Industry Overview
Starch is an abundant carbohydrate found throughout the plant kingdom and has long been an important component of the human diet as well as a major industrial raw material. Commercial starch is primarily recovered from sources such as wheat, maize and tapioca, with maize being the principal raw material consumed by the Indian starch industry. Some Indian starch industries are also based on tapioca.
Maize contains about 70% starch along with protein, fibre and fat. Maize starch is generally produced through wet milling, in which softened maize is ground and separated into germ, gluten, fibre and purified starch. The resulting by-products, including steep liquor, germ oil and germ cake, gluten and husk, have applications in pharmaceuticals, animal feed, food and chemical industries, as well as energy generation.
Starches are broadly classified into natural and modified varieties. Natural starches are obtained from cereals, roots and tubers such as maize, wheat, rice, sorghum, potato, tapioca, arrowroot and sago. Modified starches are produced by chemical or enzymatic treatment of natural starch and include dextrins, acid-modified, oxidized, ester, ether, aldehyde and cationic starches. The report covers raw materials, starch specifications, applications, maize wet milling, liquid glucose, dextrose, modified starches, market conditions, manufacturing processes, machinery, utilities, suppliers and project economics.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 60 MT/Day |
| Land & Building (16,000 sq.mt.) | Rs. 10.17 Cr |
| Plant & Machinery | Rs. 19.60 Cr |
| Working Capital for 2 Months | Rs. 6.47 Cr |
| Total Capital Investment | Rs. 37.49 Cr |
| Rate of Return | 16% |
| Break Even Point | 67% |
Content Index
- INTRODUCTION
- STARCH INDUSTRY IN INDIA
- BYPRODUCTS FROM MAIZE
- 1.0 STARCHES
- 1.1 NATURAL STARCHES
- 1.1 NATURAL STARCHES
- 1.3 CEREAL STARCHES
- 1.4 RAW MATERIALS
- 1.4.1 MAIZE
- SPECIFICATION OF STARCH
- MAIZE STARCH SPECIFICATION
- USES OF STARCH:
- A) TEXTILE INDUSTRY:
- B) FOOD INDUSTRY:
- C) PAPER INDUSTRY:
- D) PHARMACEUTICAL INDUSTRY:
- E) MANUFACTURE OF GLUCOSE AND DEXTROSE BY HYDROLYSIS:
- F) MANUFACTURE OF MODIFIED STARCHES, SUCH AS:
- G) MISCELLANEOUS OTHER USES :
- A) CONCENTRATED STEEP LIQUOR:
- B) GERM OIL AND GERM AND CAKE:
- C) GLUTEN:
- PHYSICAL AND CHEMICAL MODIFICATION OF STARCH
- COMPONENT OF YELLOW DENT CORN
- ECONOMIC SIZE UNIT AND PRODUCTION PATTERN
- PHASED PRODUCTION PROGRAMME
- USES OF LIQUID GLUCOSE
- LIQUID GLUCOSE SYRUP USES AND APPLICATIONS:
- LIQUID GLUCOSE USES
- USES OF DEXTROSE
- CONSTITUENTS AND VARIETY OF MAIZE
- PROPERTIES
- PROPERTIES OF STARCH
- PHYSICAL PROPERTIES
- CHEMICAL PROPERTIES
- STARCH GIVES A CHARACTERISTIC BLUE COLOR WITH IODINE.
