Industry Overview
Starch is an abundant, inexpensive, renewable, and biodegradable natural polymer widely used in the food and non-food industries. It is the second most abundant natural polymer after cellulose and is primarily obtained from staple crops such as maize, wheat, potato, cassava, and rice. Other commercial sources include sweet potato, sorghum, legumes, sago palm, and sugar palm. The size, shape, morphology, and composition of starch granules vary according to their botanical source.
Maize starch accounts for the largest share of the global starch market, with the United States being a major producer. Europe is an important producer of wheat and potato starch, while cassava starch is primarily produced in Asia. According to Visakh and Yu (2016), the USA and Europe together contribute about half of global commercial starch production. The reported worldwide distribution of starch sources includes maize (82%), wheat (8%), potatoes (5%), and cassava (5%).
Approximately 60 million tons of starch are extracted annually worldwide from cereals, tubers, and root crops, with around 60% used in food applications and 40% in pharmaceuticals and other industries, according to Visakh and Yu (2016). Applications include bakery products, confectionery, sauces, pharmaceuticals, paper, cardboard, adhesives, textiles, bioplastics, building materials, and oil drilling.
Chemically, starch is a polysaccharide composed of D-glucose units and consists primarily of amylose and amylopectin. Amylopectin is generally the major component, representing approximately 65–85% of starch granule material. Modified starch is produced through physical, chemical, or enzymatic treatments to improve functional properties such as water-holding capacity, heat resistance, binding, thickening, and resistance to syneresis. Modified starches, dextrins, and maltodextrins are widely used in food processing, pharmaceuticals, adhesives, textiles, and other industrial applications. Commercial starch recovery is mainly based on maize, wheat, and tapioca because of the practical and economic requirements of extraction.
Cost Estimation
| Particulars | Project Cost |
|---|---|
| Plant Capacity | 200 MT/Day |
| Land & Building (5 Acres) | Rs. 9.10 Cr |
| Plant & Machinery | Rs. 5.36 Cr |
| Working Capital for 2 Months | Rs. 27.11 Cr |
| Total Capital Investment | Rs. 42.63 Cr |
| Rate of Return | 26% |
| Break Even Point | 45% |
Content Index
- INTRODUCTION
- BYPRODUCTS FROM MAIZE
- SPECIFICATION OF STARCH
- PHYSICAL AND CHEMICAL MODIFICATION OF STARCH
- TYPES OF DEXTRIN
- DEXTRINS AND ITS USES
- WHITE DEXTRINS ARE USED AS:
- ADHESIVE INDUSTRY
- CHEMICAL & DYES INDUSTRY
- FOUNDRIES
- TEXTILE INDUSTRY
- COLOUR INDUSTRY
- APPLICATION - ADHESIVES
- OTHER APPLICATIONS
- USES AND APPLICATION
- IN GENERAL, MODIFIED FOOD STARCHES ARE USED FOR THREE REASONS:
- LIQUID GLUCOSE SYRUP USES AND APPLICATIONS:
- LIQUID GLUCOSE USES
- USES OF DEXTROSE:-
- PROPERTIES OF LIQUID GLUCOSE
- PROPERTIES OF STARCH
- PHYSICAL PROPERTIES
- CHEMICAL PROPERTIES
- STARCH GIVES A CHARACTERISTIC BLUE COLOR WITH IODINE.
