1. Process Objective
Extract, purify, and dry soluble polysaccharide gum (flaxseed mucilage) from whole or crushed flaxseed to produce a food-grade gum powder with viscosity ≥ 800 cP (1 % solution, 25 °C). The line operates at a throughput of 200 kg/hr dried gum powder. This station is designated CCP-3 (Critical Control Point — Residual Solvent & Allergen Control).
2. Equipment Configuration & Flow Diagram
Flaxseed (whole or light-crushed)
│
▼
[ Extraction Tank (Jacketed, 2000 L) ] ← Hot water (80–90 °C, pH 6–7)
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[ Decanter Centrifuge ] ───→ Wet solids (spent seed, to drying/meal)
│
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[ Vacuum Concentrator ] ───→ Concentrated gum liquor (5–8 % solids)
│
▼
[ Precipitation Tank ] ← Ethanol (96 % v/v, 2:1 vol ratio)
│
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[ Basket Centrifuge ] ───→ Spent ethanol (to recovery)
│
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Wet gum cake (≈ 60 % moisture)
│
▼
[ Spray Dryer ] ───→ Dried gum powder (≤ 6 % moisture)
│ │
▼ ▼
[ Ethanol Recovery Column ] [ Sifter / Pack-off ]
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Recovered ethanol (≥ 90 % v/v, recycled to precipitation)
3. Equipment Specifications
| Parameter |
Value |
| Type |
Jacketed, agitated, atmospheric |
| Working volume |
2 000 L |
| Material |
SS316 (all wetted parts) |
| Jacket |
Half-coil, rated 4 bar(g) steam |
| Agitator |
Dual impeller (hydrofoil + Rushton) |
| Agitator speed |
50 – 200 rpm (VFD) |
| Motor |
7.5 kW, IE3, TEFC |
| Temp. range |
Ambient – 100 °C (target 85 °C) |
| pH range |
3 – 8 (target pH 6.0 – 6.5) |
| Batch cycle |
45 – 60 min extraction |
| Water-to-seed ratio |
10:1 – 15:1 (w/w) |
| Inspection |
2 × 150 mm manway, sight glass |
| CIP |
Fixed spray ball (SS316) |
3.2 Decanter Centrifuge
| Parameter |
Value |
| Type |
Horizontal solid-bowl decanter |
| Bowl diameter |
350 mm |
| Bowl length / diameter |
3.5 : 1 |
| Max G-force |
3 500 × g |
| Differential speed |
5 – 20 rpm (VFD on scroll) |
| Capacity (slurry) |
3 000 L/hr |
| Solids capture |
≥ 95 % of suspended solids |
| Material |
SS316 bowl, SS316L scroll |
| Motor (bowl) |
15 kW |
| Motor (scroll) |
5.5 kW |
| Discharge |
Solids: gravity chute; Liquid: gravity overflow |
3.3 Vacuum Concentrator
| Parameter |
Value |
| Type |
Forced-circulation evaporator |
| Evaporation rate |
500 kg/hr (water removal) |
| Vacuum level |
−0.80 to −0.92 bar(g) |
| Temp. (product) |
≤ 65 °C (protect gum viscosity) |
| Heating surface |
15 m² (SS316 plate heat exchanger) |
| Vapour separator |
Cyclone + mesh pad (SS316) |
| Motor (circulation) |
7.5 kW |
| Material |
SS316 (all wetted surfaces) |
| Feed solids in |
0.8 – 1.5 % |
| Concentrate solids out |
5 – 8 % (20× concentration) |
| Condenser |
Shell-and-tube, SS316, 25 m² |
| Cooling water |
15 m³/hr @ 25 °C |
3.4 Precipitation Tank
| Parameter |
Value |
| Type |
Flat-bottom, agitated |
| Working volume |
3 000 L |
| Material |
SS316 |
| Agitator |
Paddle (low shear) |
| Speed |
30 – 60 rpm |
| Motor |
3 kW |
| Ethanol feed |
Sub-surface dip pipe |
| Ratio control |
In-line flowmeter + batch PLC |
3.5 Basket Centrifuge
| Parameter |
Value |
| Type |
Vertical peeler / basket |
| Basket diameter |
800 mm |
| Basket volume |
100 L |
| Max G-force |
1 200 × g |
| Filter media |
Polypropylene cloth (20–50 µm) |
| Cycle time |
15 – 25 min (fill → spin → peel) |
| Capacity (wet cake) |
100 kg/batch |
| Material |
SS316 basket, SS304 housing |
| Motor |
11 kW (VFD soft-start) |
| Explosion-proof |
Ex d IIB T4 (ethanol atmosphere) |
3.6 Spray Dryer
| Parameter |
Value |
| Type |
Co-current, centrifugal atomiser |
| Evaporation rate |
200 kg/hr (water) |
| Inlet air temperature |
180 °C (max 200 °C) |
| Outlet air temperature |
80 °C (range 75–85 °C) |
| Atomiser wheel |
Disk type, 15 000 – 25 000 rpm |
| Atomiser motor |
5.5 kW, VFD |
| Drying chamber |
SS316, Ø 2 200 mm, cylindrical |
| Cyclone |
SS316, ≥ 98 % collection |
| Bag filter |
SS316 housing, PTFE membrane bags |
| Product outlet |
Powder at ≤ 60 °C |
| Final moisture |
≤ 6 % (target 4–5 %) |
| Throughput (powder) |
≈ 200 kg/hr |
| CIP |
Fixed spray ball in chamber |
| Ex-proof |
Outlet rated for combustible dust (ATEX Zone 22) |
3.7 Sifter / Classifier
| Parameter |
Value |
| Type |
