Betaine | Batch Centrifuge Screen Optimisation

Client: A betaine factory in Finland
Application: Batch centrifuge screens for betaine separation
Industry: Sugar

Betaine is a high-value byproduct extracted from beet sugar molasses and used in animal feed and food applications. Although processed using similar equipment to sugar, betaine behaves very differently during centrifugation.

In batch centrifuges, stable cake formation is critical for even dewatering and reliable operation. When cake thickness varies, vibration increases, and separation performance becomes unpredictable.

At this site, centrifuge performance was limiting recovery and reliability rather than capacity alone. Screen geometry became a system-level risk affecting yield, stability, and equipment behaviour.

ActionLaser worked with the betaine producer on a solution that;

• Stops betaine solids loss through screens
• Stabilises cake formation on the centrifuge wall
• Reduces vibration and improves dewatering consistency
• Ultra-low open area screens made practical
• Proven and repeatable across plants
• Site-specific optimisation available

The betaine factory experienced significant product loss through conventional centrifuge screens. Typical mechanically punched 0.4mm slots allowed fine betaine solids to pass through.

At the same time, the centrifuge struggled to form a stable cake on the bowl wall. Without consistent cake thickness, dewatering became uneven, and vibration increased.

These issues reduced recovery, affected reliability, and increased operational risk. The plant required finer retention and controlled flow without destabilising centrifuge behaviour.

ActionLaser developed a laser-drilled short-slot centrifuge screen tailored to betaine behaviour. The initial design used 200 micron apertures with approximately 5% open area.

The first trial significantly reduced product loss and improved cake formation. However, further optimisation was required to fully stabilise the operation.

ActionLaser then produced an ultra-low open area variant at 200 microns and 2% open area. Laser drilling made this geometry without distortion or loss of structural integrity.

The ultra-low open area screen solved both key issues. Betaine solids losses were dramatically reduced compared to punched screens.

The centrifuge rapidly achieved a stable, uniform cake thickness. Dewatering became more consistent, and vibration levels reduced.

The design became the standard specification for the Finnish plant. It was later adopted by a betaine facility in the United States.

Subsequent trials confirmed site-specific optimisation. A new Austrian plant validated 4% open area as optimal for its operating conditions.

Laser drilling enabled a precise 200 micron slot geometry not achievable with punched screens. This prevented fine betaine solids from passing through the screen surface.

Controlling the open area proved critical to cake behaviour. Lower open area maintained sufficient resistance for uniform cake formation.

Stable cake thickness reduced vibration and improved dewatering consistency. Because geometry was predictable, performance remained stable over time.

The plant improved the recovery of a high-value product without changing centrifuge hardware. Centrifuge operation became more stable and predictable.

The solution proved transferable across multiple facilities and regions. Site-specific optimisation allowed each plant to balance retention and flow.

Screens became a turned process component rather than a consumable compromise. This supported confident operation, scale-up and new plant design.