- MODIFIED STARCHES
- PROPERTIES OF PREGELATINIZED STARCH
- MAIZE STARCH AND ALLIED PRODUCTS AND THEIR APPLICATIONS
- MAIZE STARCH
- LIQUID GLUCOSE
- MALTODEXTRIN
- DEXTROSE MONOHYDRATE
- MAIZE GLUTEN
- MAIZE GERM
- APPLICATIONS
- SORBITOL
- COSMETICS:
- FOOD INDUSTRY:
- PHARMACEUTICAL INDUSTRY:
- TOBACCO INDUSTRY:
- PAPER INDUSTRY:
- PAINT INDUSTRY:
- STARCH AND STARCH DERIVATION
- FIGURE: STARCH AND STARCH DERIVATIVES
- MACRONUTRIENTS
- CARBOHYDRATES
- GLUCOSE
- STARCH
- TABLE 1: STARCH CONTENT AND COMPOSITION IN DIFFERENT SOURCES
- NATIVE STARCH
- HYDROLYSED STARCH
- MODIFIED STARCH
- PHYSICAL MODIFICATION
- CHEMICAL MODIFICATION
- ENZYMATIC MODIFICATION
- GENETIC/BIOTECHNOLOGICAL MODIFICATION
- STARCH AND STARCH DERIVATIVE CLASSIFICATIONS
- STARCH CLASSIFICATION BASED ON HARMONIZED SYSTEM (HS) CODES
- MAIZE PRODUCTION IN SOUTH AFRICA
- FIGURE: MAIZE PRODUCTION IN SOUTH AFRICA
- FIGURE: MAIZE YIELD IN SOUTH AFRICA
- STARCH AND STARCH DERIVATIVE APPLICATIONS
- FOOD INDUSTRIES
- NON-FOOD INDUSTRIES
- STRUCTURE OF THE SOUTH AFRICAN
- STARCH INDUSTRY
- TONGAAT HULETT STARCH
- INTRODUCTION
- TONGAAT HULETT’S INPUTS
- TONGAAT HULETTS PRODUCTION AND CAPACITY
- GERMISTON
- KLIPRIVIER
- MEYERTON
- BELLVILLE
- TABLE 7: TONGAAT HULETT’S STARCH AND GLUCOSE VOLUMES
- TONGAAT HULETT’S STARCH PRODUCTS
- MODIFIED WAXY MAIZE STARCHES
- FIGURE 26: SUMMARY OF TONGAAT HULETT’S STARCH VALUE CHAIN
- OTHER MANUFACTURERS
- WFM STARCH PRODUCTS
- ITS PRODUCT LIST INCLUDES:
- FIGURE 27: SUMMARY OF WFM STARCH PRODUCTS VALUE CHAIN
- CHARKA
- THE PRODUCTION PROCESS:
- FIGURE 28: SUMMARY OF CHARKA’S VALUE CHAIN
- NATAL STARCH
- TOP PRODUCTS
- POTENTIAL SOLUTIONS TO THIS DILEMMA ARE:
- FIGURE 29: SUMMARY OF TOP PRODUCTS VALUE CHAIN
- NOUKLOOF STORE
- CONSOLIDATED STARCH INDUSTRIES
- POTENTIAL NEW ENTRANTS
- LIST OF STARCH DISTRIBUTORS IN SOUTH AFRICA
- IMPORT ANALYSIS OF STARCH AND STARCH DERIVATION
- TRADE ANALYSIS
- SOUTH AFRICA’S STARCH IMPORT VOLUMES
- MAIZE STARCH
- FIGURE 31: MAIZE STARCH IMPORT VOLUMES INTO SOUTH AFRICA
- WHEAT STARCH
- FIGURE 32: WHEAT STARCH IMPORT VOLUMES INTO SOUTH AFRICA
- POTATO STARCH
- FIGURE 33: POTATO STARCH IMPORT VOLUMES INTO SOUTH AFRICA
- CASSAVA STARCH
- FIGURE 34: CASSAVA STARCH IMPORT VOLUMES INTO SOUTH AFRICA
- OTHER STARCHES
- FIGURE 35: OTHER STARCHES IMPORT VOLUMES INTO SOUTH AFRICA
- DEXTRINS AND OTHER MODIFIED STARCH
- FIGURE 36: DEXTRINS AND OTHER MODIFIED STARCH IMPORT VOLUMES INTO SOUTH AFRICA
- SUMMARY OF SOUTH AFRICA’S IMPORT VOLUMES
- FIGURE 37: SUMMARY OF SOUTH AFRICA’S STARCH IMPORT VOLUMES
- SOUTH AFRICA’S STARCH IMPORT VALUES
- SUMMARY OF SOUTH AFRICA’S IMPORT VALUES
- FIGURE 38: SOUTH AFRICA’S IMPORT VALUES OF VARIOUS STARCHES
- TABLE 8: SOUTH AFRICA’S STARCH IMPORT VALUES IN RANDS 2009 - 2016
- SOUTH AFRICA’S STARCH IMPORTS PER REGION
- MAIZE STARCH
- FIGURE 39: MAIZE STARCH IMPORT VALUES PER REGION
- WHEAT STARCH
- FIGURE 40: WHEAT STARCH IMPORT VALUES PER REGION
- POTATO STARCH
- FIGURE 41: POTATO STARCH IMPORT VALUES PER REGION
- CASSAVA STARCH
- FIGURE 42: CASSAVA STARCH IMPORT VALUES PER REGION
- OTHER STARCHES
- FIGURE 43: OTHER STARCHES IMPORT VALUES PER REGION
- DEXTRINS AND OTHER MODIFIED STARCHES
- FIGURE 44: DEXTRINS AND OTHER MODIFIED STARCHES IMPORT VALUES PER REGION
- TECHNOLOGY/CAPITAL UTILISED
- MARKET POTENTIAL OF STARCHES AND DERIVATIONS IN SOUTH AFRICA
- FIGURE 45: NON-FOOD APPLICATIONS OF MODIFIED STARCH
- A SUMMARY OF THE MAIN APPLICATIONS OF STARCHES:
- TRADE ANALYSIS
