Industry Overview
Starch is an abundant carbohydrate found worldwide in plants and has long been an important component of the human diet as well as a major industrial raw material. Industrial starch is obtained from sources such as grains, roots, and tubers, with commercial production primarily relying on wheat, maize, and tapioca. The Indian starch industry mainly uses maize as its principal raw material, while some industries are based on tapioca.
Maize contains about 70% starch, with protein, fibre, and fat comprising other major components. Maize starch is produced primarily through wet milling, a process that separates the maize kernel into starch, germ, gluten, and fibre. The recovered byproducts also have significant industrial and commercial applications. Corn steep liquor contains amino acids and proteins and is used by antibiotic manufacturers, while it can also serve as a source of biogas. Germs yield corn oil, and the resulting oil cake is used as cattle and poultry feed. Maize gluten, which is rich in protein, is similarly used as animal feed, while maize husk is also mainly consumed as cattle feed.
Starches are broadly classified into natural and modified starches. Natural starches are obtained from cereals and roots, while modified starches are produced by chemical or enzymatic treatment. Cereal starches such as maize, wheat, rice, and sorghum are commonly recovered through wet milling, involving grain steeping, grinding, separation, dewatering, drying, and recovery of valuable byproducts.
Cost Estimation
| Particular | Value |
|---|---|
| Plant Capacity | 300 Ton/Day |
| Land & Building (10,00,000 sq.mt.) | Rs. 50.20 Cr |
| Plant & Machinery | Rs. 61.55 Cr |
| Working Capital for 1 Month | Rs. 18.27 Cr |
| Total Capital Investment | Rs. 134.89 Cr |
| Rate of Return | 60% |
| Break Even Point | 34% |
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
- MAIZE SCENARIO IN INDIA
- SPECIFICATION OF STARCH
- MAIZE STARCH SPECIFICATION
- 2.2USES 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
- COMPONENTS OF YELLOW DENT CORN
- ECONOMIC SIZE UNIT AND PRODUCTION PATTERN
- FOLLOWING THE AVERAGE ANALYSIS OF MAIZE IN INDIA:
- CONSTITUENTS AND VARIETY OF MAIZE
- PROPERTIES OF LIQUID GLUCOSE
- 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
- CONSUMPTION PATTERN OF MAIZE IN INDIA
- SEGMENT WISE CONSUMPTION OF MAIZE IN INDIA
- STARCH INDUSTRY IN INDIA: SUPPLY AND DEMAND SCENARIO
- SUPPLY
- DEMAND
- MANUFACTURERS/SUPPLIERS
- MAIZE STARCH
- LIQUID GLUCOSE
- SPECIFICATION OF STARCHES
- 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*
- 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
- MAIZE STARCH MANUFACTURING
- STARCH GLUTEN SEPARATION
- STARCH REFINING
- MODIFICATION
- 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
- SEQUENCES IN MAIZE STARCH PRODUCTION
- CORN STARCH PRODUCTION
- PRODUCTION OF STARCH SLURRY
- PRODUCTION OF STARCH SLURRY
- 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 CORN 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
- 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
- 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
- 10.00 ANIMAL FEED DEWATERING AND DRYING
- 10.03 1 DRYER FOR ANIMAL FEED
- 11. STARCH DEWATERING AND DRYING
- 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 starch product recovered from maize kernels primarily through wet milling.
The process involves receiving and cleaning maize, steeping the kernels, grinding and separating the germ and fibre, separating gluten from starch, and subsequently washing, dewatering, and drying the starch. Wet milling is particularly suitable for recovering the different components of the maize kernel as separate products, including starch and commercially useful byproducts.
Maize is the principal raw material used by the Indian starch industry, while tapioca is also used by some industries.
Other natural starch sources include wheat, rice, sorghum, potato, arrowroot, and sago. The commercial choice of raw material depends on the desired starch characteristics, availability, processing requirements, and end use. The report specifically identifies maize as the main input for starch production in India and describes tapioca-based production as another industrial route.
The major byproducts of maize wet milling include corn steep liquor, germ-derived oil and cake, gluten, and fibre or husk.
These streams can provide additional value alongside starch production. Corn steep liquor contains amino acids and proteins and can be used in industrial applications and for biogas generation. Germ is processed for corn oil, with the resulting oil cake used as animal feed. Maize gluten is valued for its protein content, while maize fibre or husk is mainly used as cattle feed.
Maize starch is used across food, textile, paper, pharmaceutical, and other industrial applications.
The report identifies applications including the textile industry, food industry, paper industry, and pharmaceutical industry. Starch is also used in the manufacture of glucose and dextrose through hydrolysis and in the production of modified starches. Additional applications depend on the functional properties required, such as thickening, binding, sizing, film formation, and process performance.
Natural starch is obtained from plant sources without deliberate chemical or enzymatic modification, whereas modified starch is produced by altering starch characteristics through chemical or enzymatic treatment.
Natural starches are commonly obtained from cereals such as maize, wheat, rice, and sorghum and from roots or tubers such as potato and tapioca. Modified starches include products such as dextrins, acid-modified starches, oxidized starches, starch esters, starch ethers, aldehyde starches, and cationic starches, each designed to provide specific functional properties.
The main stages in maize wet milling are cleaning, steeping, grinding, separation, starch and gluten separation, washing, dewatering, and drying.
Depending on the plant configuration, the process also includes germ separation, fibre washing, thickening, primary separation, gluten concentration, and starch refining. The objective is to separate the maize kernel into its principal components while recovering starch and useful coproducts. Process equipment is selected and arranged according to the required product quality, throughput, recovery, and handling requirements.
A maize starch manufacturing plant requires equipment for raw-material handling, steeping, grinding, separation, starch refining, dewatering, drying, and product storage.
The report lists equipment sections covering maize steeping, a sulphur dioxide plant, degermination and germ washing, fibre milling and washing, starch separation and refining, gluten concentration, germ dewatering and drying, steeping-water concentration, animal-feed dewatering and drying, starch dewatering and drying, and handling, holding, and storage. Laboratory testing equipment is also included for process and product quality control.
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