Detailed Project Report on maize/corn and its by products like starch, corn oil, corn syrup, dextrose monohydrate, dextrin, maltodextrin, maize germ, sorbitol powder, high fructose corn syrup, gluten, animal feed

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MAIZE/CORN AND ITS BY PRODUCTS LIKE STARCH, CORN OIL, CORN SYRUP, DEXTROSE MONOHYDRATE, DEXTRIN, MALTODEXTRIN, MAIZE GERM, SORBITOL POWDER, HIGH FRUCTOSE CORN SYRUP, GLUTEN, ANIMAL FEED

[CODE NO.3816]

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.

1.0 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 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 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.

1.1 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.

1.1 Natural Starches

1.3 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 have 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.

1.4 Raw Materials

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

1.4.1 Maize

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

COST ESTIMATION

Plant Capacity 60 MT/Day

Land & Building (16,000 sq.mt.) Rs. 10.17 Cr

Plant & Machinery Rs. 19.60 Cr

Working Capital for 2 Months Rs. 6.47 Cr

Total Capital Investment Rs. 37.49 Cr

Rate of Return 16%

Break Even Point 67%

INTRODUCTION

STARCH INDUSTRY IN INDIA

BYPRODUCTS FROM MAIZE

1.0 STARCHES

1.1 NATURAL STARCHES

1.3 CEREAL STARCHES

1.4 RAW MATERIALS

1.4.1 MAIZE

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 :

A) CONCENTRATED STEEP LIQUOR:

B) GERM OIL AND GERM AND CAKE:

C) GLUTEN:

PHYSICAL AND CHEMICAL MODIFICATION OF STARCH

COMPONENT OF YELLOW DENT CORN

ECONOMIC SIZE UNIT AND PRODUCTION PATTERN

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

PROPERTIES OF STARCH

PHYSICAL PROPERTIES

CHEMICAL PROPERTIES

STARCH GIVES A CHARACTERISTIC BLUE COLOR WITH IODINE.

OVERVIEW OF CORN WET MILLING

OVERVIEW OF MAIZE IN INDIA

MAIZE PRICE OUTLOOK

MARKET OVERVIEW

CONSUMPTION PATTERN OF MAIZE IN INDIA

IMPORT & EXPORT DATA OF MAIZE STARCH

STARCH INDUSTRY IN INDIA: SUPPLY AND DEMAND SCENARIO

SUPPLY

DEMAND

DETAILED EXPORT DATA OF CORN STARCH

DETAILED EXPORT DATA OF LIQUID GLUCOSE

DETAILED EXPORT DATA OF CORN OIL

MANUFACTURERS/SUPPLIERS

MAIZE STARCH

LIQUID GLUCOSE

SPECIFICATION

CORN WET MILLING

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

PROCESSING DETAILS OF MAIZE STARCH

RECEIVING

CLEANING

STEEPING

GRINDING

GERM SEPARATION (DEGERMINATION)

FIBRE WASHING SECTION

THICKENING

PRIMARY SEPARATION

GLUTEN THICKENING

ROTARY VACUUM FILTER

HYDROCLONE SYSTEM

DRYING

MANUFACTURES OF STARCH AND ALLIED PRODUCTS

MAIZE STARCH

AMYLOSE MOLECULE OF STARCH

TABLE NO.2.1

AMYLOPECTIN MOLECULE

DETAILS OF CORN WET MILLING

PROCESS DESCRIPTION

5.1 CLEANING AND SOAKING

5.2 STEEP LIQUOR CONCENTRATION

5.3 CRUDE GEM OIL RECOVERY

5.4 FIBRE SEPARATION

5.5 GLUTEN SEPARATION AND CONCENTRATION

5.6 MIXED FEED PROCESSING

5.7 STARCH WASHING DEWATERING AND DRYING

PROCESS FLOW DIAGRAM FOR THE MFG. OF STARCH

MANUFACTURE OF CORN SYRUP

MANUFACTURE OF HIGH FRUCTOSE CORN SYRUP

PROCESS FLOW DIAGRAM OF FRUCTOSE SYRUP

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:

MAIZE PROCESSING PROCESS SHEET

MANUFACTURING PROCESS FOR LIQUID GLUCOSE

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

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:

SUPPLIERS OF PLANT AND MACHINERY

CENTRIFUGE

HEAT EXCHANGER

LAB TESTING EQUIPMENT

BOILERS

SUPPLIERS OF RAW MATERIALS

CORN/MAIZE

SULPHUR

SULPHURIC ACID

CAUSTIC SODA

SODA ASH

PLANT & MACHINERY SECTION WISE

LIST OF MACHINERY AND EQUIPMENT

1. MAIZE STEEPING

3. DEGERMINATION AND GERM WASHING

4. FIBRE MILLING AND WASHING

6. GLUTEN CONCENTRATION

7. GERM DEWATERING AND DRYING

8. STEEPING WATER CONCENTRATION

10. DRYER FOR ANIMAL FEED

11. STARCH DEWATERING AND DRYING

12. SORBITOAL AND MALTODEXTRIN MANUFACTURING SECTION

B. HANDLING/HOLDING & STORAGE EQUIPMENTS

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)

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