- SOUTH AFRICA’S STARCH EXPORT VOLUMES
- MAIZE STARCH
- WHEAT STARCH
- FIGURE 47: WHEAT STARCH EXPORT VOLUMES
- POTATO STARCH
- FIGURE 48: POTATO STARCH EXPORT VOLUMES
- CASSAVA STARCH
- FIGURE 49: CASSAVA STARCH EXPORT VOLUMES
- OTHER STARCHES
- FIGURE 50: OTHER STARCHES EXPORT VOLUMES
- DEXTRINS AND OTHER MODIFIED STARCHES
- FIGURE 51: DEXTRINS AND OTHER MODIFIED STARCH EXPORT VOLUMES
- SUMMARY OF SOUTH AFRICA’S EXPORT VOLUMES
- FIGURE 52: SUMMARY SOUTH AFRICA’S STARCH EXPORT VOLUMES
- 5.2.2. SOUTH AFRICA’S STARCH EXPORT VALUES
- FIGURE 53: SOUTH AFRICA’S EXPORT VALUES OF VARIOUS STARCHES
- MORE DETAILS ON THE EXPORT VALUES ARE PROVIDED IN TABLE 9.
- SOUTH AFRICA’S STARCH EXPORT VALUES PER REGION
- MAIZE STARCH
- WHEAT STARCH
- POTATO STARCH
- CASSAVA STARCH
- OTHER STARCHES
- DEXTRINS AND OTHER MODIFIED STARCHES
- SUMMARY OF SOUTH AFRICA’S EXPORT VALUES
- EXPORT VALUES IN 2016, THE SOUTH AFRICAN STARCH INDUSTRY EXPORTED:
- EXISTING AND POTENTIAL DEMAND FOR STARCH LOCALLY
- FIGURE 60: ESTIMATED STARCH CONSUMPTION IN SOUTH AFRICA IN 2016
- TONGAAT HULETT’S CUSTOMERS
- INVESTMENTS
- IN TERMS OF SUPPLY OF MAIZE:
- OVERALL GROWTH TRENDS IN THE MAIN APPLICATION INDUSTRY’S
- INTERNATIONAL COMPETITION OF STARCH AND DERIVATION
- STARCHES AND INULIN
- DEXTRINS AND OTHER MODIFIED STARCHES
- TRADE BALANCES OF VARIOUS STARCHES
- THE TRADE BALANCE FIGURES SHOW THAT SOUTH AFRICA IS A:
- COMPETITIVE AND COMPARATIVE ADVANTAGE
- DEXTRINS AND OTHER MODIFIED STARCHES
- FIGURE 80: SOUTH AFRICA’S EXPORT MARKET FOR DEXTRINS AND OTHER MODIFIED STARCHES
- INDUSTRY CAPACITY ANALYSIS
- SOUTH AFRICA’S STARCH POTENTIAL
- FIGURE 81: STARCH POTENTIAL
- SOUTH AFRICA’S CURRENT STARCH CAPABILITIES
- THE THREE BEST OPPORTUNITIES ARE:
- SWOT ANALYSIS OF SOUTH AFRICAN STARCH INDUSTRY
- MANUFACTURERS/SUPPLIERS OF MODIFIED STARCH
- MANUFACTURING PROCESS OF DEXTRIN
- PROCESS FLOW DIAGRAM
- MANUFACTURING PROCESS OF MALTODEXTRIN
- MANUFACTURING PROCESS OF GLUCOSE/CORN SYRUP
- PROCESS FLOW DIAGRAM
- MANUFACTURE OF CORN SYRUP
- MANUFACTURE OF HIGH FRUCTOSE CORN SYRUP
- PROCESS FLOW DIAGRAM OF FRUCTOSE SYRUP
- MANUFACTURING PROCESS FOR LIQUID GLUCOSE-G
- 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 PREGELATINIZED STARCH
- MANUFACTURING PROCESS OF CATIONIC STARCH
- PROCESS FLOW DIAGRAM
- MANUFACTURING PROCESS OF OXIDIZED STARCH
- ENZYME TECHNOLOGY
- THERE ARE THREE STAGES IN THE CONVERSION OF STARCH:
- TABLE ENZYMES USED IN STARCH HYDROLYSIS
- STARCH OXIDATION
- OXIDIZED STARCH PRODUCTION
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF PLANT AND MACHINERY
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
Starch is a naturally occurring carbohydrate polymer obtained from plants, primarily from seeds, roots, and tubers. Major industrial sources include maize, wheat, potato, and cassava. Rice, sweet potato, sorghum, legumes, and certain palm stems also provide starch for commercial applications. The botanical source influences granule size, structure, composition, and functional properties. Manufacturers select a starch source according to its availability, extraction economics, processing requirements, and intended application in food production or other industries.
Modified starch is starch that has been processed to improve its performance for specific applications. Modification can enhance water-holding capacity, thickening, binding, heat resistance, processing stability, and resistance to syneresis, which is the separation of liquid from a gel or paste. Depending on the required properties, manufacturers use physical, chemical, enzymatic, or genetic and biotechnological approaches. Modified starch is widely used in processed foods, pharmaceuticals, paper, textiles, adhesives, packaging, and other industrial products.
