Industry Overview
Broken rice can be processed to produce ethanol, maltodextrin, and food-grade rice protein through an integrated separation and processing approach. The technology described separates rice protein before the starch fraction is further processed for products such as ethanol and maltodextrin. This approach enables the recovery of high-quality food-grade rice protein with protein purity of more than 80%. The report describes the protein as non-allergenic and non-genetically modified, with protein absorption characteristics compared with soy and other protein sources.
The proposed 300 Tons per day broken rice processing line is designed to operate for 300 days per year and 20 hours per day, corresponding to an hourly processing rate of 15 tons of broken rice. Based on a protein content of 7% on a wet basis and 80% protein recovery, the process is stated to produce 1.1 tons per hour of food-grade rice protein, equivalent to 22 tons per day and 6600 tons per year. The reported product contains 80% protein on a dry basis and 5% moisture.
The report also provides background on alcohol and ethanol, including their historical development, properties, sources, applications, production microorganisms, ethanol demand and supply in India, regulatory requirements, and the production process from broken rice and other feedstocks. Ethyl alcohol is presented as a versatile chemical with applications as a solvent, germicide, beverage component, antifreeze, fuel, depressant, and chemical intermediate.
Cost Estimation
| Particular | Value |
|---|---|
| Plant Capacity | 10 KL/Day |
| Land & Building (6 Acres) | Rs. 13.84 Cr |
| Plant & Machinery | Rs. 15.20 Cr |
| Working Capital for 2 Months | Rs. 2.52 Cr |
| Total Capital Investment | Rs. 33.21 Cr |
| Rate of Return | 26% |
| Break Even Point | 55% |
Content Index
- INTRODUCTION
- PROPERTIES OF ALCOHOL
- PHYSICAL PROPERTIES
- TABLE: PHYSICAL PROPERTIES OF ETHANOL
- SOURCES OF ALCOHOL
- USES AND APPLICATION
- BROKEN RICE
- MARKET OVERVIEW OF ETHANOL IN INDIA
- ETHANOL DEMAND IN INDIA
- GROWTH IN VEHICLE POPULATION
- TABLE: PROJECTED ADDITION OF GASOLINE VEHICLES (IN LAKHS)
- DEMAND PROJECTIONS OF GASOLINE
- TABLE: GASOLINE DEMAND PROJECTIONS
- DEMAND PROJECTION OF FUEL ETHANOL
- TABLE: ETHANOL DEMAND PROJECTION
- ADDITIONAL MODELING OF ETHANOL DEMAND SCENARIOS
- ETHANOL SUPPLY PROJECTION IN INDIA
- ETHANOL PRODUCTION CAPACITIES
- MODIFIED INTEREST SCHEME TO ENHANCE PRODUCTION CAPACITY OF ETHANOL
- AVAILABILITY OF FEED-STOCKS FOR PRODUCTION OF ETHANOL
- TABLE: AVAILABILITY OF FEED-STOCK FOR ETHANOL IN THE COUNTRY (IN LAKH TON)
- ESTIMATION OF SUPPLY AND CAPACITY AUGMENTATION
- TABLE: YEAR WISE & SECTOR WISE ETHANOL PRODUCTION PROJECTIONS
- TABLE: ETHANOL CAPACITY REQUIREMENT BY YEAR AND RAW MATERIAL
- TABLE: ETHANOL CAPACITY AUGMENTATION (20% BLENDING BY 2025-26)
- ETHANOL BLENDING PROGRAMME IN INDIA
- TABLE 4.2: QUANTITY SUPPLIED (ETHANOL) AND %BLENDING TRENDS
- FIGURE 4.2: EBP PROGRAMME PERFORMANCE
- PROCUREMENT OF ETHANOL AND ITS PRICING
- TABLE: ADMINISTERED PRICE OF ETHANOL BY SOURCE'
- PRICING MECHANISM OF ETHANOL FROM SUGAR SECTOR
- IMPACT OF EXISTING ETHANOL PRICING MECHANISM
- ALCOHOL BASED INDUSTRY IN INDIA
- MANUFACTURERS/SUPPLIERS OF ETHANOL
- TRADE AND TECHNICAL NAMES
- UNITS OF MEASUREMENT
- ORGANISM USED IN THE PRODUCTION OF ALCOHOL
- TYPE OF YEAST:-
- THEY ARE GROUPED TOGETHER IN THREE FAMILIES ARE:-
- SHAPE AND SIZE OF CELLS:-
- CONTENTS OF THE CELL:-
- YEAST SPARES:-
- REGULATORY REGIME FOR GRANT OF ENVIRONMENT CLEARANCE
- PROCEDURE FOR OBTAINING ENVIRONMENTAL CLEARANCE (EC)
- MEASURES TAKEN BY MOEF&CC TO OPTIMIZE THE REQUIRED TIME IN OBTAINING TERMS OF REFERENCE (TOR) AND FOR DATA COLLECTION FOR PREPARATION OF ENVIRONMENT IMPACT ASSESSMENT
- MEASURES TAKEN BY MINISTRY TO OPTIMIZE THE TIME TAKEN IN APPROVAL OF EC
- B.I.S. SPECIFICATION
- SEQUENCES IN ETHANOL PRODUCTION FROM BROKEN RICE/SWEET POTATOES
- BROKEN RICE HANDLING SYSTEM:-
- FLOUR WEIGHING AND BATCHING:-
- SLURRY PREPARATION:-
- ETHANOL FRODUCTION FROM BROKEN RICE/GRAIN/SWEET POTATOES
- PROCESS FLOW DIAGRAM
- PROCESS IN DETAILS FOR ALCOHOL PRODUCTION
- (A) ALCOHOL PRODUCTION FROM BROKEN RICE
- 1) GRAIN HANDLING AND MILLING:-
- MASHING:-
- FERMENTATION:
- DISTILLAITON-
- TECHNOLOGY FOR ETHANOL PRODUCTION
