Detailed Project Report on corn grits
Detailed Project Report on corn grits
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CORN GRITS
[CODE NO.3833]
Corn was first domesticated by native peoples in Mexico about 10,000 years ago. Native Americans taught European colonists to grow the indigenous grains, and, since its introduction into Europe by Christopher Columbus and other explorers, corn has spread to all areas of the world suitable to its cultivation. It is grown from 58° N latitude in Canada and Russia to 40°S latitude in South America, with a corn crop maturing somewhere in the world nearly every month of the year. It is the most important crop in the United States and is a staple food in many places.
Maize “the Queen of Cereals” is known as corn and is one of the most important cereal crops of the world. It is distinguished botanically as “Zea mays” and belongs to the grains family “Gramineae”. Maize is the only food cereal crop that can be grown in different seasons. It requires moderate climate for growth, grows well in loamy soils, but a surplus or poor rain adversely affects the yield as well as the quality. Depending on the colour and taste, it is classified into two broad groups i.e. Yellow and White. Yellow maize is traditionally used for animal feed and is grown mostly in the Northern hemisphere countries.
White maize which is generally considered as a food crop requires more favorable climatic conditions and is produced only in limited countries. Based on the size and composition of the endosperm several hybrid of maize exists viz. dent corn, flint corn, popcorn, sweet corn, etc. The maize is an important staple food in many parts of the world and is used as an important raw material in food processing, feed industry and in various other industrial applications.
The corn plant is a tall annual grass with a stout, erect, solid stem. The large narrow leaves have wavy margins and are spaced alternately on opposite sides of the stem. Staminate (male) flowers are borne on the tassel terminating the main axis of the stem.
The pistillate (female) inflorescences, which mature to become the edible ears, are spikes with a thickened axis, bearing paired spikelets in longitudinal rows; each row of paired spikelets normally produces two rows of grain. Varieties of yellow and white corn are the most popular as food, though there are varieties with red, blue, pink, and black kernels, often banded, spotted, or striped. Each ear is enclosed by modified leaves called shucks or husks. Many industrial varieties of corn are genetically modified for resistance to the herbicide glyphosate or to produce proteins from Bacillus thuringiensis (Bt) to kill specific insect pests. In addition, some strains have been genetically engineered for greater drought tolerance.
Grits are small broken grains of corn. They were first produced by Native Americans centuries ago. They made both “corn” grits and “hominy” grits. Falls Mill produces “corn” grits.
Falls Mill mills locally grown whole white hybrid corn. The corn is dried to a 14% moisture content, then each kernel is cleaned with forced air. The kernels of grain are run through the mill stone where they are ground to a certain texture and then sifted through two wire mesh screens. The three products sorted are white corn meal, white corn grits and the bran that pops off. There is a fine bran still in the grits product. This bran will never soften up with cooking. Depending on personal preference, the bran can be left in or removed by rinsing the grits before cooking Grits are an iconic southern dish that dates back as far as the 16th century. They were originally made by drying corn kernels and boiling them to create a mush.
Corn is the cereal with the highest production worldwide and is used for human consumption, livestock feed, and fuel. Various food technologies are currently used for processing industrially produced maize flours and corn meals in different parts of the world to obtain precooked refined maize flour, dehydrated nixtamalized flour, fermented maize flours, and other maize products. These products have different intrinsic vitamin and mineral contents, and their processing follows different pathways from raw grain to the consumer final product, which entail changes in nutrient composition. Dry maize mechanical processing creates whole or fractionated products, separated by anatomical features such as bran, germ, and endosperm. Wet maize processing separates by chemical compound classification such as starch and protein. Various industrial processes, including whole grain, dry milling fractionation, and nixtamalization, are described. Vitamin and mineral losses during processing are identified and the nutritional impacts outlined. Also discussed are the vitamin and mineral contents of corn.
Bihar is one of the largest maize growing state and the crop was grown primarily as a subsistence crop to meet food needs for a long time till recently. But now like in nontraditional areas (Karnataka and Andhra Pradesh), it is also grown for commercial purposes (i.e., mainly to meet the raw material requirements of the animal feed sector). It is third largest maize producing state contributing around 10 percent to national production.