- OVERVIEW OF CORN WET MILLING
- OVERVIEW OF MAIZE IN INDIA
- MAIZE PRICE OUTLOOK
- MARKET OVERVIEW
- CONSUMPTION PATTERN OF MAIZE IN INDIA
- IMPORT & EXPORT DATA OF MAIZE STARCH
- STARCH INDUSTRY IN INDIA: SUPPLY AND DEMAND SCENARIO
- SUPPLY
- DEMAND
- DETAILED EXPORT DATA OF CORN STARCH
- DETAILED EXPORT DATA OF LIQUID GLUCOSE
- DETAILED EXPORT DATA OF CORN OIL
- MANUFACTURERS/SUPPLIERS
- MAIZE STARCH
- LIQUID GLUCOSE
- SPECIFICATION
- CORN WET MILLING
- SEQUENCES IN CORN WET MILLING
- PROCESSING STEPS
- CLEANING
- STEEPING
- MILLING & SEPARATION
- FINE GRINDING AND SCREENING
- SEPARATION OF STARCH AND GLUTEN
- PROCESS FLOW DIAGRAM OF WET CORN MILLING PROCESSES
- MANUFACTURING PROCESS OF LIQUID GLUCOSE
- PROCESSING DETAILS OF MAIZE STARCH
- RECEIVING
- CLEANING
- STEEPING
- GRINDING
- GERM SEPARATION (DEGERMINATION)
- FIBRE WASHING SECTION
- THICKENING
- PRIMARY SEPARATION
- GLUTEN THICKENING
- ROTARY VACUUM FILTER
- HYDROCLONE SYSTEM
- DRYING
- MANUFACTURES OF STARCH AND ALLIED PRODUCTS
- MAIZE STARCH
- AMYLOSE MOLECULE OF STARCH
- TABLE NO.2.1
- AMYLOPECTIN MOLECULE
- DETAILS OF CORN WET MILLING
- PROCESS DESCRIPTION
- 5.1 CLEANING AND SOAKING
- 5.2 STEEP LIQUOR CONCENTRATION
- 5.3 CRUDE GEM OIL RECOVERY
- 5.4 FIBRE SEPARATION
- 5.5 GLUTEN SEPARATION AND CONCENTRATION
- 5.6 MIXED FEED PROCESSING
- 5.7 STARCH WASHING DEWATERING AND DRYING
- PROCESS FLOW DIAGRAM FOR THE MFG. OF STARCH
- MANUFACTURE OF CORN SYRUP
- MANUFACTURE OF HIGH FRUCTOSE CORN SYRUP
- PROCESS FLOW DIAGRAM OF FRUCTOSE SYRUP
- RAW MATERIALS AND UTILITIES
- RAW MATERIALS
- A) CORN:
- B) CLASSES:
- I) YELLOW CORN:
- II) MIXED CORN:
- SPECIAL GRADES FOR CORN:
- A) FLINT CORN:
- B) FLINT AND DENT CORN:
- C) WEEVILY CORN:
- MAIZE PROCESSING PROCESS SHEET
- MANUFACTURING PROCESS FOR LIQUID GLUCOSE
- RAW MATERIALS
- CONFECTIONERI GLUCOSE-D:
- LOW CONVERSION:
- REGULAR CONVERSION
- INTERMIDIATE CONVERSION
- HIGH CONVERSION
- MANUFACTURE OF DEXTROSE MONOHYDRATE & DEXTROSE ANHYDROUS
- DEXTROSE MANUFACTURE
- MANUFACTURING DIAGRAM OF LIQUID GLUCOSE
- MANUFACTURING DIAGRAM OF ANHYDROUS DEXTROSE
- MAIZE STARCH
- APPLICATIONS
- LIQUID GLUCOSE
- APPLICATIONS
- MALTODEXTRIN
- DEXTROSE MONOHYDRATE
- MAIZE GLUTEN
- MAIZE GERM
- APPLICATIONS
- SORBITOL
- APPLICATIONS:
- COSMETICS:
- FOOD INDUSTRY:
- PHARMACEUTICAL INDUSTRY:
- TOBACCO INDUSTRY:
- TEXTILE INDUSTRY:
- PAPER INDUSTRY:
- PAINT INDUSTRY:
- SUPPLIERS OF PLANT AND MACHINERY
- CENTRIFUGE
- HEAT EXCHANGER
- LAB TESTING EQUIPMENT
- BOILERS
- SUPPLIERS OF RAW MATERIALS
- CORN/MAIZE
- SULPHUR
- SULPHURIC ACID
- CAUSTIC SODA
- SODA ASH
- PLANT & MACHINERY SECTION WISE
- LIST OF MACHINERY AND EQUIPMENT
- 1. MAIZE STEEPING
- 3. DEGERMINATION AND GERM WASHING
- 4. FIBRE MILLING AND WASHING
- 6. GLUTEN CONCENTRATION
- 7. GERM DEWATERING AND DRYING
- 8. STEEPING WATER CONCENTRATION
- 10. DRYER FOR ANIMAL FEED
- 11. STARCH DEWATERING AND DRYING
- 12. SORBITOAL AND MALTODEXTRIN MANUFACTURING SECTION
- B. HANDLING/HOLDING & STORAGE EQUIPMENTS
- LAB TESTING EQUIPMENT
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 by the Indian starch industry are maize and tapioca. Maize is particularly important because its kernel contains a high proportion of starch and can be processed into starch along with several commercially useful by-products. Tapioca is also used as a starch source by some industries. The selection of raw material depends on availability, quality requirements, processing technology and the intended end applications of the starch and associated products.
