Industry Overview
Starch is an abundant carbohydrate found throughout the plant kingdom and has been an important component of the human diet for centuries. It is also a major industrial raw material. Industrial starch can be recovered from seeds, roots, and tubers, although commercial starch production is concentrated mainly on wheat, maize, and tapioca. In India, maize is the principal raw material used by the starch industry, with some industries also based on tapioca.
Maize contains about 70% starch, with protein, fiber, and fat making up other major components. The wet milling process separates the maize kernel into starch and valuable by-products, including germ, gluten, fiber, and steep liquor. Maize starch has applications across the food, textile, paper, pharmaceutical, and other industries, while its by-products are used in animal feed, food and chemical products, and industrial applications.
Industrially, 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. Modified starches are produced by chemical or enzymatic treatment to alter the characteristics of natural starch. Cereal starches are predominantly recovered through wet milling, which involves grain steeping, milling, separation, dewatering, drying, and recovery of important by-products.
Cost Estimation
| Particular | Value |
|---|---|
| Plant Capacity | 150 MT/Day |
| Land & Building (40,000 sq.mt.) | Rs. 33.04 Cr |
| Plant & Machinery | Rs. 63.40 Cr |
| Working Capital for 2 Months | Rs. 18.69 Cr |
| Total Capital Investment | Rs. 117.50 Cr |
| Rate of Return | 27% |
| Break Even Point | 53% |
Content Index
- INTRODUCTION
- STARCH INDUSTRY IN INDIA
- BYPRODUCTS FROM MAIZE
- STARCHES
- NATURAL STARCHES
- CEREAL STARCHES
- OVERVIEW OF MAIZE IN INDIA
- FIGURE: PERCENTAGE SHARE OF MAJOR PRODUCING COUNTRIES IN WORLD MAIZE PRODUCTION
- TABLE: INDIAN EXPORTS AND IMPORTS OF MAIZE
- FIGURE: PERCENTAGE OF EXPORT SHARE TO PRODUCTION OF MAIZE.
- TABLE: BALANCE SHEET OF MAIZE
- TABLE: CONSUMPTION BREAKUP
- TABLE: AREA AND PRODUCTION OF MAJOR PRODUCING STATES OF MAIZE (AREA- LAKH HA, PRODUCTION-LAKH TONNES)
- TABLE: AREA AND PRODUCTION OF MAJOR MAIZE GROWING DISTRICTS OF ANDHRA PRADESH
- TABLE: GROWTH PARAMETERS OF MAIZE BEFORE AND AFTER BIFURCATION OF ANDHRA PRADESH
- TABLE: SEASONAL INDICES OF ARRIVALS AND PRICES OF MAIZE IN KURNOOL MARKET
- FIGURE: TRENDS IN ARRIVALS AND PRICES OF MAIZE KURNOOL MARKET
- FIGURE: AVERAGE MONTHLY PRICES OF MAIZE IN KURNOOL MARKET
- FEATURES AND APPLICATION OF LIQUID GLUCOSE
- APPLICATIONS OF LIQUID GLUCOSE
- SWEETENER:
- PHARMACEUTICAL:
- SPECIFICATION
- HANDLING AND STORAGE
- 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
- COMPONENTS OF YELLOW DENT CORN
- MARKET OVERVIEW OF MAIZE STARCH
- ECONOMIC SIZE UNIT AND PRODUCTION PATTERN
- FOLLOWING THE AVERAGE ANALYSIS OF MAIZE IN INDIA:
- PHASED PRODUCTION PROGRAMME
- USES OF LIQUID GLUCOSE:-
- LIQUID GLUCOSE SYRUP USES AND APPLICATIONS:
- IN CONFECTIONERY:
- LIQUID GLUCOSE USES
- OTHER FOODS:
- BAKERY PRODUCTS:
- IN ICE CREAMS:
- PHARMACEUTICALS:
- IN TOBACCO:
- IN LEATHER PRODUCTS:
- OTHER USES:
- USES OF DEXTROSE:-
- CONSTITUENTS AND VARIETY OF MAIZE
- PROPERTIES OF LIQUID GLUCOSE
- PROPERTIES OF STARCH
- PHYSICAL PROPERTIES
- CHEMICAL PROPERTIES
- STARCH GIVES A CHARACTERISTIC BLUE COLOR WITH IODINE.
