved and approx. 1/3 energy has been saved. By redesigning starch production and pulp dehydration, the Emsland Group was also able to significantly reduce noise emissions.