Maize/corn can be utilized in many different forms by converting it into a variety of products, through grinding, alkali processing, boiling, cooking and fermenting, such as corn starch, corn flakes and cereals, ethanol etc. It also has many industrial applications, which can make it a profitable crop in the state. Maize processing and utilization pattern shows that in India, around 60 per cent of the total produce is for animal feed, 28 per cent for human consumption and 12 per cent is used by the industry (starch, brewery etc). In Bihar only 8-10% of maize (5% directly by the processors and another 3-5% is being used by road side snack joints etc.) is processed within the state despite the fact that the state has huge and rising marketable surplus.
COST ESTIMATION
Plant Capacity 50 MT/Day
Land & Building (400 sq.mt.) Rs. 30 Lac
Plant & Machinery Rs. 42 Lac
Working Capital for 1 Month Rs. 2.75 Cr
Total Capital Investment Rs. 3.62 Cr
Rate of Return 146%
Break Even Point 25%
INTRODUCTION
AGRICULTURAL MAP OF BIHAR
ORIGIN AND IMPORTANCE
ORIGIN
IMPORTANCE
NUTRITIONAL VALUE OF MAIZE
MAIZE KERNEL ANATOMY
COMPONENTS OF THE CORN KERNEL.
MAIZE KERNEL COMPOSITION
APPLICATION
PHYSICAL PROPERTIES OF MAIZE
MATERIALS AND METHODS
SAMPLING AND REPLICATING
DETERMINATION OF MOISTURE CONTENT
DETERMINATION OF PHYSICAL PROPERTIES
SIZE
SPHERICITY
TRUE DENSITY
MARKET POSITION
MAIZE PRODUCTION – GLOBAL AND NATIONAL SCENARIO
GENERALLY FOLLOWING THREE TYPES OF CORN IS GROWN
DRY MILLING
COMPONENTS OF MAIZE/CORN
BIHAR MAIZE (CORN) PHYSICAL MARKET
INDIA MAIZE PRODUCTION
MILLED-CORN PRODUCTS MARKET OUTLOOK
MILLED-CORN PRODUCTS MARKET: REASONS FOR COVERING THIS TITLE
GLOBAL MILLED-CORN PRODUCTS: MARKET SEGMENTATION
GLOBAL MILLED-CORN PRODUCTS MARKET: KEY PLAYERS
MILLED CORN PRODUCTS MARKET
DRY MILLING MARKET FOR CORN WORTH 88.61 BILLION USD BY 2022
THE ETHANOL SEGMENT, BY END PRODUCT, IS PROJECTED TO GROW
AT THE HIGHEST CAGR FROM 2017 TO 2022
THE YELLOW CORN SEGMENT ACCOUNTED FOR LARGEST MARKET
SHARE IN 2016.
ASIA-PACIFIC IS PROJECTED TO GROW AT THE HIGHEST CAGR
FROM 2017 TO 2022
MILLED-CORN PRODUCTS MARKET: KEY TRENDS
KEY PRODUCT LAUNCHES IN MILLED-CORN PRODUCTS MARKET
OPPORTUNITIES FOR MILLED-CORN PRODUCTS MARKET PARTICIPANTS
THE YELLOW CORN SEGMENT ACCOUNTED FOR LARGEST MARKET
SHARE IN 2016.
ASIA-PACIFIC IS PROJECTED TO GROW AT THE HIGHEST CAGR
FROM 2017 TO 2022
MANUFACTURING PROCESS
TECHNOLOGY INTRODUCTION OF CORN GRITS & FLOUR PRODUCTION LINE
TECHNOLOGICAL PROCESS OF CORN GRITS AND FLOUR PRODUCTION LINE
MULTIFUNCTIONAL CORN GRITS AND CORN FLOUR MACHINE SET
TECHNOLOGICAL PROCESS:
TECHNICAL INDEX
QUALITY ISSUES AND STANDARDS
TECHNICAL PARAMETER
PROCESS FLOW DIAGRAM
PRODUCT PHOTOGRAPHS
END PRODUCTS OF CORN GRITS, FLOUR AND GERM EXTRACTION LINE:
MACHINERY PHOTOGRAPHS
CORN CLEANING MACHINE
CORN GRINDING MACHINE
CORN PEELING MACHINE
MINI DESTONER MACHINE
FOUR-SIZE GRITS MACHINE
RAW MATERIAL PHOTOGRAPHS
MACHINERY SUPPLIER
COMPLETE MACHINERY:-
CORN CLEANING MACHINE
CORN GRINDING MACHINE
CORN PEELING MACHINE
FOUR-SIZE GRITS MACHINE
RAW MATERIAL SUPPLIER
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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