Detailed Project Report on maize starch processing plant

MAIZE STARCH PROCESSING PLANT

[CODE NO.4128]  

Starch Industry in India

 Starch is an abundant carbohydrate distributed worldwide in plants. Starch has been a major ingredient in man's diet over the centuries. In addition it has become a major industrial raw material. Plant seeds, roots and tubers are all sources of industrial starch production. The commercial realities of the starch recovery process limit the industrial sources mainly to wheat, maize and tapioca. Indian starch industry mainly consumes maize as input raw material. 

Also some industries are tapioca based.

Maize is doing wonderful things in our everyday life. Maize is present in one form or other in  

The Food we eat 

The Milk we drink

The Chocolates/Biscuits we take

The Clothes we wear

The Paper we read

The Medicines we take

Maize (Corn) contains about 70% starch, other components being protein, fibers and fat. The basis of the maize milling process is the separation of the maize kernel into its different parts. Maize starch is produced by the wet milling process, which involves grinding of softened maize and separation of corn oil seeds (germs), gluten (proteins), fibers (husk) and finally pure starch.  

Byproducts from Maize

The byproducts from maize based industries find various applications:

i. Maize (Corn) Steep Liquor: It contains amino acids, proteins and are used by antibiotics drugs manufacturers. Also it is a large source of biogas, which is being used as fuel for driers, boilers etc.

ii. Maize Gum: Corn Oil is produced by expelling oil from the germs. Corn Oil finds applications in food and other chemical industries. Maize oil cake obtained after expelling oil is used as cattle and poultry feeds.

iii. Maize Gluten: Maize Gluten contains high protein content and it is used as cattle and poultry feeds.

iv. Maize Husk: It contains starch, protein and fat as minor components and mainly consumed as cattle feed.

Starches

Starch is a group of polysacchrides, composed of glucopyranose units joined together by-glucosidric linkages. It conforms to the molecular formula, (C6-H10O5)u, where nvaries from a few hundred to over one million. Starch is found as the reserve carbohydrate in various parts of plants and is enzymatically broken down to glucose to other carbohydrates according to the metabolic needs of the plants.

Industrially, starch is broadly divided into two types viz, natural and modified. Natural starches also designated as unmodified starches or simply starches are obtained from grains such as and sorghum. From roots like potato, tapioca and arrow root, and from the pith of the stems of certain palms such a sago. They are further classified into cereal starches and root starches. The characteristics of the natural starches are changed by chemical or enzymatic action and the products of these reactions are termed modified starches. This group includes dextrins, acid-modified starches, oxidized starches, starch esters, starch ethers, aldehyde starches and cationic starches.

Natural Starches

Starch occurs naturally in the plants and its percentage varies with the plant and also in different parts of the same plant. Corn (maize) sorghum grain wheat, rice, potato, tapioca, arrowroot and sago are among the important sources of natural starches. The grains of barley, rye, oat and the millets are also employed in the production of starches.

Cereal Starches 

The cereal starches such as maize wheat, rice and sorghum are recovered by several processes, of which the wet-milling is by far the most important. Other processes commercially employed in the manufacture of unmodified starches are that alkali, Martin and batter in the order of decreasing importance. Of the material methods earlier used for the production of starch and which has now become obsolete, mention may be made of the Hakka, Alsation and Fescas processes. In all the above processes, Starch is recovered in five stages:

a. Softening or steeping of the grains, after thorough washing in water.

b. Tabling or centrifugation of the ground mass.

c. Dewatering and drying of the final products.

d. The recovery of important by products.

MAIZE SCENARIO IN INDIA 

The principal raw materials, used by the Indian Starch Industry are maize and tapioca.

Maize  is  grown in Uttar Pradesh,  Bihar,  Rajasthan, Punjab,  Madhya  Pradesh, Himachal Pradesh, Gujarat,  Jammu  and Kashmir,  Andhra  Pradesh, Mysore, and Haryana.

Among the maize growing countries India rank 4th in area and 7th in production, representing around 4% of world maize area and 2% of total production. During 2018-19 in India, the maize area has reached to 9.2 million ha (DACNET, 2020). During 1950-51 India used to produce 1.73 million MT maize, which has increased to 27.8 million MT by 2018-19, recording close to 16 times increase in production. The average productivity during the period has increased by 5.42 times from 547 kg/ha to 2965 kg/ha, while area increased nearly by three times. Though the productivity in India is almost half of world the average per day productivity of Indian maize is at par with many lead maize producing countries.

In India, maize is principally grown in two seasons, rainy (kharif) and winter (rabi). Kharif maize represents around 83% of maize area in India, while rabi maize correspond to 17% maize area. Over 70% of kharif maize area is grown under rainfed condition with prevalence of many biotic and abiotic stresses. The stress prone ecology contributes towards lower productivity of kharif maize (2706 kg/ha) as compared to rabi maize (4436 kg/ha), which is predominantly grown under assured ecosystem. In recent past spring maize area is also growing quite fast in north western parts of the country, in the states of Punjab, Haryana and Western Uttar Pradesh. Unfortunately the area and production data of spring maize is not well documented. However, informal estimate suggest the area to be around 150 thousand ha. Among cereals maize has highest growth rate in terms of area and productivity. Since last decade maize productivity in India is increasing @ over 50 kg/ha/year, which is highest among food crops.

