Citric Acid Manufacturing Process for Starch-Based Production Lines

Welcome to the zesty world of sourness! From classic lemonades to industrial beverages that refresh you on a scorching hot summer day! All of them rely on citric acid, whether sourced from classic lemon juice or simulated alternatives. However, as demand for citric acid continues to grow, natural sources alone are no longer enough to fulfill the rising needs. That’s why market research shows the citric acid market valued at USD 3.9–4.2 billion in 2022–2023.

The manufacturing process of citric acid starts with enzymatic hydrolysis of starch-based raw materials like corn or cassava; then the slurry goes through the fermentation process using black molds for 5-7 days under a controlled condition (pH, temperature, and oxygen supply to achieve the highest yield. After all, it undergoes a filtration and drying process to create that final result of citric acid.

Moreover, recent global trends in starch fermentation are increasingly focused on eco-friendly methods. Follow us till the end to master the citric acid manufacturing process!

What is Citric Acid and Why It’s in High Demand

As a weak organic acid derived from organic sources like citrus fruits or starches through microbial fermentation, citric acid plays a crucial role in various industries.

• Food and Beverages: used for adding flavor or pH adjusting
• Pharmaceuticals: improving the taste of oral medications or used as an excipient in the formulation
• Cleaning Products: effective in water stain removal, while having such a lower environmental impact than harsh chemicals.

The market of citric acid was valued at USD 3.3 billion in 2018 and is projected to reach USD 7 billion by 2032, growing at a CAGR of 5.6% from 2023 to 2032. This growth shows the rising demand for ready-to-eat food and clean-label ingredients in production methods.

By developing sustainable trends all around the world, consumer behavior is changed continuously. Therefore, starch-based production derived from raw materials through bio-based manufacturing methods is rising.

Starch-Based Production Process: How It Works

In industrial citric acid production methods, manufacturers use starchy materials such as corn, cassava, and potato. Due to the cost efficiency and polysaccharide structure of these materials, they contain a rich amount of carbon for the fermentation process. PubMed highlights how the choice of raw material impacts on the quality and yield of final citric acid production.

Now, let’s dive into the step-by-step process of citric acid manufacturing from starch hydrolysis to fermentation:

1.    Starch Hydrolysis to Simple Sugars

Firstly, complex starch molecules are crushed into smaller glucose units through enzymatic hydrolysis to achieve a fermentable finish for microbial activities.

For instance, corn starch goes through heating with water to shape a slurry and enzymatic hydrolysis at certain temperatures (90-110°C for liquefaction, 60-65°C for saccharification), then gets filtered to create a pure glucose mixture for the next step.

2.    Fermentation with Aspergillus Niger

The carbon sources go through microbial fermentation with Aspergillus Niger, a black mold that is famous for high citric acid manufacturing. According to Microbe Notes, an estimated practical yield of CA is 70 % of the theoretical estimate, which is 112g per 100g of sucrose.

This black mold ferments glucose to citric acid under specific conditions like jacketed batches. Also, there should be some controlled conditions to reach the best fermentation process:

1. pH: To achieve the best quality, the pH must be around 2.0-3.5.
2. Temperature: For the maximum fermentation efficiency, keep the temperature at 28-30°C based on your raw material.
3. Oxygen Supply: For microbial growth, adequate aeration during the week of fermentation is needed to gain that rich citric acid batch.

Benefits of Using Starch as a Feedstock

There are several reasons for starch usage for citric acid manufacturing, such as availability, high sugar content for fermentation, and existence of agro-industrial infrastructures.

Availability and Cost-Effectiveness: Basically, full-starch materials like corn or potato are planted widely to fulfill the economic demands.

High Sugar Yield: Starch can contain a high amount of sugar and glucose for fermentation that increases the final citric acid quality. (Source: ScienceDirect)

Compatibility with Existing Agro-Industrial Infrastructure: Following the recent agricultural trends aids manufacturers in their choice of raw materials.

Setting Up a Starch-Based Citric Acid Production Line

Running a starch-based citric acid business requires a well-planned production line design adapted to the most used raw materials like corn or potato.

Required Equipment

To crush raw starchy material into glucose slurry, a hydrolyzer with high-temperature tolerance is needed, while for the microbial fermentation process via black molds, a stainless-steel fermenter with pH 2.0-3.5 resistance is recommended.

Lastly, to remove impurities, a filtration system for citric acid separation from the fermentation broth, like vacuum filters, while a crystallizer and dryer are necessary for the final market product.

Key Parameters to Monitor for High Yield

For the best citric acid finish ever, we should maintain the process in a way to control all these controlled conditions below:

• pH Levels: An acidic environment (mainly between 2.0-3.5) is required.
• Temperature: to have the perfect A. niger activity, the temperature should undergo a 30–31.5°C during the fermentation process.
• Aeration: the way of oxygen supply during the fermentation process (mainly 5-7 days) requires aerobic conditions.
• Nutrient Concentration: to increase the quality of final citric acid, controlling the nitrogen and phosphate levels will aid the process.

Common Issues and Troubleshooting Tips for Citric Acid Manufacturing Process

During the citric acid manufacturing process, from starch hydrolysis to fermentation, there are some possibilities for troubles like foaming or contamination.

Incomplete fermentation: All we had in the last section, from temperature to nutrient level are prioritized to make sure the process goes right.

Foaming: To eliminate any disturbing foams during the fermentation process, antifoaming agents or foam breakers are crucially needed.

Contamination: To avoid contamination from microorganisms, sterilization, and equipment maintenance are suggested.

Automation and Control Systems in Modern Plants

In the last few decades, automated machinery has changed the game of the citric acid manufacturing process. PAC systems control pH, temperature, and sugar levels, while SCADA systems monitor the process via data visualization and help manufacturers make decisions quickly. (Source: Procurement Resource)

Recovery and Purification: Getting Citric Acid from the Broth

After the fermentation process, the fermentation batch needs to be separated from citric acid via recovering and purifying sections. Downstream purification is one essential step of citric acid production from starches.

Filtration: To remove black molds and other impurities from the fermented mixture, a vacuum filter of the centrifuge system will aid the process.

Precipitation: By adding calcium hydroxide to the purified broth, it forms to calcium citrate, then it goes through converting to citric acid via treatment with sulfuric acid.

Solvent Extraction or Ion Exchange: This method is mainly used for pharmaceutical applications to remove residual impurities based on USP standards.

Tips for Improving Purity and Minimizing Product Loss

Firstly, to increase yield of filtration, use high-quality filtration systems.

Secondly, control pH and temperature at the right range during the purification process.

Thirdly, using closed process systems will avoid any contaminations.

Lastly, regular maintenance and control systems are going to create such a perfect final product.

Comparing Other Citric Acid Production Methods

Although citric acid manufacturing through starch is widely used and efficient, other methods are available to meet various demands.

Molasses-Based Fermentation

As a traditional way of citric acid production, molasses goes through fermentation, but due to containing heavy metals, the purifying process is highly expensive.

Glucose and Sucrose Routes

Using glucose or sucrose eases the process and is perfect for small-scale manufacturing. Moreover, the cost of raw materials is higher than starch-based production.

Solid-State Fermentation vs. Submerged Methods

The raw material used in solid-state fermentation (SSF) is mainly from cassava bagasse, which needs less water to make a slurry, but it presents a lower output.

On the other hand, starch-based production shines in yield and efficiency while requiring a stronger energy source for aeration.

Pros and Cons vs. Starch-Based Approach

Starch-based production includes several benefits like sustainable considerations or cost-effectiveness, while other methods may profit for niche markets such as small-scale lines. Below, is a comparison table provided with the pros and cons of these methods:

Method	Advantages	Disadvantages
Molasses-Based	Cost-effective, abundant substrate	Variable composition, requires pretreatment
Glucose/Sucrose Routes	High purity, consistent yields	Higher substrate cost
Solid-State Fermentation	Low energy/water use, uses residues	Control challenges, scale-up issues
Submerged Fermentation	Controlled environment, scalable	Higher operational costs
Starch-Based	Renewable materials, agro-industry integration	Requires hydrolysis step, potential lower yields

Regulatory and Quality Considerations

As the two most-used applications of citric acid are directly related to body health and large-scale production needs exportation, the citric acid manufacturing process must undergo regulatory and standardization sections as well.

Compliance with Food-Grade and Pharma-Grade Standards

There are dozens of standards worldwide to prove the quality of citric acid for food-grade or pharma-grade applications, here are some reliable ones for both pharma-grade and food-grade:

• Food Chemicals Codex (FCC)
• United States Pharmacopeia (USP)
• European Pharmacopoeia (Ph. Eur.)
• Japanese Pharmacopoeia (JP)
• S. Food and Drug Administration (FDA)
• Hazard Analysis and Critical Control Points (HACCP)
• ISO 9001

Certifications and Testing Required for Export Markets

The idea of exportation requires lots of qualifications for manufacturers to include. It depends on the target market. For instance, the USDA’s Food Safety and Inspection Service (FSIS) includes export guidelines and required certification for various destinations.

