![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 in plants and has long been an important component of the human diet. It has also developed into a significant industrial raw material, with commercial starch production primarily relying on wheat, maize, and tapioca. In India, maize is the principal raw material for the starch industry, although tapioca is also used by some producers.
Maize contains about 70% starch along with protein, fiber, and fat. Maize starch is primarily produced through wet milling, a process that separates the softened maize kernel into starch, germ, gluten, and fiber. The process also generates valuable by-products, including corn steep liquor, corn germ and oil, gluten, and husk, which are used in animal feed, food, chemical, pharmaceutical, and other industrial applications.
Industrial starches are broadly classified as natural and modified starches. 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 to alter their functional characteristics. The report covers starch specifications, applications, maize processing, wet milling technology, starch and sweetener production, market aspects, raw materials, equipment suppliers, and related allied products.
Cost Estimation
| Cost Parameter | Value |
|---|---|
| Plant Capacity | 400 Ton/Day |
| Land & Building (1,20,000 sq.mt.) | Rs. 62.30 Cr |
| Plant & Machinery | Rs. 95.00 Cr |
| Working Capital for 2 Months | Rs. 54.27 Cr |
| Total Capital Investment | Rs. 215.77 Cr |
| Rate of Return | 18% |
| Break Even Point | 62% |
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:
- 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
- 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
- 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*
- USES AND APPLICATION OF DEXTROSE
- CONFECTIONERY INDUSTRY
- SOFT DRINK INDUSTRY
- TINNED FISH PRODUCTS
- BAKERY INDUSTRY
- MEAT INDUSTRY
- PHARMACEUTICAL INDUSTRY
- MALTOSE SYRUP
- HIGH MALTOSE SYRUP
- EXTRA HIGH MALTOSE SYRUP
- HIGH CONVERSION MALTOSE SYRUP
- HIGH & EXTRA HIGH MALTOSE SYRUP
- HIGH CONVERSION MALTOSE SYRUP
- GLUCOSE SYRUP
- LOW CONVERSION
- INTERMEDIATE CONVERSION
- HIGH CONVERSION
- VERY HIGH CONVERSION
- MANNITOL AND ITS APPLICATION
- PHARMACEUTICAL USE
- FRUCTOSE AND ITS APPLICATION
- FRUCTOSE SYRUP CAN REPLACE SUCROSE IN THE FOLLOWING PRODUCTS:
- 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
- DETAILS OF DEXTROSE FROM STARCH
- 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
- SEPARATING CORN STARCH FROM CORN
- 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
- LIQUID GLUCOSE MANUFACTURE
- 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
- 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 MATERIAL
- 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
- PROCESSING DETAILS OF DEXTROSE MONOHYDRATE
- 1. PREPARATION FOR STARCH MILK:
- 2. LIQUEFACTION:
- 3. SACCHARIFICATION:
- 4. REFINING:
- 5. ION EXCHANGE:
- 6. CONCENTRATION:
- 7. CRYSTALLIZATION:
- 8. SEPARATION:
- 9. DRYING, PACKAGE:
- PROCESS DESCRIPTION OF SWEETENERS
- LIQUEFACTION
- SACCHARIFICATION
- FILTRATION OF INSOLUBLE COMPONENTS
- VACUUM FILTRATION
- MEMBRANE FILTRATION
- CARBON TREATMENT
- ION EXCHANGE
- CONCENTRATION BY EVAPORATION
- CRYSTALLISATION
- ISOMERIZATION
- FRACTIONATION
- HYDROGENATION
- FLUID BED DRYING
- SPRAY DRYING
- 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
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 the primary input for many Indian starch manufacturing operations because the maize kernel contains a substantial proportion of starch along with protein, fiber, and fat. Tapioca is also used by some starch producers. The report identifies maize and tapioca as the principal raw materials and discusses maize production, varieties, specifications, market conditions, and processing requirements in detail.
Maize starch is primarily manufactured through a wet milling process that separates starch from the other components of the maize kernel.
The process generally includes receiving and cleaning the maize, steeping, grinding, germ separation, fiber washing, thickening, primary separation, gluten separation, starch refining, dewatering, and drying. The wet milling route is designed to recover starch while also separating useful by-products such as germ, gluten, fiber, and steep liquor.
Starch is widely used in the food, textile, paper, pharmaceutical, and sweetener industries.
Its applications include food processing, textile finishing, paper manufacturing, pharmaceutical formulations, and the production of glucose and dextrose through hydrolysis. Starch can also be chemically or enzymatically modified to produce products with specific functional properties. The report covers natural and modified starches as well as applications of starch-derived products such as liquid glucose, dextrose, maltodextrin, and other sweeteners.
The important by-products of maize wet milling include corn steep liquor, maize germ, corn oil and oil cake, gluten, and husk.
These by-products can provide additional value streams for a maize processing plant. Corn steep liquor contains amino acids and proteins and can have industrial and fermentation-related applications. Germ is used for corn oil recovery, while the resulting oil cake can be used as animal feed. Maize gluten is protein-rich and can also be used as cattle and poultry feed, while maize husk has feed applications.
Natural starch is obtained directly from plant sources, whereas modified starch is chemically or enzymatically treated to change its functional characteristics.
Natural or unmodified starches are derived from sources such as maize, wheat, rice, sorghum, potato, tapioca, arrowroot, and sago. Modification changes selected properties of the starch to make it suitable for particular industrial requirements. The report identifies several modified starch categories, including dextrins, acid-modified starches, oxidized starches, starch esters, starch ethers, aldehyde starches, and cationic starches.
Maize starch can serve as a feedstock for starch, glucose, dextrose, maltodextrin, fructose and other allied products.
The report covers manufacturing technologies and processing details for maize starch and several starch-derived products. These include liquid glucose, maltose syrups, dextrose monohydrate, anhydrous dextrose, fructose syrup, high fructose corn syrup, sorbitol, and other sweeteners. It also discusses corn oil production from maize germ and the recovery and utilization of other valuable maize-processing fractions.
A maize wet milling plant uses equipment for cleaning, steeping, grinding, separation, concentration, dewatering, and drying.
The process described in the report includes cleaning and soaking, steep liquor concentration, germ separation and oil recovery, fiber separation, gluten separation and concentration, mixed feed processing, and starch washing, dewatering, and drying. The report also covers equipment and supplier categories including plant and machinery, centrifuges, heat exchangers, laboratory testing equipment, boilers, and raw materials required for the operation.
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