SORBITOL 70% PROCESS FLOW CHART
CRYSTALLIZING & NON CRYSTALLIZING GRADES
Technical Data & Specifications
Description
Appearance of solution Clear, colourless, syrupy liquid, miscible with water.
D-Sorbitol%(m/m) Min.50%
Water Content Between 28% to 31%
Dry Matter Min.69%
Reducing Sugar Max.0.2%
pH 5.00 to 7.00
Sulphated Ash%(m/m) Max.0.1%
Lead Max.0.5ppm
Nickel Max 1ppm
Sulphate Max 100ppm
Chloride Max 50ppm
Arsenic(As) Max 3mg/Kg
Heavy metals Max 10ppm
Sorbitol 70% - Non-Crystalline (Pharmaceutical Grade / IP Grade)
Specific Gravity: 1.296 – 1.298
D Sorbitol: 72 – 92%
Total Sugar: 4 – 9 % (as per client requirement)
% R.S < 0.2%
R.I: 1.455 – 1.456
Sorbitol 70% - Crystalline (Non-Pharmaceutical Grade / NIP Grade)
Specific Gravity: 1.296 - 1.298
D Sorbitol: >92%
Total Sugars: 1.8 – 2.5%
% R.S < 0.2%
R.I: 1.455 – 1.456
GULSHAN POLYOLS LTD Revised: 30/01/2014 SOP NO.: GPL/SOP/PR/7.5/11 1
SORBITOL 70% PROCESS FLOW CHART
CRYSTALLIZING & NON CRYSTALLIZING GRADES
QC Sample
Colour: Off white
STARCH SLURRY TANKS
Caustic Solution to Be: 16.0 - 17.5
bring pH 5.6 to 5.8 Prepare slurry: SO2 Aeration. Ph: 5.0 – 5.8
Parameters: % Protein (Insoluble):
Alpha Amylase (0.5 D.S. 30 - 33%, pH 5.6 to 5.8, Process 0.45 - 0.55%
Kg/ ton of starch) water 70 - 67% % Protein (Soluble): 0.025
- 0.035%
Slurry Tanks: 50m3 (5 % Oil/fat: 0.1 - 0.14 %
mtr) + 16m3 (3 tanks) SO2 ppm: 90 -100
HYDROLYSIS /JET COOKING
Steam Consumption Start with converting starch into saccharides. This
(0.33 Kg/Tone of DS step enables alpha amylase to break starch
Starch) molecules into saccharides/ Dextrin. Slurry is cooked
for 5-8 minutes at Temp. 107 ± 1°C
QC Sample
DEXTRINATION TANK % DE: NIP: 12-14
% DE: IP: 12-14
Here conversion continues.
Starch test: Slightly +ve
Retention Time: 1.5 to 2.0 Hours at 94-99° C
(purple colour with
Parameters:
Starch: –ve, D.E: 12-14% for NIP and 12 – Iodine solution)
14% for IP (pure dextrose: 6-8%) Colour: slight yellow
(visual)
DS: 29 – 32 %
Dex. Tanks: 45m3 (Tank (By Refractometer)
behind coiled tubes
)
ONLINE DOSING:
HCL for pH:4.0 - 4.5 PLATE COOLER (4 PHE)
Gluco Amylase (0.5 Material is cooled to 60± 2°C to further break
Kg/Tone of starch) dextrin chains into dextrose/ monomer.
GULSHAN POLYOLS LTD Revised: 30/01/2014 SOP NO.: GPL/SOP/PR/7.5/11 2
SORBITOL 70% PROCESS FLOW CHART
CRYSTALLIZING & NON CRYSTALLIZING GRADES
CONTROL
POINT QC Sample
SACCHARIFICATION TANK
DS: 29 – 32 %
Conversion into Dextrose requires retention time (By refractometer )
(IP: 20-25 hours; NIP: 30-35 hours) % DE: NIP: 96 – 99 (As
Tanks: Chemical: n (C6H10O5) + n H2O →n (C6H12O6) per lab manual)
NIP: 8 x 100m3 (6 Parameters: IP: 80 – 90
mtr tank) (TEMP: 60± 2°C & PH:- 4.0 – 4.5), D.S. 29-32% Starch test: - ve
IP: 10 x 32m3 (4 % D.E. ≥ 96% for Crystallizing Grade
mtr height) % D.E. 80 - 90% for Non Crystallizing Grade
CONTROL
POINT
PRESSURE LEAF FILTER
Filter Aid Primary filtration takes place to attain REJECT: Suspended
(2.5 kg/ton physical clarity. impurities + Filter Aid
Sorbitol 70%)
Filters:
` NIP: 4 IP: 2
BENTONITE CLEAR SOLUTION TANK
to absorb oil
SUSPENDED IMPURITIES REMOVED
content
CONTROL
Tank: 50m3 (50% level) POINT
2 tanks (IP & NIP)
PRESSURE LEAF FILTER
Filter Aid Secondary filtration takes place to REJECT: Suspended
(1 kg/ton attain physical clarity. impurities + Filter Aid
Sorbitol 70%)
5 PLF: 2 for Dex NIP, 1 for
Dex IP, and 1 for 1 Sorb
CLEAR CRUDE DEXTROSE TANK
Tanks:
NIP D1: 100m3 (6 mtr)
IP D1: 30m3 (4 mtr)
GULSHAN POLYOLS LTD Revised: 30/01/2014 SOP NO.: GPL/SOP/PR/7.5/11 3
SORBITOL 70% PROCESS FLOW CHART
CRYSTALLIZING & NON CRYSTALLIZING GRADES
HCL AND CAUSTIC SODA CRITICAL
LYE ARE USED FOR CONTROL
REGENERATION OF ION POINT
EXCHANGE RESIN DEXTROSE ION - EXCHANGE
CHECK :Ph 4.5 ;
conductivity 30µS Dissolved ionic impurities like chloride, sulphate and
enzymes are remove.
