Detailed Project Report (DPR) on maize & by-products processing plant

MAIZE & BY-PRODUCTS PROCESSING PLANT 

[CODE NO.4185] 

Starch Industry in India

 Starch is an abundant carbohydrate distributed worldwide in plants. Starch has been a major ingredient in man's diet over the centuries. In addition it has become a major industrial raw material. Plant seeds, roots and tubers are all sources of industrial starch production. The commercial realities of the starch recovery process limit the industrial sources mainly to wheat, maize and tapioca. Indian starch industry mainly consumes maize as input raw material. 

Also some industries are tapioca based.

Maize is doing wonderful things in our everyday life. Maize is present in one form or other in  

The Food we eat 

The Milk we drink

The Chocolates/Biscuits we take

The Clothes we wear

The Paper we read

The Medicines we take

Maize (Corn) contains about 70% starch, other components being protein, fibers and fat. The basis of the maize milling process is the separation of the maize kernel into its different parts. Maize starch is produced by the wet milling process, which involves grinding of softened maize and separation of corn oil seeds (germs), gluten (proteins), fibers (husk) and finally pure starch.  

Y PRODUCTS FROM MAIZE

The byproducts from maize based industries find various applications:

i. Maize (Corn) Steep Liquor: It contains amino acids, proteins and is used by antibiotics drugs manufacturers. Also it is a large source of biogas, which is being used as fuel for driers, boilers etc.

ii. Maize Gum: Corn Oil is produced by expelling oil from the germs. Corn Oil finds applications in food and other chemical industries. Maize oil cake obtained after expelling oil is used as cattle and poultry feeds.

iii. Maize Gluten: Maize Gluten contains high protein content and it is used as cattle and poultry feeds.

iv. Maize Husk: It contains starch, protein and fat as minor components and mainly consumed as cattle feed.

1.0 Starches

Starch is a group of polysaccharides, composed of glucopyranose units joined together by-glucosidric linkages. It conforms to the molecular formula, (C6-H10O5)u, where  n varies from a few hundred to over one million. Starch is found as the reserve carbohydrate in various parts of plants and is enzymatic ally broken down to glucose to other carbohydrates according to the metabolic needs of the plants.

Industrially, starch is broadly divided into two types viz, natural and modified. Natural starches also designated as unmodified starches or simply starches are obtained from grains such as and sorghum. From roots like potato, tapioca and arrow root, and from the pith of the stems of certain palms such as ago. They are further classified into cereal starches and root starches. The characteristics of the natural starches are changed by chemical or enzymatic action and the products of these reactions are termed modified starches. This group includes dextrin, acid-modified starches, oxidized starches, starch esters, starch ethers, di-aldehyde starches, and cationic starches.

1.1 Natural Starches

Starch occurs naturally in the plants and its percentage varies with the plant and also in different parts of the same plant. Corn (maize) sorghum grain wheat, rice, potato, tapioca, arrowroot and sago are among the important sources of natural starches. The grains of barley, rye, oat, and the millets are also employed in the production of starches.

1.1 Natural Starches

Starch occurs naturally in the plants and its percentage varies with the plant and also in different parts of the same plant. Corn (maize) sorghum grain wheat, rice, potato, tapioca, arrowroot and sago are among the important sources of natural starches. The grains of barley, rye, oat and the millets are also employed in the production of starches.

1.2 Tapioca

The roots of tapioca plant (manihot utillissimax) from one of the major sources of starch, ranking next to potato in the commotion by starch industry. Tapioca plant, also known as cassava and manioc, thrives in equatorial regions between the Topic of Capricorn. There are as many as seventy five varieties of cassava plant of which two varieties viz., bitter and sweet are widely cultivated; the bitter is usually grown for the purposes if the manufacture of starch, as it contains a higher content of starch. The starch content of the plant varies between 12 and 33 per cent. The ratio of the percentage of any lase to amylopection has been found to be 16:84. More than hal of the total world  arreage under tge cultivation of cassava is confined to the African countries such as Gambia, Ghana, Kenya, Mauritius, Nigeria, Zambia, Nyasaland, Sierra Leone and Zanzibar and the rest  come from the tropical regions of other continents.

1.3 Cereal Starches 

The cereal starches such as maize wheat, rice and sorghum, are recovered by several processes of which the wet-milling is by far the most important. Other processes commercially employed in the manufacture of unmodified starches are that alkali, Martin and batter in the order of decreasing importance. Of the material methods earlier used for the production of starch and which has now become obsolete mention may be made of the Hakka, Alsation and Fescas processes. In all the above processes, Starch is recovered in five stages:

a) Softening or steeping of the grains, after thorough washing in water.

b) Tabling or centrifugation of the ground mass.

c) Dewatering and drying of the final products.

d) The recovery of important by products.

1.4 Raw Materials 

The principal raw materials, used by the Indian Starch Industry are maize and tapioca.

1.4.1 Maize

Maize is grown in Uttar Pradesh, Bihar, Rajasthan, Punjab, Madhya Pradesh, Himachal Pradesh, Gujarat, Jammu and Kashmir, Andhra Pradesh, Mysore, and Haryana.

1.4.2 Chemicals

The important chemicals used by the starch industry are hydrochloric acid, sulphuric acid, soda ash, sulphur and activated carbon and all these are manufactured in the country

1.4.3 Tamarind Seed

Tamarind trees (Tamarindus indica) are found natur alized almost throughout the plains and sub- Himalayan tracts of India. The pulp of tamarind fruits, known as imli, is used as an acid flavoring agent. The seeds constitute 34 percent starch of the fruits and contain on an average 60 percent starch, Statistical information on the annual production of fruit pulp and seeds is not available.

COST ESTIMATION

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%

• 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 – 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)