Starch to Sweeteners (Maltodextrin, DE40 Syrup, Maltitol, Dextrose Monohydrate) (Cap: 166.667 MT/Day)

STARCH TO SWEETENERS (MALTODEXTRIN, DE40 SYRUP, MALTITOL, DEXTROSE MONOHYDRATE) (CAP: 166.667 MT/DAY)

[EIRI/EDPR/4500] J.C.: 2716INR, 2716US$

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.  

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 n varies 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 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.

COST ESTIMATION

Plant Capacity            166.667 MT/Day  

Land & Building (40,000 sq.mt.)    Rs. 27.37 Cr    

Plant & Machinery                    Rs. 55.00 Cr 

Working Capital for 1 Month    Rs. 27.35 Cr 

Total Capital Investment          Rs. 110.85 Cr 

Rate of Return                          43%

Break Even Point                      42%

CONTENTS

INTRODUCTION

SPECIFICATION OF STARCH

MAIZE STARCH SPECIFICATION

USES AND APPLICATION OF MALTITOL

CHEMICAL PROPERTIES

USES OF LIQUID GLUCOSE:-

LIQUID GLUCOSE SYRUP USES AND APPLICATIONS:

LIQUID GLUCOSE USES

MAIZE SCENARIO IN INDIA

PROPERTIES

PROPERTIES OF STARCH

PHYSICAL PROPERTIES

CHEMICAL PROPERTIES

STARCH GIVES A CHARACTERISTIC BLUE COLOR WITH IODINE.

PROPERTIES OF MALTITOL

MARKET OVERVIEW OF STARCH BASED SWEETENER

MANUFACTURERS/SUPPLIERS OF STARCH BASED PRODUCTS

MAIZE STARCH

LIQUID GLUCOSE

SEQUENCES IN LIQUID GLUCOSE MANUFACTURING (DE 40)

BLOCK DIAGRAM OF SWEETENER PLANT

PRODUCTION METHOD OF GLUCOSE/CORN SYRUP

ACID-CATALYZED HYDROLYSIS

FIGURE: TYPICAL CORN/GLUCOSE SYRUP PROCESS

FIGURE: TYPICAL ACID CONVERTER

FIGURE: CARBON TREATMENT AND REGENERATION SYSTEM

ACID–ENZYME PROCESSES

FIGURE: SYRUP DEMINERALIZATION SEQUENCE

FIGURE: MULTIPLE-EFFECT EVAPORATOR

PRODUCTION METHOD OF MALTODEXTRIN

FIGURE: GENERAL PROCESS FLOW FOR STARCH-DERIVED SWEETENERS (CORN/GLUCOSE SYRUPS, HIGH FRUCTOSE SYRUPS, DEXTROSE, FRUCTOSE, MALTODEXTRINS AND SYRUP SOLIDS)

MALTITOL PRODUCTION METHOD

LOW DE GLUCOSE SYRUP FROM STARCH

CONDITIONING OF STARCH MILK

RAW MATERIAL PREPARATION

ENZYME HYDROLYSIS

BIOREACTION

PURIFICATION

PRODUCT ISOLATION AND CONCENTRATION

MALTODEXTRIN

SEQUENCES IN CORN SYRUP AND HIGH FRUCTOSE CORN SYRUP

SEPARATING CORN STARCH FROM CORN

CONVERTING CORN STARCH INTO CORN SYRUP

CONVERTING CORN SYRUP INTO HIGH FRUCTOSE CORN SYRUP

HIGH FRUCTOSE CORN SYRUP MANUFACTURING PROCESS

(1) PREPARATION:

(2) ISOMERIZATION:

(3) DECOLORIZATION:

(4) DEMINERALIZATION:

(5) EVAPORATION:

HFCS 55 PROCESS DESCRIPTION

PURE CRYSTALLINE FRUCTOSE (PCF) PROCESS DESCRIPTION

(1) CHROMATOGRAPHIC SEPARATION

(2) BLENDING

(3) POLISHING

(4) EVAPORATION

PROCESS FLOW DIAGRAM OF FRUCTOSE SYRUP

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:

RAW MATERIALS

CONFECTIONERI GLUCOSE-D:

LOW CONVERSION

REGULAR CONVERSION

INTERMIDIATE CONVERSION

HIGH CONVERSION

MANUFACTURE OF DEXTROSE MONOHYDRATE & DEXTROSE ANHYDROUS

DEXTROSE MANUFACTURE

MANUFACTURING DIAGRAM OF LIQUID GLUCOSE

MANUFACTURING DIAGRAM OF ANHYDROUS DEXTROSE

MANUFACTURING PROCESS OF SORBITOL

TURNKEY SUPPLIERS OF STARCH YO SWEETENERS

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 SULPHURIC ACID

SUPPLIERS OF CAUSTIC SODA

SUPPLIERS OF SODA ASH

DETAILS OF PLANT & MACHINERY FOR CORN WET MILLING

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

SECTION: 9.00

10. ANIMAL FEED DEWATERING AND DRYING

11. STARCH DEWATERING AND DRYING

12. SORBITOL AND MALTODEXTRIN MANUFACTURING SECTION

13. DMH SECTION

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)