Detailed Project Report on Potato Starch
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POTATO STARCH
[EDPR/EIRI/1459] J.C. 213
INTRODUCTION
Native Potato Starch is basically a carbohydrate, consisting of amylose and amylopectin. The quality and consistency of native Potato Starch produced by Siddharth Starch has made it a role model among Potato Starch users in India. In spite of being sole manufacturer of native Potato Starch in India, Siddharth Starch is supplying native Potato Starch to Indian customers at most competitive price. (there are other manufacturer of potato starch in INDIA such as Crystal agro product and Purthvi foods Gujarat) Siddharth Starch is also very responsive to needs of its clients and uses its laboratory and R&D facilities to tailor make modifications as required by Potato Starch users. Presently Siddharth Starch is manufacturing Potato Starch from recovery system installed in Potato processing companies
Potato is widely consumed as food all over the world. It contains the starch as a major carbohydrate. Surplus and cull potatoes are used as feed for live stock and also as raw material for the manufacture of starch, ethyl-alcohal and a few other industrial products like, dextrose, liquid Glucose etc.
The potato contains approximately 18-21% of carbohydrates. The major carbohydrate is starch. This starch is comprising 65-80% of the dry weight of the tuber, is calorifically the most important nutritional component. In the raw tuber, it is present as microscopic granules in levcoplasts lining the interior cell walls of parenchyma tissue. The granule is ellipsoidal in shape, 100N*60N, with striations like an oyster shell. Under polarized light, the granule shows an irregular black cross.
Electron micrographs reveal a surprising smooth surface structure. The ratio of amylase to amylopectine in potato starch is 24:76 and the gelatinization temperature ranges from 56oC to 69oC with water this starch forms a translucent paste of high viscosity. Freshly harvested mature tubers contain more sugars than the large ones. A slight rise in total sugars is observed when tubers are stored at 20-30oC. However when the storage temperature is 4o or less., the total reducing sugars increase, the rate and extent of increase being greater when lower the temperature down to the freezing point. The maximum sugar concentration (3 to 10%) is reached after 4-8 weeks.
Potato starch is produced from varieties selected and grown for their high starch, low protein and low fibre contains. In USA and else where, only surplus potatoes and tubes unsuitable for table use are used for starch production.
For starch manufacture, potatoes are washed and milled in a rasp or hammer mill to disintegrate the cells and liberate starch. Sulphur dioxide is added to inhibit the action of oxidizing enzymes and the slurry is passed through centrifugal separator to remove 'protein water'. The residual cake is mixed with water and the suspension pumped on to starch tables, where starch settles and major part of the fibre and soluble salts pass off. The cake is scrap off the table, mixed with water and passed through rotary vacuum filters. The cake obtained is the pure starch.
COST ESTIMATION
Plant Capacity 10.00 TPD./Day
Land & Building (Area 2 Acrst.) Rs. 2.75 Cr
Plant & Machinery Rs. 8.50 Cr
W.C. for 1 Month Rs. 2.56 Cr
Total Capital Investment Rs.14.54 Cr.
