![Detailed Project Report (DPR) on maize processing [wet milling] starch, corn oil, corn syrup, dextrose monohydrate, dextrin, maltodextrin, maize germ, sorbitol, high fructose corn syrup, gluten, fiber etc.](https://www.eiriindia.org/image/project-report/detailed-project-report-cma-data.png)
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 used across food, textile, paper, pharmaceutical and other industries. Commercial starch production primarily uses wheat, maize and tapioca, with maize being the principal raw material consumed by the Indian starch industry, while some manufacturers use tapioca-based processes.
Maize contains about 70% starch along with protein, fiber and fat. Maize starch is commercially produced through wet milling, in which softened maize is ground and separated into its principal components, including germ, gluten, fiber and purified starch. The process also generates valuable byproducts such as maize steep liquor, germ and corn oil, gluten and husk, which have applications in animal feed, food, chemical and pharmaceutical industries and, in some cases, biogas production.
Industrial starches are broadly classified as natural or modified starches. Natural starches are obtained from grains, roots, tubers and certain palm stems, while modified starches are produced by chemical or enzymatic treatment of natural starch. The report covers maize starch manufacturing, wet milling technology, allied products such as liquid glucose, dextrose, sorbitol and maltodextrin, applications, raw materials, plant and machinery, market information, suppliers and project economics.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 300 MT/Day |
| Land & Building (100000 sq.mt.) | Rs.46.10 Cr |
| Plant & Machinery | Rs. 50.60 Cr |
| Working Capital for 1 Month | Rs.20.11 Cr |
| Total Capital Investment | Rs. 120 Cr |
| Rate of Return | 24% |
| Break Even Point | 56% |
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
- 2.2 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:
- 2.2.2 IN ADDITION TO THESE USES, BY PRODUCTS OF STARCH ARE ALSO OBTAINED DURING THE WET MILLING OF MAIZE.
- 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
- FOLLOWING THE AVERAGE ANALYSIS OF MAIZE IN INDIA:
- PHASED PRODUCTION PROGRAMME
- USES OF LIQUID GLUCOSE:-
- LIQUID GLUCOSE SYRUP USES AND APPLICATIONS:
- LIQUID GLUCOSE USES
- USES OF DEXTROSE:-
- MAIZE SCENARIO IN INDIA
- 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
- BASED ON CORN TYPE, THE CORN WET-MILLING MARKET IS SEGMENTED INTO THE FOLLOWING:
- BASED ON EQUIPMENT, THE CORN WET-MILLING MARKET IS SEGMENTED INTO THE FOLLOWING:
- BASED ON APPLICATION, THE CORN WET-MILLING MARKET IS SEGMENTED INTO THE FOLLOWING:
- BASED ON END PRODUCTS, THE CORN WET-MILLING MARKET IS SEGMENTED INTO THE FOLLOWING:
- OVERVIEW OF MAIZE IN INDIA
- INTERNATIONAL GRAIN COUNCIL’S WORLD CORN PROJECTIONS (IN MILLION METRIC TONNES)