Gyratory / tumbler screen |
| Mesh |
250 µm (60 mesh) |
| Capacity |
250 kg/hr |
| Material |
SS316 contact |
3.8 Ethanol Recovery Column
| Parameter |
Value |
| Type |
Packed column (Raschig rings / Pall rings) |
| Column diameter |
DN 300 |
| Packed height |
4 000 mm |
| Distillate rate |
50 L/hr (≈ 90 % v/v ethanol) |
| Feed (spent ethanol) |
40 – 60 % v/v ethanol |
| Reboiler |
Thermosiphon, SS316, 12 m² |
| Condenser |
Shell-and-tube, SS316, 10 m² |
| Reflux ratio |
2:1 – 4:1 (PID controlled) |
| Column ΔP |
≤ 50 mbar |
| Material |
SS316 column + internals |
| Automation |
Temp. profile (top/bottom) → reflux control valve |
| Metric |
Target |
Monitoring Method |
| Gum extraction yield |
≥ 85 % of available gum |
Mass balance (seed vs powder) |
| Gum purity (as polysaccharide) |
≥ 75 % (w/w) |
AOAC 991.43 (TDF) |
| Viscosity (1 % sol., 25 °C) |
≥ 800 cP |
Brookfield LVDV (spindle #3) |
| Residual ethanol in powder |
≤ 50 ppm (CCP-3) |
GC-HS (per batch) |
| Moisture content (powder) |
≤ 6 % |
Halogen analyser (105 °C) |
| Particle size (D90) |
≤ 250 µm |
Sieve analysis / laser diff. |
| Ethanol recovery efficiency |
≥ 95 % |
Mass balance (in vs recovered) |
| Spray dryer outlet temp (CCP-3) |
75–85 °C |
In-line RTD (interlocked on T-out) |
5. HACCP — CCP-3 Integration
| CCP |
Hazard |
Critical Limit |
Monitoring |
Corrective Action |
| 3a |
Residual ethanol > 50 ppm → off-flavour, non-compliant |
Ethanol ≤ 50 ppm in gum powder |
GC-HS every batch |
Re-dry / re-purge batch; recalibrate dryer |
| 3b |
Spray dryer outlet too high → gum degradation / scorch |
T-out ≤ 85 °C |
Continuous RTD |
Reduce inlet temp / feed rate; clean atomiser |
| 3c |
Allergen cross-contact |
Dedicated line; CIP between campaigns |
Visual CIP check + swab |
Stop line; full CIP repeat |
| 3d |
Ethanol vapour explosion |
LEL ≤ 25 % in basket centrifuge zone |
Fixed LEL detector |
Emergency vent; stop centrifuge; Evacuate |
6. Maintenance Schedule
| Component |
Frequency |
Activity |
| Extraction tank agitator |
Weekly |
Seal flush; check impeller for wear |
| Decanter centrifuge |
200 hr |
Inspect scroll flights; check bowl hard surfacing |
| Decanter gearbox |
1 000 hr |
Change oil (ISO VG 220); inspect ring gear |
| Vacuum concentrator |
Monthly |
PHE plate cleaning (CIP); check condenser fouling |
| Basket centrifuge |
50 cycles |
Replace filter cloth; check brake lining |
| Spray dryer atomiser |
100 hr |
Wheel balance check; bearing temp. logging |
| Spray dryer bags |
Quarterly |
Replace PTFE bags; check cage integrity |
| Ethanol column |
Semi-annual |
Inspect packing for fouling / channelling; ΔP check |
| LEL sensors |
Quarterly |
Bump-test; calibration |
| CIP circuit |
Monthly |
Verify flow rates, detergent conc., rinse pH |
7. Spare Parts Inventory (Minimum Stock)
| Part |
Qty |
Supplier Reference |
| Spray dryer atomiser wheel |
2 |
SD-2000-ATD (OEM) |
| Spray dryer PTFE filter bags |
12 |
SD-2000-BAG-PTFE |
| Decanter scroll tips (tungsten) |
1 set |
DC-350-SCR-TIPS |
| Basket centrifuge cloth (PP) |
20 |
BC-800-CLOTH |
| Basket centrifuge brake pads |
2 |
BC-800-BRAKE |
| Ethanol column packing (Pall) |
0.5 m³ |
PC-300-PALL-SS316 |
| RTD sensors (PT100, 3-wire) |
5 |
RTD-PT100-316 |
| Concentrator PHE gaskets |
2 sets |
PHE-15-GSK-SS316 |
8. Utility Requirements
| Utility |
Connection |
Peak Demand |
| Electrical |
400 V, 3-phase, 50 Hz |
85 kVA |
| Steam |
4 bar(g) saturated |
400 kg/hr |
| Cooling water |
25 °C supply, ΔT 10 °C |
25 m³/hr |
| Chilled water |
7 °C supply |
5 m³/hr (column condenser) |
| Compressed air |
6 bar(g), oil-free |
10 Nm³/hr |
| Water (process) |
Potable, ≤ 5 µS/cm |
4 m³/hr |
| Drainage |
Chemical-resistant |
3 m³/hr |
9. Safety & Compliance
- ATEX Zone 1 (basket centrifuge, ethanol column area, precipitation tank): Ex d IIB T4.
- ATEX Zone 22 (spray dryer outlet, powder collection): combustible dust rated.
- Ethanol storage: Bunded tank farm with fire-water deluge; bonded/grounded.
- Combustible dust: Explosion vent panels on spray dryer; bonded bag filter.
- PPE: Chemical-resistant gloves + apron for ethanol handling; hearing protection in centrifuge area.
- LOTO: Lockout on basket centrifuge door interlock; spray dryer atomiser drive.
Document Owner: Process Engineering Manager
Revision: 1.0
Date: 2026-07-20
CCP-3 Validated: Production Manager / HACCP Team