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Modified starches are produced to achieve specific functional properties, but variability during chemical modification can generate off-spec fractions, including partially degraded or soluble starch that cannot be recovered downstream. Following modification, starch is washed to remove residual chemicals and salts, typically using multi-stage, counter-current hydrocyclone systems that require large volumes of water to meet starch purity requirements.
During washing, insoluble starch granules are separated from dissolved material and fine particles. However, fine starch and soluble fractions are carried into the aqueous phase, resulting in direct product yield loss. These losses also increase chemical oxygen demand (COD) and total suspended solids (TSS) in effluent streams, contributing to higher treatment loads, sludge generation, and associated disposal costs. Further downstream, the washed starch is dewatered and dried, both of which are energy-intensive operations, where additional starch losses during dewatering compound overall yield and cost impacts.
Technologies that reduce the formation of unrecoverable fractions during modification or improve the recovery of starch during washing and/or dewatering could significantly increase yield and reduce operating costs. In addition, solutions that enable effective washing with lower water use or allow partial water reuse within the process could further improve operational efficiency and sustainability.
We seek technologies, equipment, process innovations, and digital tools that reduce yield variability during starch modification, minimize starch loss, improve recovery of starch during washing, or enable efficient washing with reduced water use or partial water reuse. Solutions that offer energy-efficient concentration are also of interest. Ideal solutions should drive cost reduction without compromising product quality through increased yield, reduced water or energy use, or lower effluent load and treatment costs.
- Improved reaction control & mixing technologies reducing formation of soluble/off-spec starch (e.g., advanced mixing, dosing, inline monitoring)
- High-efficiency starch washing & separation equipment
- Smart equipment design improvements enhancing separation and recovery (e.g., flow distribution, inlet geometry, lamella settlers)
- Starch fines & solids recovery from wash streams (e.g., centrifugation, membranes, flocculants, dissolved air flotation)
- Smart process control systems or AI optimization tools (e.g., model predictive control, digital twins)
- Water-reuse or low-water process redesign (e.g., membranes, in-process recycling, hybrid separation systems)
- Energy-efficient dewatering and drying technologies (e.g., advanced dewatering, low-energy drying, heat integration)
- Advanced sensors enabling real-time measurement of process indicators (e.g., solids, protein, starch, turbidity) to improve control of product functionality (e.g., viscogram by RVA)
- Improves starch yield, reduces water or energy use, and/or lower operating costs (e.g., water, energy, effluent load)
- Applicable at industrial scale in starch processing facilities (e.g., corn and wheat plants)
- Deployable in 3–24 months
- Real-time monitoring and data insights
- Cross-compatibility across multiple starch sources (e.g., corn, wheat)
- Requires minimal additional assets
- Non-scalable lab concepts
Our global team includes more than 1,500 research, development, applications, technical services and intellectual property specialists working in more than 200 locations. Together, they provide a spectrum of services encompassing technical service, applications, development, research, intellectual asset management, and scientific and regulatory affairs.
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