Detailed Project Report on Liquid Glucose from Potatoes

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LIQUID GLUCOSE FROM POTATOES

[EIRI/EDPR/1530] J.C. 323

INTRODUCTION

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 which is used for preparation of liquid glucose.

Commercial or liquid glucose is a thick, syrupy, colourless to yellowish liquid obtained by partial hydrolysis of starch. Liquid glucose is distinct from commercial dextrose which is a white or cream coloured crystalline powder (sp.Gr.1.544) obtained by the complete hydrolysis of starch.

The raw materials required for the manufacture of glucose are starch and mineral acids; amylolytic enzymes may also be used for starch hydrolysis.

COST ESTIMATION

Plant Capacity 25.00 MT/Day

Land & Building (5 Acres)                         Rs. 3.39 Cr
Plant & Machinery                                        Rs. 8.5 Cr
W.C. for 2 Months                                        Rs. 2.12 Cr
Total Capital Investment                              Rs. 14.17 Cr
Rate of Return                                              17%
Break Even Point                                         68%

CONTENTS

INTRODUCTION

PROPERTIES

B I S SPECIFICATION

RAW MATERIALS

MARKET SURVEY

MARKET POSITION

NAME AND ADDRESS OF MANUFACTURERS OF LIQUID GLUCOSE & STARCH

LIQUID GLUCOSE AND DEXTROSE - AN ASSESSMENT OF MARKET

SPECIFICATIONS

MANUFACTURES OF LIQUID GLUCOSE

PROCESS FLOW DIAGRAM FOR THE MFG. OF STARCH

MANUFACTURING PROCESS FOR LIQUID GLUCOSE-G

MANUFACTURING DIAGRAM OF LIQUID GLUCOSE

POTATO STARCH AND ALLIED PRODUCTS AND THEIR APPLICATIONS

TURNKEY CONSULTANT FOR SETTINGUP POTATO PROCESSING UNIT

COMPLETE PLANT AND MACHINERY SUPPLIERS

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF PLANT & MACHINERY

EFFLUENT TREATMENT AND DISPOSAL

EQUIPMENT REQUIREMENTS

MANPOWER

IMPLEMENTATION SCHEDULE

LIST OF FOOD AND AGRO PROCESSING CONSULTANTS

PLANT & MACHINERY

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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