I. Customer Background
A biotechnology enterprise in South China, mainly engaged in deep processing of sugarcane sugar-maltose. The core process is sugarcane sugar-maltose acid hydrolysis + fermentation. The annual production of sugar-maltose fermentation products is over 30,000 tons. The upstream of the enterprise, after acid hydrolysis, neutralization, and flocculation pretreatment of sugarcane sugar-maltose, needs to efficiently separate suspended solids from sedimentary impurities to obtain clear filtrate for downstream fermentation, ensuring the activity of fermentation strains and product purity. Previously, traditional plate-and-frame filtration was used, which had problems such as high water content in the filter cake, significant sugar loss, cumbersome manual operation, and unstable filtrate quality, which hindered fermentation efficiency and production cost control.
II. Process Pain Points
1. Material Characteristics: After flocculation of acid-hydrolyzed sugar-maltose liquid, there are a large number of fine suspended impurities, with fine particles and strong adhesiveness, making solid-liquid separation difficult;
2. Production Requirements: The batch processing volume is approximately 2 tons per batch, with a temperature of 45-55℃ and pH ≈ 6 after neutralization, requiring stable retention of solid impurities and strict control of sugar loss;
3. Existing Problems: Traditional equipment has a filter cake water content of over 40%, sugar loss of 3%-5%, long manual unloading time, long batch cycle, high turbidity of the filtrate, and affecting the fermentation conversion rate.
III. Solution
Based on the customer’s process parameters, material characteristics, and production pain points, it is recommended to select a 45㎡ fully automatic diaphragm filter press (food-grade acid-resistant configuration), which is suitable for its batch production mode. Relying on the core advantages of diaphragm high-pressure pressing, PLC program-controlled automatic operation, and automatic filter cloth cleaning, it solves the problem of solid-liquid separation.
IV. Application Effect
1. Stable separation effect: The filtrate is clear and transparent, with an impurity removal rate of over 99%, fully meeting the purity requirements for fermentation feedstock, and significantly reducing the contamination rate of fermentation strains;
2. Filter cake quality optimization: The solid content of the filter cake is stable at 72%-78%, with a water content reduced to 22%-28%, compared to traditional equipment, it increases by 15 percentage points, and the filter cake is easy to unload and transport;
3. Sugar loss reduction: The sugar content carried by the filter cake is controlled at 1.0%-2.0%, reducing sugar loss by over 80 tons per year, directly increasing revenue by over 400,000 yuan;
4. Production efficiency improvement: The single batch cycle is shortened to 45-60 minutes, fully automatic operation, no need for dedicated personnel to monitor, reducing labor costs by 60%, and batch processing capacity increases by 30%;
5. Operating cost controllable: The equipment is acid-resistant and corrosion-resistant, filter cloth life is extended, maintenance frequency is reduced, annual operation and maintenance costs are reduced by 40%, and the overall benefits are significant.
V. Customer Evaluation
“The diaphragm filter press has completely solved the problem of clarifying sugarcane sugar-maltose acid hydrolyzate filtrate. The filtrate quality is stable, the filter cake moisture is low, and sugar loss is small. It not only reduces costs and increases efficiency, but also builds a solid foundation for quality in the fermentation process. It is an ideal choice for solid-liquid separation in sugarcane sugar-maltose deep processing.”
Post time: May-22-2026