Maize starch is commonly manufactured through a wet milling process that separates the maize kernel into its principal components. The process generally involves receiving and cleaning the grain, steeping, grinding, germ separation, fibre washing, gluten separation, starch washing, dewatering and drying. Hydrocyclone systems, centrifuges and filtration equipment may be used for separation and purification. The process also enables recovery of valuable co-products such as germ, gluten, fibre and steep liquor.
Starch is used across food, textile, paper and pharmaceutical industries and also serves as a raw material for several downstream products. In food applications, it can contribute to texture, thickening and formulation. Textile and paper processing use starch for functional and finishing purposes, while pharmaceutical applications use starch as an excipient and processing aid. Starch can also be hydrolysed to manufacture products such as glucose and dextrose and can be chemically or enzymatically modified for specialised industrial applications.
Maize wet milling produces several useful by-products in addition to starch. These include maize steep liquor, germ and germ-derived oil and cake, gluten and fibre-rich husk fractions. Steep liquor contains amino acids and proteins and can have industrial applications, while germ is processed for oil and the resulting cake can be used in animal feed. Gluten is valued for its protein content, and fibre-containing fractions can also be incorporated into feed products. Effective by-product recovery can therefore form an important part of an integrated maize processing operation.
Natural starch is obtained from plant sources without deliberately changing its basic starch structure, whereas modified starch is treated to alter its functional properties. Natural starches are sourced from cereals, roots, tubers and other plants, including maize, wheat, rice, potato and tapioca. Modification may involve chemical or enzymatic treatment to improve properties such as stability, viscosity, processing performance or suitability for particular applications. The report identifies dextrins, acid-modified, oxidized, ester, ether, aldehyde and cationic starches among modified starch categories.
A maize starch plant requires equipment covering grain preparation, separation, concentration, drying, storage and quality control. The report includes maize steeping, degermination and germ washing, fibre milling and washing, gluten concentration, germ dewatering and drying, steeping-water concentration, animal-feed drying, and starch dewatering and drying sections. Handling and storage equipment and laboratory testing equipment are also included. Depending on the process configuration, centrifuges, heat exchangers, hydroclone systems, rotary vacuum filters and boilers may form part of the plant infrastructure.
Maize starch can serve as a feedstock for several downstream products, including liquid glucose, dextrose, maltodextrin, modified starches and related carbohydrate products. The report also covers corn syrup, high fructose corn syrup, dextrose monohydrate, anhydrous dextrose and sorbitol. These products have applications in sectors such as food, pharmaceuticals, cosmetics, textiles, paper and other industries. The choice of downstream product depends on processing technology, product specifications, available raw materials and the requirements of the intended market.
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