- ACID HYDROLYSIS OF DAMAGED RICE
- INCUBATION AT VARYING CONDITIONS
- ACID HYDROLYSIS AT VARYING TEMPERATURES
- ACID HYDROLYSIS AT VARYING PHYSICAL TREATMENT
- THERMO CHEMICAL PROCESS IN HYDROLYSIS
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF BROKEN RICE
- SUPPLIERS OF PLANT AND MACHINERY
- SUPPLIERS OF SILO
- SUPPLIERS OF HAMMER MILLS
- SUPPLIERS OF COOLING TOWER
- SUPPLIERS OF REACTORS
- SUPPLIERS OF D.G. SETS
- SUPPLIERS OF BOILERS
- SUPPLIERS OF CONDENSER
- SUPPLIERS OF DISTILLATION COLUMN
- SUPPLIERS OF SCRUBBER
Appendix
- APPENDIX – A:
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
Broken rice can serve as a starch-rich feedstock for ethanol production. In the process described in the report, broken rice is handled, milled, converted into a suitable mash, fermented, and then distilled to recover alcohol. The approach can also separate rice protein before processing the starch fraction, allowing the feedstock to support the production of both food-grade protein and ethanol-related products. This integrated utilization can improve the value obtained from broken rice by making use of more than one component of the raw material.
Ethanol from broken rice is produced by converting the grain starch into fermentable material, fermenting it with yeast, and separating the resulting alcohol by distillation. The report identifies grain handling and milling, mashing, fermentation, and distillation as key stages. It also discusses hydrolysis approaches for damaged rice, including acid hydrolysis and thermochemical processing. The exact process configuration depends on the selected technology, feedstock characteristics, required product quality, and integration with other products such as rice protein or maltodextrin.
Yeast converts fermentable sugars into ethanol and carbon dioxide during fermentation. In an ethanol plant, yeast selection and fermentation conditions influence process performance, alcohol yield, and operational stability. The report includes sections covering the organism used in alcohol production, types of yeast, yeast families, cell shape and size, cell contents, and yeast spores. Maintaining appropriate conditions for the selected microorganism is important because temperature, pH, nutrient availability, sugar concentration, contamination control, and fermentation time can affect the overall process.
The main stages include feedstock handling, milling or preparation, slurry or mash preparation, fermentation, and distillation. Depending on the feedstock and process design, hydrolysis may be required to convert starch into fermentable sugars before fermentation. The report also identifies supporting systems such as silos, hammer mills, cooling towers, reactors, boilers, condensers, distillation columns, scrubbers, and power-generation equipment. A complete plant design must integrate these systems with appropriate material handling, utilities, process controls, safety provisions, and environmental management measures.
Yes, the report describes an integrated approach in which rice protein is separated first and the remaining starch is subsequently used for products such as ethanol and maltodextrin. This configuration allows different fractions of broken rice to be utilized for different value-added products. The reported process is intended to recover food-grade rice protein with more than 80% protein purity while also enabling downstream processing of starch. Such integration requires suitable separation technology and careful control of the subsequent starch-processing and fermentation stages.
Environmental approval requirements depend on the project category, capacity, location, process configuration, and applicable Indian regulations. The report specifically addresses the regulatory regime for obtaining environmental clearance, the procedure for obtaining Environmental Clearance (EC), Terms of Reference (TOR), Environmental Impact Assessment data collection, and measures intended to optimize the approval process. Project developers should assess the applicable requirements during project planning and prepare the required technical and environmental documentation in accordance with the regulations and authorities applicable to the proposed site.
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