Detailed Project Report on maize dry milling plant

MAIZE DRY MILLING PLANT
[CODE NO.3200]  


Maize/corn dry milling process is a less versatile, less capital intensive process that focuses primarily on the production of grain ethanol. In this process, the corn kernel are hammer milled into a medium to fine grind meal for introduction to the ethanol production process. The products of a traditional dry grind ethanol facility and dried distillers grain (DDG) a low value animal feed product.

Dry milling technology has been standardized by Central Food Technological Research Institute (CFTRI) Mysore.

The grits is the main product of dry milling process, which is used as porridge by boiling domestically. The processing units, use grits for manufacture of products like ready to eat snacks (Corn flakes), manufacture of glucose by direct hydrolysis etc.

Maize is one of the staple foods in India. The annual maize production in India is around 21 million tons with the highest maize cultivation in Karnataka, Andhra
Pradesh and Rajasthan.

India is one of the largest cultivators of maize in the world, and it is a crop suitable for all the growing seasons in nearly every agro-climatic zone within the country’s borders. India has seen a dramatic increase in maize cultivation over the past few years, which explains its pre-eminence as a starch source among processors.

Traditionally, the grain is converted into flour in mill for making bread immature cobs are roasted and eater all over the country. It is an important material for animal and poultry feed, corn flakes etc.

The quantity of maize utilized by this unit, is limited as the existing units are of small scale nature. They make only a few products having limited demand where as a large scale unit can process a large quantity of maize to different value added products.

COST ESTIMATION

Plant  Capacity                                                           :    32.00 Tons/day          
land & Building (8000 Sq.Mtr)                                 :    Rs. 1.46 Cr
Plant & Machinery                                                      :    Rs. 65.00 Lacs
Working Capital for 2 Months                                  :    Rs. 2.70  Cr
Total Capital Investment                                          :    Rs. 5.11  Cr
Rate of Return                                                           :    16%
Break Even Point                                                      :    61%

INTRODUCTION    
GRITS/CONES    
FLOUR    
GERM    
MAIZE KERNEL ANATOMY AND COMPOSITION    
MAIZE KERNEL COMPOSITION    
OVERVIEW OF MAIZE PRODUCTION AND TRENDS IN INDIA    
TABLE: MAIZE AREA, PRODUCTION AND YIELD STATISTICS IN INDIAN
STATES FROM 2012-13 TO 2014-15    
MARKET SURVEY    
PRODUCTION OF MAIZE IN INDIA HAS INCREASED AT A CAGR OF 5.5 PER
CENT FROM 14 MNMT IN 2004-05 TO 23 MNMT IN 2013-14    
MAIZE CONSUMPTION HAS INCREASED AT A CAGR OF 3.6 PER CENT
OVER THE LAST FIVE YEARS; POULTRY FEED ACCOUNTS FOR ~50
PER CENT OF MAIZE CONSUMPTION    
END-USE FOR MAIZE    
EXPORT OF MAIZE HAS INCREASED SIGNIFICANTLY OVER THE YEARS; INDONESIA, VIETNAM & MALAYSIA ARE THE KEY EXPORT

DESTINATION    
THE GOVERNMENT HAS BEEN PROVIDING PRICE SUPPORT MECHANISM
TO ENCOURAGE FARMERS TO GROW MAIZE    
ANNUAL MAIZE PRICES HAVE BEEN FOLLOWING THE MSP DECLARED
BY THE GOVERNMENT, AS CAN BE SEEN FROM THE GRAPH BELOW.    
STOCK TO CONSUMPTION RATIO FOR INDIA INCREASED FROM 3.7 PER
CENT IN 2004-05 TO 6.6 PER CENT IN 2013-14 VIS-À-VIS GLOBAL
AVERAGE OF 16.3 PER CENT IN 2013-14    
IMPORT & EXPORT DATA OF CORN FLAKES    
DETAILED EXPORT DATA OF MAIZE GRITS    
PRESENT MANUFACTURERS/SUPPLIERS    
COMPOSITION OF YELLOW DENT CORN    
SAMPLING PROBE    
CORN TESTING    
GRAIN STORAGE    
CLEANING    
TEMPERING CONVEYOR    
DEGERMINATOR    
INDUSTRIAL MAIZE PROCESSES    
TYPES OF DRY GRINDERS    
THERE ARE THREE METHODS USED FOR CORN DRY MILLING:    
PROCESS OVERVIEW    
TEMPERING    
DEGERMINATION    
ASPIRATION    
GRAVITY SEPARATION    
ROLLER MILLING AND SIFTING    
MANUFACTURING PROCESS    
CLEANING:    
CONDITIONING:    
DEGERMINATION:    
DRYING:    
COOLING:    
GRADING:    
MILLING:    
DRY CORN MILLER’S PROCESS CORN IN ONE OF THREE WAYS:    
PROCESS FLOW DIAGRAM    
TEMPERING DEGERMING PROCESS    
TECHNOLOGICAL PROCESS OF CORN GRITS    
AND FLOUR PRODUCTION LINE    
CORN GRITS AND FLOUR PRODUCTION LINE    
WITH DRY METHOD    
TECHNOLOGY INTRODUCTION OF CORN GRITS AND FLOUR PRODUCTION
LINE:    
DETAILS OF DRY MILLING PROCESS OF MAIZE    
DRY MILLING AND FRACTIONATION OF GRAIN    
THE DRY MILLING PROCESS INCLUDES A NUMBER OF UNIQUE FEATURE    
THE TABLE BELOW IS A COMPILATION OF PARTICLE SIZE AND YIELD
OF MILLED MAIZE PRODUCTS.    
EXPERIMENTAL DRY MILLING OF CORN    
MATERIALS AND METHODS    
MATERIALS    
EXPERIMENTAL METHODS    
ANALYTICAL METHODS    
RAW MATERIALS & FINISHED PRODUCTS    
PRINCIPLES OF PLANT LAYOUT    
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE
SERVICE ARE:    
PLANT LOCATION FACTORS    
PRIMARY FACTORS    
SPECIFIC FACTORS    
EXPLANATION OF TERMS USED IN THE PROJECT REPORT    
PROJECT IMPLEMENTATION SCHEDULES    
PLANT LAYOUT    
SUPPLIERS OF RAW MATERIALS    
HDPE WOVEN BAGS    
SUPPLIERS OF PLANT AND MACHINERY    
BUCKET ELEVATOR    
CYCLONE    
SCREW CONVEYORS    


APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET