Industry Overview
Starch is an abundant carbohydrate found in plants and has served both as an important dietary ingredient and as a major industrial raw material for centuries. Industrial starch is primarily recovered from plant seeds, roots, and tubers, with commercial production largely relying on wheat, maize, and tapioca. In India, maize is the principal raw material used by the starch industry, although some manufacturers also use tapioca.
Maize contains about 70% starch, along with protein, fiber, and fat. Maize starch is generally produced through wet milling, in which softened maize is ground and separated into germ, gluten, fiber or husk, and purified starch. The process also generates valuable by-products such as maize steep liquor, corn oil and oil cake, maize gluten, and maize husk, which have applications in pharmaceuticals, food, chemical industries, animal feed, and energy generation.
Starches are broadly classified as natural or modified. Natural starches are obtained from sources such as maize, wheat, rice, sorghum, potato, tapioca, arrowroot, and sago, while modified starches are produced by chemical or enzymatic treatment. The Indian starch industry uses maize and tapioca as its principal raw materials, supported by chemicals such as hydrochloric acid, sulphuric acid, soda ash, sulphur, and activated carbon.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 250 MT/Day |
| Land & Building (40,000 sq.mt.) | Rs. 5.18 Cr |
| Plant & Machinery | Rs. 49.26 Cr |
| Working Capital for 2 Months | Rs. 21.17 Cr |
| Total Capital Investment | Rs. 76.05 Cr |
| Rate of Return | 64% |
| Break Even Point | 31% |
Content Index
- INTRODUCTION
- PRODUCT DESCRIPTION AND USE
- ECONOMIC SIZE UNIT AND PRODUCTION PATTERN
- PROPERTIES
- MARKET SURVEY
- NAME AND ADDRESS OF MANUFACTURERS OF LIQUID GLUCOSE
- DEXTROSE - AN ASSESSMENT OF MARKET
- ESTIMATED DEMAND FOR DEXTROSE
- LIST OF MANUFACTURERS OF RAW MATERIAL-DEXTROSE
- SPECIFICATION
- INDIAN STANDARDS
- SPECIFICATIONS
- MANUFACTURES OF STARCH AND ALLIED PRODUCTS
- PROCESS DESCRIPTION
- PROCESS FLOW DIAGRAM FOR THE MFG. OF STARCH
- RAW MATERIALS AND UTILITIES
- MANUFACTURING PROCESS FOR LIQUID GLUCOSE-G
- MANUFACTURE OF DEXTROSE MONOHYDRATE AND DEXTROSE ANHYDROUS
- MANUFACTURING DIAGRAM OF LIQUID GLUCOSE
- MANUFACTURING DIAGRAM OF ANHYDROUS DEXTROSE
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF PLANT & MACHINERY
- PLANT AND MACHINERY
- IMPLEMENTATION SCHEDULE
- LIST OF FOOD AND AGRO PROCESSING CONSULTANTS
- MANUAL ON STANDARDS OF MAIZE
- PLANT ECONOMICS
- PLANT & MACHINERY
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
The principal raw materials used in the Indian starch industry are maize and tapioca. Maize is the major input for many Indian starch manufacturing operations because its kernel contains a substantial proportion of starch and can be efficiently processed through wet milling. Tapioca is another important starch source, particularly for manufacturers using cassava-based processes. The report also identifies chemicals including hydrochloric acid, sulphuric acid, soda ash, sulphur, and activated carbon as important materials used by the starch industry.
Maize starch is generally manufactured through a wet milling process that separates the starch from other components of the maize kernel. The grain is thoroughly washed and softened or steeped before grinding. The ground material is then processed to separate germ, gluten, fiber or husk, and starch. Starch recovery involves separation and purification, followed by dewatering and drying of the final product. Valuable by-products are also recovered during processing, including corn oil, gluten, steep liquor, and husk.
The major types of starch are natural starch and modified starch. Natural, or unmodified, starch is obtained directly from plant sources such as maize, wheat, rice, sorghum, potato, tapioca, arrowroot, and sago. Modified starch is produced by changing the characteristics of natural starch through chemical or enzymatic treatment. The report identifies several modified starch products, including dextrin, acid-modified starches, oxidized starches, starch esters, starch ethers, dialdehyde starches, and cationic starches.
The principal by-products of maize-based starch processing include maize steep liquor, corn oil, maize oil cake, maize gluten, and maize husk. Steep liquor contains amino acids and proteins and can be used by antibiotic manufacturers and for biogas generation. Corn oil has food and chemical applications, while oil cake can be used as cattle and poultry feed. Maize gluten is valued for its protein content and is also used as animal feed. Husk containing residual starch, protein, and fat is mainly consumed as cattle feed.
Wet milling is the principal commercial process used to recover starch from cereal grains such as maize, wheat, rice, and sorghum. The process begins with thorough washing and softening or steeping of the grain, followed by grinding. The resulting material undergoes separation, including tabling or centrifugation, to recover starch and other components. The recovered starch is subsequently dewatered and dried. The process also emphasizes recovery of commercially useful by-products, improving the overall utilization of the raw material.
Maize-derived products have applications across food, pharmaceutical, chemical, animal feed, paper, textile, and energy-related industries. Maize starch is an important industrial raw material, while corn oil is used in food and chemical applications. Maize gluten and oil cake are used as cattle and poultry feed. Maize steep liquor can supply amino acids and proteins for industrial applications and can also contribute to biogas generation. These diverse uses make maize an important raw material for integrated starch processing operations.
Tapioca is an important starch source because cassava roots contain a significant amount of recoverable starch and are widely cultivated in tropical regions. The report identifies tapioca, also known as cassava or manioc, as one of the major sources of starch and notes that bitter and sweet varieties are widely cultivated. The bitter variety is generally preferred for starch manufacture because of its higher starch content. Tapioca therefore provides an alternative raw material base for starch manufacturing alongside cereal sources such as maize and wheat.
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