- CORN AND CORN OIL
- A. PARTS OF CORN KERNEL, B. NUTRIENT COMPOSITION OF CORN KERNELS
- CORN OIL VALUE
- OVERVIEW OF CORN WET MILLING
- CORN-WET MILLING MARKET – NOTABLE DEVELOPMENTS
- CORN-WET MILLING MARKET DYNAMICS
- CONSUMPTION PATTERN OF MAIZE IN INDIA
- SEGMENT WISE CONSUMPTION OF MAIZE IN INDIA
- STARCH INDUSTRY IN INDIA: SUPPLY AND DEMAND SCENARIO
- MANUFACTURERS/SUPPLIERS
- MAIZE STARCH
- LIQUID GLUCOSE
- SPECIFICATION
- REQUIREMENT FOR MAIZE, TAPIOCA & ARROW ROOT STARCHES, EDIBLE GRADE*
- REQUIREMENTS FOR MAIZE AND TAPIOCA STARCHES FOR USE IN COTTON TEXTILE INDUSTRY*
- REQUIREMENTS OF TAMARIND STARCH FOR USE IN COTTON TEXTILE AND JUTE INDUSTRIES*
- SEQUENCES IN STARCH AND LIQUID GLUCOSE
- IT CONSISTS OF FOLLOWING STEPS:-
- MIXING AND LIQUEFYING PROCESS:
- SACCHARIFY:
- LIQUID GLUCOSE DECOLORIZING:
- FILTRATION:
- ION EXCHANGE SYSTEM:
- LIQUID GLUCOSE EVAPORATION:
- PROCESS DESCRIPTION OF CORN STARCH
- 1. CORN CLEANING AND STEEPING
- 2. MILLING, GERM SEPARATION AND DRYING
- 3. GRIT MILLING AND FIBER WASHING
- 4. STARCH AND GLUTEN SEPARATION AND STARCH WASHING
- 5. GLUTEN DEWATERING AND DRYING
- 6. STARCH DEWATERING AND DRYING
- METHODS OF MAIZE PROCESSING
- MAIZE IS USUALLY PROCESSED BY TWO PROCESSES:
- DRY MILLING PROCESS FLOW
- WET MILLING PROCESS FLOW
- STARCH MANUFACTURING PROCESS FLOW DIAGRAM
- DETAILS OF CORN WET MILLING
- VARIOUS USES OF CORN
- MAIZE STARCH MANUFACTURING
- CLEANING:
- STEEPING:
- WET MILLING:
- GERM SEPARATION:
- MILLING (FINE GRINDING):
- STARCH GLUTEN SEPARATION
- STARCH REFINING
- DRYING:
- MODIFICATION
- MANY TECHNIQUES ARE APPLIED FOR MODIFICATION FOR EXAMPLE:
- MAIZE STARCH PRODUCTION TECHNOLOGY
- MAIZE STARCH PROCESSING TECHNOLOGY
- MAIZE CLEANING
- MAIZE SOAKING
- MAIZE COARSE CRUSHING
- GERM SEPARATION
- MAIZE GRINDING
- MAIZE STARCH SIEVING
- PROTEIN SEPARATION AND MAIZE STARCH CLEANING
- CENTRIFUGAL SEPARATION AND DRYING
- 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
- LIQUID GLUCOSE MANUFACTURE
- SEQUENCES IN MAIZE STARCH
- CORN STARCH PRODUCTION
- PRODUCTION OF STARCH SLURRY
- PRODUCTION OF STARCH SLURRY
- PRODUCTION OF STARCH AND DEXTRINS:
- PRODUCTION OF STARCH
- 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
- PROCESS DESCRIPTION OF CORN WET MILLING
- CLEANING AND SOAKING
- STEEP LIQUOR CONCENTRATION
- CRUDE GEM OIL RECOVERY
- FIBRE SEPARATION
- GLUTEN SEPARATION AND CONCENTRATION
- MIXED FEED PROCESSING
- STARCH WASHING DEWATERING AND DRYING
- 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:
- MANUFACTURE OF DEXTROSE MONOHYDRATE & DEXTROSE ANHYDROUS
- DEXTROSE MANUFACTURE
- MANUFACTURING DIAGRAM OF LIQUID GLUCOSE
- MANUFACTURING DIAGRAM OF ANHYDROUS DEXTROSE
- MAIZE STARCH AND ALLIED PRODUCTS AND THEIR APPLICATIONS
- 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:
- TURNKEY SUPPLIERS OF STARCH AND ALLIED PRODUCTS
- SUPPLIERS OF PLANT AND MACHINERY
- SUPPLIERS OF CENTRIFUGE
- SUPPLIERS OF HEAT EXCHANGER
- SUPPLIERS OF LAB TESTING EQUIPMENT
- SUPPLIERS OF BOILERS
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF CORN/MAIZE
- SUPPLIERS OF SULPHUR
- SUPPLIERS OF SULPHURIC ACID
- SUPPLIERS OF CAUSTIC SODA
- SUPPLIERS OF SODA ASH
- 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
Maize starch manufacturing is the industrial recovery and purification of starch from maize kernels.