Among Indian states Madhya Pradesh and Karnataka has highest area under maize (15% each) followed by Maharashtra (10%), Rajasthan (9%), Uttar Pradesh (8%) and others. After Karnataka and Madhya Pradesh Bihar is the highest maize producer. Andhra Pradesh is having highest state productivity. Some districts like Krishna, West Godavari etc. records as high as 12 t/ha productivity.

Bulk of the maize production in India, approximately 47%, is used as poultry feed. Of the rest of the produce, 13% is used as livestock feed and food purpose each, 12% for industrial purposes, 14% in starch industry, 7% as processed food and 6% for export and other purposes.

COST ESTIMATION

Plant Capacity                                    150 Ton./Day  

Land & Building (48,000 sq.mt.)  Rs. 27.27 Cr    

Plant & Machinery                            Rs. 40.55 Cr 

Working Capital for 2 Months            Rs. 20.42 Cr 

Total Capital Investment                  Rs. 90.11 Cr 

Rate of Return                                  32%

Break Even Point                               48%

• INTRODUCTION
  
• STARCH INDUSTRY IN INDIA
• BYPRODUCTS FROM MAIZE
• STARCHES
• NATURAL STARCHES
• CEREAL STARCHES
• MAIZE SCENARIO IN INDIA
• SPECIFICATION OF STARCH
• MAIZE STARCH SPECIFICATION
• 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:
• 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:
• 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 OF LIQUID GLUCOSE
• PROPERTIES OF STARCH
• PHYSICAL PROPERTIES
• CHEMICAL PROPERTIES
• STARCH GIVES A CHARACTERISTIC BLUE COLOR WITH IODINE.
• CORN AND CORN OIL
• A. PARTS OF CORN KERNEL, B. NUTRIENT COMPOSITION 
•        OF CORN KERNELS
• CORN OIL VALUE
• OVERVIEW OF CORN WET MILLING
• CORN-WET MILLING MARKET – NOTABLE DEVELOPMENTS
• FEW ARE PROMINENT COMPETITORS OPERATING IN THE COMPETITIVE
•     LANDSCAPE OF GLOBAL CORN-WET MILLING MARKET INCLUDE
• CORN-WET MILLING MARKET DYNAMICS
• OVERVIEW OF MAIZE IN INDIA
• INTERNATIONAL GRAIN COUNCIL’S WORLD 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
• 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
• 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*
• SEQUENCES IN STARCH AND LIQUID GLUCOSE
• IT CONSISTS OF FOLLOWING STEPS:-
• PROCESS DESCRIPTION OF CORN STARCH
• 1. CORN CLEANING AND STEEPING
• 2. MILLING, GERM SEPARATION AND DRYING
• 3. GRIT MILLING AND FIBER WASHING
• 4. STARCH AND GLUTEN SEPARATION AND STARCH WASHING
• 5. GLUTEN DEWATERING AND DRYING
• 6. STARCH DEWATERING AND DRYING
• METHOD OF MAIZE PROCESSING
• MAIZE IS USUALLY PROCESSED BY TWO PROCESSES:
• DRY MILLING PROCESS FLOW
• WET MILLING PROCESS FLOW
• STARCH MANUFACTURING PROCESS FLOW DIAGRAM
• PROCESSING CORN BY WET MILLIING
• DETAILS OF 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
• MANUFACTURING PROCESS OF LIQUID GLUCOSE
• PROCESS DESCRIPTION OF LIQUID GLUCOSE MANUFACTURE
• SEQUENCES IN MAIZE STARCH
• CORN STARCH PRODUCTION
• PRODUCTION OF STARCH SLURRY
• PRODUCTION OF STARCH SLURRY
• PRODUCTION OF STARCH AND DEXTRINS:
• PROCESSING DETAILS OF MAIZE STARCH
• 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
• PROCESS DESCRIPTION OF CORN WET MILLING
• CLEANING AND SOAKING
• STEEP LIQUOR CONCENTRATION
• CRUDE GEM OIL RECOVERY
• FIBRE SEPARATION
• GLUTEN SEPARATION AND CONCENTRATION
• MIXED FEED PROCESSING
• STARCH WASHING DEWATERING AND DRYING
• RAW MATERIALS AND UTILITIES
• RAW MATERIALS
• 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:
• MANUFACTURE OF DEXTROSE MONOHYDRATE AND DEXTROSE 
•     ANHYDROUS
• DEXTROSE MANUFACTURE
• MANUFACTURING DIAGRAM OF LIQUID GLUCOSE
• MANUFACTURING DIAGRAM OF ANHYDROUS DEXTROSE
• 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 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
• LAB TESTING EQUIPMENT:-

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)