Rate of Return 62%
Break Even Point 36%
CONTENTS
INTRODUCTION
PROPERTIES
CHEMICAL FORMULA- (C6H10O5)N
POTATO STARCH IN FOOD APPLICATIONS
PRESENT CONSUMPTION PATTERN
CATEGORY WISE ESTIMATED CONSUMPTION PATTERN OF POTATO
USES OF STARCH:
B.I.S. SPECIFICATION
MARKET SURVEY
WORLD WIDE PRODUCTION OF STARCH FROM DIFFERENT SOURCE
PRODUCTION OF STARCH IN VARIOUS GEOGRAPHIC AREAS
ESTIMATED FUTURE DEMAND IN 10 YEARS
POTATO STARCH PRODUCTION IN MT. FROM 2008 TO 2017
IMPORT STATICS OF POTATO STARCH FROM 1991 TO 2012
EXPORT STATICS OF POTATO STARCH FROM 1995 TO 2012
GROWTH IN PROCESSED FOOD INDUSTRY VIS-A-VIS STARCH INDUSTRY
STARCH INDUSTRY IN INDIA;
PRESENT STATUS:
PRESENT STATUS OF POTATO STARCH IN CHINA TILL 2014
CONSUMPTION:
IMPORTS POTATO STARCH 2014
SYNTHESIS OF RAW MATERIAL SPECIFICITIES AND USES
USES OF STARCH PRODUCTS
THE DIFFERENT USES OF THE STARCH PRODUCTS ARE PRESENTED IN THE TABLE BELOW
PRESENT CONSUMPTION PATTERN
CATEGORY‐WISE ESTIMATED CONSUMPTION PATTERN OF POTATO
WORLD MARKET FOR STARCH BY RAW MATERIALS, 2008
OVERALL ORGANISATION OF THE POTATO STARCH SUPPLY CHAIN
STARCH PRODUCTION IN THE EU - 2011
BASED ON FIGURES OBTAINED FROM EU COMMISSION AND USDA A DIFFERENT ESTIMATE FOR STARCH PRODUCTION 2000 BY STARCH ORIGIN IS:
STARCH INDUSTRY: AN OVERVIEW
GLOBAL STARCH MARKET BY 2015
INDIAN STARCH INDUSTRY
POLYMERIC USED OF STARCH IN: STARCH INDUSTRY IN INDIA
STATE-WISE LIST OF STARCH INDUSTRIES IN INDIA
MAJOR END – USERS OF STARCH AND STARCH BASED PRODUCTS
GLOBAL STARCH MARKET TO REACH 133.5 MILLION METRIC TONS BY 2018
POTATO STARCH PACKAGED FOR SHIPPING
PROMISING FUTURE
FUTURE BEHOLDS FOR MODIFIED STARCH MARKET
MODIFIED STARCH MARKET
SEGMENTATION AND FORECASTING
FOOD: BREWERY, BAKERY, CONFECTIONARY AND PROCESSED FOODS FROM 2012 TO 2017
NON-FOOD: DETERGENT, PAPER, CHEMICALS AND PHARMACEUTICALS FROM 2012 TO 2017
IMPORT DATA OF POTATO STARCH FROM 2004 TO 2013
EXPORT DATA OF 'POTATO STARCH' IN 2013
MANUFACTURERS/EXPORTERS/SUPPLIERS OF POTATO STARCH
RAW MATERIALS
INDIAN PRODUCTION OF POTATO IN 2012-13
MARKET SURVEY
SCENARIO OF POTATO SECTOR FROM 2007-09
FIG. 1. POTATO PRODUCTION GROWTH (%) OVER CONTINENTS DURING TE 1998 AND TE 2009
POTATO IN AGRICULTURAL ECONOMY IN 2008
PROCESS OF MANUFACTURE
POTATO STARCH -
IS THIS COMPANY CAN PROVIDE MACHINE (GELGOOG)
PROCESS FLOW SHEET FOR MANUFACTURE
OCCURRENCE OF STARCH
THE BASIS FOR STARCH QUALITY IS LAID IN THE POTATO CLAMP.
REFINING BEGINS ALREADY DURING RAW MATERIAL INTAKE.
EFFICIENT WASHING MAKES REFINING EASIER.