The process generally uses wet milling, in which cleaned and softened maize is ground and separated into its principal components, including germ, fiber, gluten, and starch. The starch fraction is subsequently refined, dewatered, and dried. The process also enables recovery of useful by-products such as corn oil from the germ, gluten, fiber, and steep liquor. These co-products can provide additional industrial or feed applications and form an important part of an integrated maize-processing operation.
The wet milling process separates maize into starch and other valuable kernel components through controlled washing, steeping, grinding, and separation.
Typical operations include corn cleaning and steeping, milling and germ separation, fine grinding and fiber washing, starch and gluten separation, starch washing, dewatering, and drying. The sequence is designed to recover a relatively pure starch fraction while also separating germ, gluten, fiber, and steep liquor. Process configuration and equipment selection depend on the desired product specifications, raw material quality, plant scale, and required co-product recovery.
Maize starch is used in food, textile, paper, pharmaceutical, and several other industries.
In food applications, starch can contribute to texture, thickening, and processing characteristics. Textile applications use starch-based materials for processing and finishing, while the paper industry uses starch in various stages of paper manufacture. Pharmaceutical applications can use starch as a functional ingredient or excipient. The report also identifies starch as a raw material for producing glucose and dextrose and for manufacturing modified starches with properties tailored to specific industrial requirements.
The major by-products of maize wet milling include steep liquor, germ, gluten, and fiber or husk.
Maize steep liquor contains amino acids and proteins and can have industrial applications. The germ is a source of corn oil, while the resulting oil cake can be used in animal feed. Maize gluten has a high protein content and is also used as cattle and poultry feed. The fiber or husk fraction contains smaller quantities of starch, protein, and fat and is mainly used as feed. Efficient recovery of these streams can improve overall resource utilization within a maize-processing plant.
Natural starch is obtained from plant sources in its native form, while modified starch is processed to change its functional characteristics.
Natural starches can be produced from grains such as maize, wheat, rice, and sorghum, or roots and other plant sources such as potato, tapioca, arrowroot, and sago. Modification may involve chemical or enzymatic treatment to obtain properties suited to particular applications. The report identifies several modified starch categories, including dextrins, acid-modified starches, oxidized starches, starch esters, starch ethers, aldehyde starches, and cationic starches.
Maize or corn is the principal raw material used for the maize starch plant described in the report.
The report discusses different classes and grades of corn, including yellow corn, mixed corn, flint corn, flint and dent corn, and weevily corn. Raw material selection is important because kernel characteristics and quality influence processing performance and product recovery. A commercial plant must also consider consistent supply, cleanliness, moisture and quality characteristics, storage requirements, and suitability for the intended starch and allied-product specifications.
Maize starch processing can produce starch along with several allied products and derivatives.
The report covers maize starch, liquid glucose, maltodextrin, dextrose monohydrate, maize gluten, maize germ, sorbitol, and other related products. It also discusses liquid glucose and dextrose manufacture through downstream processing of starch. Depending on the plant configuration, the operation may therefore combine starch production with recovery or manufacture of additional products. The suitability of each product depends on process design, equipment, raw material quality, required specifications, and the intended market.
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