Environmental Aspects: Waste Treatment and Sustainability

Recent trends rely on eco-friendly strategies; then, citric acid production manufacturers should consider sustainable practices through wastewater treatment and using renewable resources.

Wastewater Treatment: This process creates wastewater that must be removed to reduce the environmental impacts.

Sustainable production practices: recycling the treated wastewater is one of those eco-friendly practices that decreases the footprint of citric acid production. (Source: ScienceDirect)

Applications of Citric Acid from Starch-Based Production

Citric acid, especially the starch-based one, is used globally for different aims. Due to its renewable raw materials like corn and cassava, it’s widely used in food and beverages. Here are some of the most-used applications of citric acid:

Use in Food and Beverage Industry

Starch-based citric acid creates such a perfect sourness in soft drinks and candies, while showing itself as a preservative in jams. PMC emphasizes on the standard number of heavy metals there for organic-labeled products (<1 ppm).

Pharmaceutical-Grade Production Possibilities

Due to its USP and EP standards, starch-based citric acid is utilized in tablets, emulsifying syrups, and drug-inactive substances.

Emerging Applications in Biodegradable Materials and Green Cleaning

Citric acid is a reliable alternative to petroleum materials and is used as a plasticizer in biodegradable plastics. At the same time, green cleaning represents a chelating application for eco-friendly aims.

Why Invest in a Starch-Based Citric Acid Line Now

Having a plan for investment in a starch-based citric acid manufacturing process depends on time, available opportunities, and market trends.

Market Trends Favoring Bio-Based Products

The changes in consumer perception of eco-friendly products made a challenging movement toward bio-based products. Citric acid made of starch-based materials like corn or potato eases the way of aiming for those purposes.

Otherwise, the growing demand for clean-label products pushes food and pharma manufacturers to look for renewable ingredients.

Return on Investment and Scalability

It’s predicted the market of citric acid will reach such rapid growth, providing a perfect opportunity for an investment with a great return rate.

Additionally, a starch-based citric acid manufacturing process is a cost-effective choice due to the availability of materials like corn or cassava, rather than other methods.

Due to submerged fermentation, the final output will reach the highest percentage, and that’s all about the scalability of starch-based production. Additionally, automatic machinery provides manufacturers with a significant yield and low energy usage.

How We Help: Your Partner in Citric Acid Production

At YasminTrading, we not only play our role as a supplier, but we’re also your partner in each step of the citric acid manufacturing process with such a well-designed plan and solution.

Discover Our All-in-One Turnkey Production Solutions

Rely on our end-to-end solutions to respond to each mishap you might face in your production line:

At first, we start with evaluating your market, availability of raw materials, and technical methods based on your needs to help you design the most adopted and personalized production model.

From starch hydrolyzers to filtration systems, we’ll provide you with a wide range of equipment just to ease the way of production lines’ setting up!

Customization Options for Feedstock and Capacity

It does not matter if you’re seeking a small-scale or large-scale production line; we’ll be there for you to design the lines to achieve the highest yield.

Type of starch source: Corn, cassava, potato, or mixed input

Plant capacity: From small-scale (500 kg/day) to large-scale (10,000+ kg/day) operations

Automation level: Manual, semi-automatic, or fully automated control systems

After-Sales Support, Training, and Optimization

Our journey doesn’t end with just installation; we’ll be your long-term partner to support our clients with technical training through hands-on guidelines, troubleshooting each step, and upgrading systems and operations based on recent trends.

At YasminTrading, we aid our clients from crops to crystallization just to reach prosperity!

Let us help you create that zesty world together!

Conclusion

The citric acid manufacturing process is changing through starch-based production, using raw materials like corn for an eco-friendly, cost-effective finish. With market growth to USD 5.17 billion by 2030, now is the time to invest. YasminTrading offers turnkey solutions and support, providing scalability and compliance. Despite primary costs, the eco-friendly approach and rising bio-based demand will make sure the high return rate of your investment.

FAQs

1- What equipment is essential for starch processing?

To crush raw starchy material into glucose slurry, a hydrolyzer with high-temperature tolerance is needed, while for the microbial fermentation process via black molds, a stainless-steel fermenter with pH 2.0-3.5 resistance is recommended.

2- What are common issues in citric acid production?

During the citric acid manufacturing process, from starch hydrolysis to fermentation, there are some possibilities for troubles like foaming or contamination.

3- How does the choice of raw material affect citric acid production?

Due to the cost efficiency and polysaccharide structure of these materials, they contain a rich amount of carbon for the fermentation process. PubMed highlights how the choice of raw material impacts the quality and yield of final citric acid production.