RASPING
USE OF SULPHUR
EXTRACTION
OPERATING PRINCIPLE OF A STARCH EXTRACTOR
CONCENTRATING THE CRUDE STARCH SLURRY
REFINING
HYDROCYCLONES
COOLING
CIP - CLEANING IN PLACE
DRYING AND SIFTING
COMPOSITION OF POTATO STARCH
SIZE DISTRIBUTION
PROPERTIES OF STARCH
STARCH CONTENT OF POTATOES VERSUS DENSITY ACCORDING TO
EU-DIRECTION
SPECIFICATIONS OF POTATO STARCH
MANUFACTURING PROCESS OF POTATO STARCH
STARCH PROCESSING PLANT LAYOUT
EFFLUENT TREATMENT AND DISPOSAL
EFFLUENT TREATMENT PLANT SPECIFICATION AND NORMS
STANDARDS
TOLERANCE LIMITS FOR INDUSTRIAL EFFLUENT DISCHARGE
WASTE TREATMENT
PRIMARY TREATMENT
SECONDARY TREATMENT
TERTIARY TREATMENT
SOLIDS CONCENTRATION
TYPICAL WASTE SOLIDS CHARACTERISTICS
EQUIPMENT REQUIREMENTS
MANPOWER
GENERAL
BASIS OF ESTIMATION
GENERAL PLANT LAYOUT
GMP/GHP CRITERIA FOR STARCH
2. DESIGN AND FACILITIES
2.1 LOCATION
2.2 PREMISES AND ROOMS
DESIGN AND LAYOUT
INTERNAL STRUCTURES & FITTINGS
2.3 EQUIPMENT
2.4 CONTAINERS FOR WASTE AND INEDIBLE SUBSTANCES
2.5 FACILITIES
WATER SUPPLY
DRAINAGE AND WASTE DISPOSAL
CLEANING
PERSONNEL HYGIENE FACILITIES AND TOILETS
TEMPERATURE CONTROL
AIR QUALITY AND VENTILATION
LIGHTING
STORAGE
3. CONTROL OF OPERATION
3.1 TIME AND TEMPERATURE CONTROL
3.2 CONTROL OF OTHER SPECIFIC PROCESS STEPS
3.3 SPECIFICATIONS
3.4 MICROBIOLOGICAL CROSS CONTAMINATION
3.5 PHYSICAL AND CHEMICAL CONTAMINATION
3.6 INCOMING MATERIALS REQUIREMENTS
3.7 PACKAGING
3.8 WATER
WATER, ICE AND STEAM IN CONTACT WITH FOOD
WATER, ICE AND STEAM NOT IN CONTACT WITH FOOD
3.9 MANAGEMENT AND SUPERVISION
3.10 DOCUMENTATION AND RECORDS
3.11 PRODUCT RECALL & TRACEABILITY
3.12 STORAGE
4. MAINTENANCE AND SANITATION
4.2 PEST CONTROL
4.3 WASTE MANAGEMENT
5. PERSONAL HYGIENE
6. QUALITY CONTROL
7. TRANSPORTATION
8. PRODUCT INFORMATION AND CONSUMER AWARENESS
9. COMPETENCE & TRAINING
10. TEMPORARY/MOBILE PREMISES; VENDING MACHINES
TURNKEY CONSULTANT FOR SETTING-UP STARCH PROCESSING UNIT
LIST OF SOME STARCH PROCESSING INDUSTRIES
SUPPLIERS OF COMPLETE PLANT
AND MACHINERY FOR POTATO STARCH
SUPPLIERS OF RAW MATERIALS
HYDROCHLORIC ACID
SULPHURIC ACID
SODA ASH
CAUSTIC SODA
ACTIVATED CARBON
OTHER PLANT AND EQUIPMENTS SUPPLIERS
BOILER
TANKS
TRAY DRIER
DISINTEGRATORS
PULVERISER/GRINDER
INDUSTRIAL ETP PLANT MANUFACTURE/SUPPLIER
MIXER
REACTOR
WEIGHING MACHINES
LIST OF FOOD AND AGRO PROCESSING CONSULTANTS
IMPLEMENTATION SCHEDULE
PROJECT IMPLEMENTATION WILL TAKE A PERIOD OF 12 MONTHS.
DETAILS OF PLANT & MACHINERY
POTATO STARCH FACTORY
SECTION: 1.00
POTATO STEEPING
SECTION: 2.00
SECTION: 3.00
WASHING
SECTION: 4.00
FIBRE MILLING AND WASHING
SECTION: 5.00
STARCH SEPARATION AND REFINING
TO FILTER OUT PARTICLES THAT COULD BLOCK SEPARATOR NOZZLES.
SECTION: 6.00
JUICE CONCENTRATION
SECTION: 7.00
DEWATERING AND DRYING
SECTION: 8.00
STEEPING WATER CONCENTRATION
SECTION: 9.00
SECTION: 10.00
ANIMAL FEED DEWATERING AND DRYING
SECTION: 11.00
STARCH DEWATERING AND DRYING
1 BUFFER TANK WITH VENTILATOR
FOR SIFTED STARCH
SECTION: 12.00
HANDLING/HOLDING & STORAGE EQUIPMENTS
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)
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