- INTERNATIONAL GRAIN COUNCIL’S INDIAN CORN PROJECTIONS (IN MILLION METRIC TONNES)
- MONTH-WISE AVERAGE PRICES OF MAIZE AT VARIOUS MARKETS
- MAIZE ARRIVALS AND PRICES IN KESAMUDRAM MARKET FOR THE MONTH OF MARCH 2019
- MAIZE PRICE OUTLOOK
- CORN WET MILLING MARKET OVERVIEW
- CORN-WET MILLING MARKET DYNAMICS
- SEGMENTATION OF CORN-WET MILLING MARKET
- ON THE BASIS OF EQUIPMENT, THE CORN WET-MILLING MARKET IS CATEGORIZED INTO,
- ON THE BASIS OF TYPE, THE CORN WET-MILLING MARKET IS SEGMENTED INTO,
- ON THE BASIS OF APPLICATION, THE CORN WET-MILLING MARKET IS CATEGORIZED INTO,
- ON THE BASIS OF END PRODUCTS, THE CORN WET-MILLING MARKET IS SEGMENTED INTO,
- MARKET OVERVIEW
- CONSUMPTION PATTERN OF MAIZE IN INDIA
- SEGMENT WISE CONSUMPTION OF MAIZE IN INDIA
- IMPORT & EXPORT DATA OF MAIZE STARCH
- STARCH INDUSTRY IN INDIA: SUPPLY AND DEMAND SCENARIO
- SUPPLY
- DEMAND
- MANUFACTURERS/SUPPLIERS
- MAIZE STARCH
- LIQUID GLUCOSE
- SPECIFICATION
- REQUIREMENT FOR MAIZE, TAPIOCA & ARROW ROOT STARCHES, EDIBLE GRADE*
- TABLE III REQUIREMENTS FOR MAIZE AND TAPIOCA STARCHES FOR USE IN COTTON TEXTILE INDUSTRY*
- REQUIREMENTS OF TAMARIND STARCH FOR USE IN COTTON TEXTILE AND JUTE INDUSTRIES*
- METHOD OF MAIZE PROCESSING
- MAIZE IS USUALLY PROCESSED BY TWO PROCESSES:
- DRY MILLING PROCESS FLOW
- WET MILLING PROCESS FLOW
- STARCH MANUFACTURING PROCESS FLOW DIAGRAM
- CORN WET MILLING
- VARIOUS USES OF CORN
- CORN WET MILLING PROCESS FLOW DIAGRAM.
- SEQUENCES IN WET MILLING OF CORN
- THE DIFFERENT STEPS INVOLVED IN THE WET MILLING ARE PRESENTED BELOW.
- RECEIVING
- CLEANING
- STEEPING
- GRINDING
- GERM SEPARATION (DEGERMINATION)
- FIBRE WASHING SECTION
- THICKENING
- PRIMARY SEPARATION
- GLUTEN THICKENING
- ROTARY VACUUM FILTER
- HYDROCLONE SYSTEM
- DRYING
- DETAILS 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
- SEQUENCES IN MAIZE STARCH
- CORN STARCH PRODUCTION
- PRODUCTION OF STARCH SLURRY
- PRODUCTION OF STARCH SLURRY
- PRODUCTION OF STARCH AND DEXTRINS:
- PRODUCTION OF STARCH
- 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
- MAIZE STARCH MANUFACTURE
- STARCH GLUTEN SEPARATION
- STARCH REFINING
- MODIFICATION
- CORN OIL PRODUCTION METHOD
- CORN GERM SEPARATION PROCESS
- CORN GERM OIL EXTRACTION PROCESS
- CORN OIL MANUFACTURING PROCESS
- ABOUT 100%-EXPELLER-PRESSED CORN OIL
- SEQUENCES IN CORN SYRUP AND HIGH FRUCTOSE CORN SYRUP
- CONVERTING CORN STARCH INTO CORN SYRUP
- CONVERTING CORN SYRUP INTO HIGH FRUCTOSE CORN SYRUP
- HIGH FRUCTOSE CORN SYRUP MANUFACTURING PROCESS
- (1) PREPARATION:
- (2) ISOMERIZATION:
- (3) DECOLORIZATION:
- (4) DEMINERALIZATION:
- (5) EVAPORATION:
- HFCS 55 PROCESS DESCRIPTION
- PURE CRYSTALLINE FRUCTOSE (PCF) PROCESS DESCRIPTION
- (1) CHROMATOGRAPHIC SEPARATION
- (2) BLENDING
- (3) POLISHING
- (4) EVAPORATION
- MANUFACTURING PROCESS OF LIQUID GLUCOSE
- PROCESSING DETAILS OF MAIZE STARCH
- THE DIFFERENT STEPS INVOLVED IN THE WET MILLING ARE PRESENTED BELOW.