Starch serves as a thickener, binder, stabilizer, and functional ingredient across food and non-food industries. Food applications include bakery products, sauces, soups, confectionery, syrups, ice cream, snacks, meat products, and beverages. Non-food applications include paper and cardboard manufacturing, adhesives, textiles, seed coatings, packaging, bioplastics, building materials, fertilizers, and oil drilling. Its usefulness depends on the starch source and whether native or modified starch is required to achieve the desired viscosity, texture, adhesion, or processing performance.
Amylose and amylopectin are the two principal carbohydrate components of starch, but they differ in molecular structure. Amylose is predominantly linear, whereas amylopectin has a much larger, highly branched molecular structure. Amylopectin generally forms the larger proportion of starch granule material, although the exact composition varies with the botanical source. These structural differences influence gelatinization, viscosity, gel formation, and other functional characteristics that manufacturers consider when selecting starch for food processing and industrial applications.
Dextrin and maltodextrin are starch-derived products obtained by breaking starch into smaller carbohydrate molecules. Dextrins are commonly produced through controlled starch conversion, while maltodextrins are generally manufactured through partial enzymatic or acid hydrolysis under suitable processing conditions. Their properties depend on the raw material and conversion method. These products have applications in food processing, pharmaceuticals, adhesives, paper, textiles, and other industries. Process control is important to obtain the required solubility, viscosity, binding properties, and product consistency.
The main starch modification methods are physical, chemical, enzymatic, and genetic or biotechnological modification. Physical methods alter starch behaviour through controlled processing conditions. Chemical methods introduce structural changes to improve particular functional properties. Enzymatic modification uses enzymes to break down starch molecules into products such as dextrins and maltodextrins. Genetic and biotechnological approaches influence starch characteristics through the selection or development of plant varieties. The appropriate method depends on the desired product properties, raw material, application, processing requirements, and applicable safety standards.
Planning a starch manufacturing plant requires evaluating raw material availability, product specifications, process technology, equipment selection, water and energy requirements, effluent treatment, storage, and quality control. The project assessment should also consider land and building requirements, labour, utilities, working capital, packaging, logistics, and access to target markets. For modified starch and starch derivative production, the selected process must match the intended product range and customer requirements. Financial feasibility should be assessed using documented project costs, operating assumptions, market research, and applicable regulatory requirements.
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