4 sets NIP (9m3 each)
4 sets IP (6m3 each)
Tanks: DEIONISED DEXTROSE SOLUTION
NIP D2: 100m3 (6 mtr)
IP D2: 30m3 (4 mtr)
DEXTROSE EVAPORATOR
Evap Outlet Tanks: Maintain 90ºC to raise concentration to DS: 50 - 55%
NIP D3 A,B: 30m3 x 2 (4
mtr) IP D3: 30m3 x 1 (4
QC Sample
mtr)
% DS: 50 – 55
GFT/ DEXTROSE FEED TANK % DE: NIP: 96 – 99
% DE: IP: 87 – 92
Caustic Parameters: 50 - 55% D.S. pH: NIP: 6.5 – 7.5
Solution Crystalline pH 6.5 to 7.5, Cond 30 µS pH:IP: 7.5 – 8.5
Non-Cryst. & 7.5 to 8.5, Cond 50 µS Cond: 50 us Max.
So2: 11 – 15 ppm Max
Nickle Catalyst (0.5 Kg/ Tone
of Sorbitol 70%) GFT Tanks:
NIP 3,4: 15m3 x 2 (14 mt)
Magnesium Metal Powder
(0.3 Kg/Tone of Sorbitol 70%) IP 1,2: 6m3 x 2 (5 mt)
HYDROGENATION /AUTOCLAVE QC Sample
HYDROGEN
30 – 35 kg/cm2 Dextrose converts into Sorbitol here at
148 ± 2ºC. Conduct Benedicts solution RS: 6.0 -8.0 ml
Pressure
test to 6-7ml to complete reaction. (By benedict solution
green colour)
Steam Pressure n(C6H12O6)+ H2 Ni & Mg→ C6H14O6 % DS: Check & Report
5Kg/cm2
Parameters: RS < 0.2% before cooling, % RS: 0.2 Max.
Steam Temp:160 oC
DS: 50-54% % TS: NIP: 2.0 +/- 0.2
IP: 3.8 - 8%
Autoclaves:
IP 1,2,3,4: m3 x 4 ( mt)
NIP 5,6,7,8: m3 x 4 ( mt)
GULSHAN POLYOLS LTD Revised: 30/01/2014 SOP NO.: GPL/SOP/PR/7.5/11 4
SORBITOL 70% PROCESS FLOW CHART
CRYSTALLIZING & NON CRYSTALLIZING GRADES
CRUDE SORBITOL COLLECTION TANK
Parameters: 48 – 52% D.S.
Tank: CTT 1 & 2
constant level at 1.3
mtr is maintained
SORBITOL PRESSURE LEAF
REJECT: Suspended
FILTER
impurities + Filter Aid
Parameters:
1 each in IP & NIP
CONTROL
POINT
Tank: ST1 A,B
ION EXCHANGE FEED TANK
NIP: 100m3 x 2 (6m3 )
IP: 30m3 x 2 (4m3)
HYDROCLORIC ACID AND
SORBITOL ION EXCHANGE REJECT: Dissolved
COSTIC SODA LYE ARE
USED FOR REGENERATION impurities: Ni, Mg
OF ION EXCHANGE RESIN 4 sets each for NIP + IP.
CRITICAL
CONTROL
POINT
DEIONISED SORBITOL COLLECTION TANK
Conductivity <20µse
Parameters: pH 6.5
Tank: Max. Conductivity: 20ms, DS: 50% max.
NIP: 65m3 Crystalline: pH 6.5; Non Cryst: pH 6.5
IP: 30m3
GULSHAN POLYOLS LTD Revised: 30/01/2014 SOP NO.: GPL/SOP/PR/7.5/11 5
SORBITOL 70% PROCESS FLOW CHART
CRYSTALLIZING & NON CRYSTALLIZING GRADES
TRIPLE EFFECT EVAPORATOR
Sorbitol 70% (D.S. - 70%)
QC Sample
Colour: NIP: A Clean
colourless (Visual)
IP: Upto faintly yellowish
HOMOGENISATION TANK (Visual )
For final adjustment and solution mixing Sp. gr@ 25o C: 1.296 –
for consistency and quality control 1.298
pH: 5.0 – 7.5
Parameters: RS < 0.2% 70 ± 1 % D.S
% RS: 0.2% Max.
Crystalline: Specific Gravity 1.296 – 1.298 % TS: IP: 3.8-8.0%
Non Cryst: Specific Gravity 1.296 – 1.298 NIP: 2.0 +/- 0.2
Heat test: To pass the
pH: 5.0 to 7.5 for Crystalline & Non- test (Asian paint/Burger
Crystalline grades method)
Mixing Tank: Dye test: To pass the test
( HLL/Prime method)
MT 1,2,3,4 NIP: 20m3 x 4
MT 1, 2IP: 20m3 x 2
STORAGE TANK
Tank:
Paint Grade: 65m3 x 2
Drum Filling: 20m3 x 2
Prime: 65m3
Colgate: 200m3 x 2
IP: 200m3 x 2
New tanks: 200m3 x 2
MATERIAL PACKING
Sorbitol 70% is delivered in 2 type of packing:
1. SS TANKERS
2. HM HDPE BARRELS
GULSHAN POLYOLS LTD Revised: 30/01/2014 SOP NO.: GPL/SOP/PR/7.5/11 6