- 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
- PROCESS DESCRIPTION OF WET MILLING
- 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
- 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:
- MANUFACTURING PROCESS FOR LIQUID GLUCOSE
- RAW MATERIALS
- CONFECTIONERI GLUCOSE-D:
- LOW CONVERSION
- REGULAR CONVERSION
- INTERMIDIATE CONVERSION
- HIGH CONVERSION
- MANUFACTURE OF DEXTROSE MONOHYDRATE AND DEXTROSE ANHYDROUS
- DEXTROSE MANUFACTURE
- MANUFACTURING DIAGRAM OF LIQUID GLUCOSE
- MANUFACTURING DIAGRAM OF ANHYDROUS DEXTROSE
- MANUFACTURING PROCESS OF SORBITOL
- PROCESS FLOW DIAGRAM OF MAIZE WET MILLING
- 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 MAIZE WET MILLING
- 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
- PLANT & MACHINERY SECTION WISE
- LIST OF MACHINERY AND EQUIPMENT
- 1. MAIZE STEEPING
- 2.SULPHURDIOXIDE PLANT
- 3. DEGERMINATION AND GERM WASHING
- 4. FIBRE MILLING AND WASHING
- 5. STARCH SEPARATIONS AND REFINING
- 6. GLUTEN CONCENTRATION
- 7. GERM DEWATERING AND DRYING
- 8. STEEPING WATER CONCENTRATION
- 9. SECTION:
- 10. ANIMAL FEED DEWATERING AND DRYING
- 10.03 DRYER FOR ANIMAL FEED
- 11. STARCH DEWATERING AND DRYING
- 12. SORBITOL AND MALTODEXTRIN MANUFACTURING SECTION
- 13. DMH 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
Maize starch is a carbohydrate product recovered from maize through a wet milling process.
The process generally involves receiving and cleaning maize, steeping the kernels, grinding and separating the germ, washing the fiber, separating starch from gluten, refining the starch slurry, dewatering and drying the final starch. Wet milling enables the different components of the maize kernel to be recovered as separate products and byproducts, including starch, germ, gluten, fiber and steep liquor.
Maize is the principal raw material for the maize starch manufacturing process described in the report.
Industrial starch can also be obtained from other sources such as wheat, tapioca, potato and arrowroot. The choice of raw material depends on the required starch characteristics, availability, process technology and intended application. In maize wet milling, additional process chemicals and utilities are also required for operations such as steeping, separation, refining and drying.
The major byproducts of maize wet milling include steep liquor, germ, corn oil, gluten and husk.
These streams can provide additional commercial value to a maize wet milling plant. Steep liquor contains amino acids and proteins and may be used in industrial applications, while germ is processed to recover corn oil and oil cake. Gluten is valued for its protein content and is commonly used in feed applications. Maize husk and other fiber-rich fractions can also be utilized, including as animal feed.
Maize starch is used in food, textile, paper and pharmaceutical applications as well as in the manufacture of other starch-based products.
Its functional properties make it useful as a thickener, binder, sizing material and processing aid, depending on the application. Starch can also be hydrolyzed to produce products such as liquid glucose and dextrose, or modified through chemical or enzymatic processes to obtain specialized starches with altered functional characteristics.
Natural starch is obtained from plant sources without intentionally altering its basic starch structure, while modified starch is processed to change its functional properties.
Natural or unmodified starches may be derived from cereals, roots, tubers and certain palms. Modified starches are produced through chemical or enzymatic treatment and can include dextrins, acid-modified starches, oxidized starches, starch esters, starch ethers, aldehyde starches and cationic starches. Modification is used to achieve properties suited to particular industrial applications.
A maize wet milling plant requires equipment for steeping, grinding, germ separation, fiber washing, starch separation, refining, concentration, dewatering and drying.
The report identifies sections and equipment covering maize steeping, sulphur dioxide preparation, degermination and germ washing, fiber milling and washing, starch separation and refining, gluten concentration, germ dewatering and drying, steeping water concentration, animal feed processing, starch dewatering and drying, and allied product manufacturing. Supporting handling, storage and laboratory testing equipment is also required.
Maize starch can serve as a feedstock for several allied products, including liquid glucose, dextrose, maltodextrin, sorbitol and fructose-based products.
The report describes processes for corn syrup, high fructose corn syrup, pure crystalline fructose, liquid glucose, dextrose monohydrate, anhydrous dextrose and sorbitol. The wet milling process also produces commercially useful maize germ, gluten and other streams. Developing multiple product lines can allow a plant to utilize different fractions of the maize kernel and serve diverse industrial markets.
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