Detailed Project Report (DPR) on maize semolina processing plant

MAIZE SEMOLINA PROCESSING PLANT
[CODE NO.3092] J.C.: 1131

Semolina is the coarse purified wheat middlings of durum wheat. The term semolina is also used to designate coarse middling from other varieties of wheat
and from other grain such as maize.

Corn is the cereal with the highest production worldwide and is used for human consumption, livestock feed, and fuel. Various food technologies are currently
used for processing industrially produced maize flours and corn meals in different parts of the world to obtain precooked refined maize flour, dehydrated
nixtamalized flour, fermented maize flours, and other maize products. These products have different intrinsic vitamin and mineral contents, and their
processing follows different pathways from raw grain to the consumer final product, which entail changes in nutrient composition. Dry maize mechanical
processing creates whole or fractionated products, separated by anatomical features such as bran, germ, and endosperm. Wet maize processing separates by
chemical compound classification such as starch and protein. Various industrial processes, including whole grain, dry milling fractionation, and
nixtamalization.

Maize food products can be processed at home on a small local scale as well as on a larger industrial scale, transforming the raw material into food products.

Some of the products are more suitable for commercial trade because they require further processing or provide convenience and extended shelf life, while other
products should be consumed immediately after production. For example, degerminated corn grits, meal, or flour has an extended shelf life and can be
moved and traded easily. The product itself has to be further processed, including some degree of cooking, in order for it to be palatable as a food
product.

Nixtamalized maize, when prepared in the household or by a small-scale processor, is typically used to form ready-to-eat finished masa products with a limited shelf life. On an industrial scale, nixtamalized maize flour may be processed and sold as a shelf-stable product that can be prepared for consumption in the home, reducing meal preparation time and providing convenience. Industrial processors strive to offer maize products that replicate the ones consumed in the target market region. Identifying the market share of
industrially produced maize product consumed in the market place is essential in evaluating the potential for implementing a successful maize product
fortification program. The influence of a small-scale maize processing industry with local impact may also play a significant role in some target populations,
especially in some poor countries.

Maize color is important to specific consumer groups in Central and South

America as well as in Africa, and white maize is preferred for food consumption.

In some areas of the world, such as North America, the desired color depends on the region or the food use. For example, in the eastern United States, cornmeal,
grits, and homily are white, while in the northern part of the country, maize meal, and maize products used for breakfast cereals and snack foods are expected
to be manufactured with yellow maize.

Maize meal or flour composition can also be driven by regional preferences, with some preferring whole ground maize rather than degerminated or partially
degerminated maize products. The nutrient composition, including vitamins, minerals, and antinutrient factors, are influenced by local product preferences,
which include not only the way the corn product is consumed, but also what other food items or additives are part of a complete meal. Local and regional
standards for both the form and composition are to be evaluated as part of planning a maize flour or cornmeal fortification program.


COST ESTIMATION

Plant  Capacity                                :    50.00 MT./day               
Land & Building (1500 Sq.MT)    :    Rs. 1.72 Cr
Plant & Machinery                          :    Rs. 99.00 Lacs
Working Capital for 1 Month        :    Rs. 1.91 Cr
Total Capital Investment              :    Rs. 4.72 Cr
Rate of Return                               :    37%
Break Even Point                           :    44%


INTRODUCTION    
USES AND APPLICATION    
MAIZE KERNEL ANATOMY AND COMPOSITION    
SPECIFICATION OF MAIZE SEMOLINA    
CORN GRITS AND SEMOLINA    
MARKET SURVEY    
OVERVIEW OF SNACK MARKET    
PRESENT MANUFACTURERS OF MAIZE SEMOLINA    
CORN MILL PRODUCTS & BY-PRODUCTS    
METHOD OF MAIZE SEMOLINA PROCESSING    
PROCESS FLOW DIAGRAM    
METHOD OF MAIZE PROCESSING    
FEATURES AND YIELD OF DRY MILLING PROCESS    
DRY MILLING OF MAIZE    
SWOT ANALYSIS OF MAIZE PROCESSING IN KARNATAKA    
PRINCIPLES OF PLANT LAYOUT    
PLANT LOCATION FACTORS    
EXPLANATION OF TERMS USED IN THE PROJECT REPORT    
PROJECT IMPLEMENTATION SCHEDULES    
SUPPLIERS OF PLANT AND MACHINERY    
SUPPLIERS OF RAW MATERIALS    


APPENDIX – A:

 1.      COST OF PLANT ECONOMICS  
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET