potato processing unit

POTATO PROCESSING UNIT

[CODE NO.4404] 

Native Potato Starch is basically a carbohydrate, consisting of amylose and amylopectin.

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 elsewhere, 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.

The raw material required for the manufacture potato starch is selected varieties of potato having high starch and low protein and low fibre contents.

• Potato starch is starch extracted from potatoes. The cells of the root tubers of the potato plant contain starch grains (leucoplasts).

• To extract the starch, the potatoes are crushed; the starch grains are released from the destroyed cells. The starch is then washed out and dried to powder.

• Potato starch contains typical large oval spherical granules; their size ranges between 5 and 100 μm.

• Potatoes contain around 20% starch, 2% fibres and 1% protein.

• Potato starch is a very refined starch, containing minimal protein or fat. This gives the powder a clear white colour.

• Potato starch absorbs and retains moisture to a far greater degree than wheat flour.

• The cooked starch typical characteristics of neutral taste, good clarity, high binding strength, long texture and a minimal tendency to foaming or yellowing of the solution.

• Potato starch and potato starch derivatives are used in many recipes, for example in noodles, wine gums, cocktail nuts, potato chips, hot dog sausages, bakery cream and instant soups and sauces, in gluten-free recipes.

• Potato starch is also used in technical applications as wallpaper adhesive, for textile finishing and textile sizing, in paper coating and sizing and as an adhesive in paper sacks and gummed tape.

• Potato starch was also used in one of the earlier color photography processes.

• Potato starch also lowers plasma cholesterol and triglyceride concentrations, increases satiety, and possibly even reduces fat storage.

• Potato starch is gluten free, it is very useful for people with gluten intolerance or wheat sensitivity. It is also a good source of energy.

• The granule size of potato starch is definitely larger than other starches.

• Compared to other starches, potato starch has a higher phosphorus content. Due to higher phosphorus content, potato starch exhibits extremely high viscosity.

COST ESTIMATION

Plant Capacity                                     53.4 MT/Day

Land & Building (3000 sq.yard)        Rs. 2.14  Cr

Plant & Machinery                              Rs. 8.15  Cr

Working Capital for 1 Month            Rs. 1.28  Cr

Total Capital Investment                   Rs. 12.21 Cr

Rate of Return                                      59%

Break Even Point                                 36%

• INTRODUCTION
• PROPERTIES
• ADVANTAGE OF POTATO STARCH
• USES AND APPLICATION
• POTATO STARCH IN FOOD APPLICATIONS
• USES AND APPLICATION OF POTATO FLAKES
• INDUSTRIAL PROTEIN
• THE MAJOR POTATO PROTEINS
• POTATO JUICE
• DETAILS OF POTATO PROTEIN
• NUTRITIONAL QUALITY
• CURRENTLY AVAILABLE PROTEIN INGREDIENT FORMS
• POTENTIAL FUNCTIONALITY AND APPLICATIONS
• PRESENT CONSUMPTION PATTERN
• CATEGORY‐WISE ESTIMATED CONSUMPTION PATTERN OF POTATO
• USES OF STARCH
• A) TEXTILE INDUSTRY:
• B) FOOD INDUSTRY:
• C) PAPER INDUSTRY:
• D) PHARMACEUTICAL INDUSTRY:
• B.I.S. SPECIFICATION
• MARKET SCENARIO OF POTATO STARCH
• SWEET RICE FLOUR:
• CORN STARCH:
• ARROWROOT STARCH:
• TAPIOCA STARCH:
• COCONUT FLOUR:
• RICE FLOUR:
• OPPORTUNITIES
• CONCERNS
• MAJOR CHALLENGES
• NATIVE POTATO STARCH IS SUITABLE FOR USE IN PET FOODS AND ANIMAL NUTRITION
• INCREASED PRODUCTION IN LESSER TIME BOOSTING THE INDUSTRIAL USAGE OF MICROBIAL ENZYMES
• KEY MARKET PLAYERS
• BUYERS OF POTATO STARCH, FLAKES & POWDER
• POTATO STARCH PRODUCTION IN INDIA
• POTATO & POTATO STARCH
• ROTARY WASHING MACHINE
• FLASH DRYING MACHINE
• GROWTH IN PROCESSED FOOD INDUSTRY VIS-A-VIS STARCH INDUSTRY
• STARCH INDUSTRY IN INDIA;
• PRESENT STATUS:
• CONSUMPTION:
• SYNTHESIS OF RAW MATERIAL SPECIFICITIES AND USES
• USES OF STARCH PRODUCTS
• MAJOR STARCH END-USE SECTORS BY STARCH PRODUCT
• PRESENT CONSUMPTION PATTERN
• CATEGORY‐WISE ESTIMATED CONSUMPTION PATTERN OF POTATO
• OVERALL ORGANISATION OF THE POTATO STARCH
• SUPPLY CHAIN
• STARCH INDUSTRY: AN OVERVIEW
• 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
• PROMISING FUTURE
• FUTURE BEHOLDS FOR MODIFIED STARCH MARKET
• MODIFIED STARCH MARKET
• MANUFACTURERS/EXPORTERS/SUPPLIERS OF POTATO STARCH
• RAW MATERIALS
• GLOBAL MARKET OF POTATO STARCH
• BREAKUP BY CATEGORY:
• BREAKUP BY APPLICATION:
• REGIONAL INSIGHTS:
• OVERVIEW OF POTATO FLAKES
• OVERVIEW OF INDIAN SNACKS MARKET
• PROCESS OVERVIEW OF POTATO STARCH
• PROCESS OVERVIEW FOR PRODUCTION OF POTATO STARCH
• DE-SANDING CYCLONE     
• RASPER
• PROTEIN DEWATERING
• MANUFACTURE OF POTATO STARCH
• POTATO STARCH:-
• IS THIS COMPANY CAN PROVIDE MACHINE (GELGOOG)
• PROCESS FLOW SHEET FOR MANUFACTURE OF STARCH
• 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
• SPECIFICATIONS OF POTATO STARCH
• NUTRITIONAL VALUE OF POTATO PROTEIN
• NUTRITIONAL VALUE OF POTATO PROTEINS
• USES AND APPLICATION OF POTATO PROTEIN
• MANUFACTURING PROCESS OF POTATO PROTEIN
• FOOD GRADE COAGULATED POTATO PROTEIN
• STEPS IN POTATO STARCH MANUFACTURE
• DESCRIPTION OF POTATO STARCH MANUFACTURING PROCESS FOR YOUR REFERENCE
• (1) RAW MATERIAL RECEIVING UNIT:
• (2) WATER TRANSPORT:
• (3) DE-STONE AND WASHING UNIT OF POTATO STARCH MANUFACTURING PROCESS:
• (4) RASPER UNIT OF POTATO STARCH MANUFACTURING PROCESS:
• (5) DE-SANDING CYCLONE UNIT OF POTATO STARCH MANUFACTURING PROCESS:
• (6) CENTRIFUGAL EXTRACTING UNIT:
• (7) POTATO RESIDUE DEWATERING UNIT OF POTATO STARCH MANUFACTURING PROCESS:
• (8) CONCENTRATION AND REFINING UNIT:
• (9) VACUUM DEWATERING UNIT OF POTATO STARCH MANUFACTURING PROCESS:
• (10) AIR DRYING UNIT OF POTATO STARCH MANUFACTURING PROCESS:
• (11) SIEVING AND STORAGE UNIT:
• POTATO STARCH EXTRACTION DETAILS
• FIG. 6 - POTATO STARCH EXTRACTION PROCESS
• POTATO STARCH PRODUCTION METHOD
• DELIVERY AND UNLOADING POTATOES
• CLEANING
• RASPING OF TUBERS
• POTATO JUICE SEPARATION
• STARCH EXTRACTION
• STARCH MILK RAFFINATION
• DEWATERING OF REFINED STARCH MILK AND STARCH DRYING
• TABLE: POTATO STARCH PRODUCTION CHARACTERISTIC.
• WASTE PRODUCTS
• MANUFACTURE OF POTATO FLAKES
• WASHING & SORTING
• PEELING
• COOKING
• PULPING AND DRUM DRYING OF PULP TO PRODUCE FLAKES
• CONTINUOUS PROCESS TO MANUFACTURE POTATO FLAKES
• A POTATO FLAKE PRODUCTION LINE
• FIRST PHASE OF PRODUCTION
• CUTTING, PRE-COOKING AND COOLING
• DRYING, SIZING AND PACKING.
• EFFLUENT TREATMENT AND DISPOSAL
• EFFLUENT TREATMENT PLANT SPECIFICATION AND NORMS
• STANDARDS
• TOLERANCE LIMITS FOR INDUSTRIAL EFFLUENT DISCHARGE
• WASTE TREATMENT
• PRIMARY TREATMENT
• ANAEROBIC TREATMENT
• SECONDARY TREATMENT
• TERTIARY TREATMENT
• SOLIDS CONCENTRATION
• TYPICAL WASTE SOLIDS CHARACTERISTICS
• EQUIPMENT REQUIREMENT
• EQUIPMENT REQUIREMENTS
• MANPOWER
• GENERAL
• BASIS OF ESTIMATION
• GENERAL PLANT LAYOUT
• GMP/GHP CRITERIA FOR STARCH
• 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 [GLOBAL]
• SUPPLIERS OF PLANT AND MACHINERY (INDIAN)
• SUPPLIERS OF RAW MATERIALS
• SUPPLIERS OF HYDROCHLORIC ACID
• SUPPLIERS OF SULPHURIC ACID
• SUPPLIERS OF SODA ASH
• SUPPLIERS OF CAUSTIC SODA
• SUPPLIERS OF ACTIVATED CARBON
• OTHER PLANT AND EQUIPMENTS SUPPLIERS
• SUPPLIERS OF BOILER
• SUPPLIERS OF TANKS
• SUPPLIERS OF TRAY DRIER
• SUPPLIERS OF DISINTEGRATORS
• SUPPLIERS OF PULVERISER/GRINDER
• SUPPLIERS OF INDUSTRIAL ETP PLANT MANUFACTURE/SUPPLIER
• SUPPLIERS OF MIXER
• SUPPLIERS OF REACTOR
• SUPPLIERS OF WEIGHING MACHINES
• SUPPLIERS OF LIST OF FOOD AND AGRO PROCESSING CONSULTANTS
• IMPLEMENTATION SCHEDULE
• DETAILS OF PLANT & MACHINERY SECTION:
• POTATO STARCH FACTORY
• SECTION: 1.00
• POTATO STEEPING
• POTATO STARCH FACTORY
• SECTION: 2.00
• SULPHUR DIOXIDE PLANT
• POTATO STARCH FACTORY
• SECTION: 3.00
• WASHING
• POTATO STARCH FACTORY
• SECTION: 4.00
• FIBRE MILLING AND WASHING
• POTATO STARCH FACTORY
• SECTION: 5.00
• STARCH SEPARATION AND REFINING
• TO FILTER OUT PARTICLES THAT COULD BLOCK SEPARATOR NOZZLES.
• POTATO STARCH FACTORY
• SECTION: 6.00
• JUICE CONCENTRATION
• POTATO STARCH FACTORY
• SECTION: 7.00
• DEWATERING AND DRYING
• POTATO STARCH FACTORY
• SECTION: 8.00
• STEEPING WATER CONCENTRATION
• POTATO STARCH FACTORY
• 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)