Detailed Project Report on maize processing plant (wet milling) corn oil, corn syrup, hfcs dextrin, malto dextrin, corn starch, liquid glucose etc. cap: 300 ton/day input

MAIZE PROCESSING PLANT
(WET MILLING) CORN OIL, CORN SYRUP,
HFCS DEXTRIN, MALTO DEXTRIN, CORN STARCH, LIQUID GLUCOSE ETC. CAP: 300 TON/DAY INPUT
[CODE NO.3485]


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.


COST ESTIMATION

Plant  Capacity                                            :     300.00 MT./day                       
land & Building  (15 Acres)                       :    Rs. 34.22 Cr
Plant & Machinery                                       :    Rs. 95.00 Cr
Working Capital for 2 Months                   :    Rs. 29.63 Cr
Total Capital Investment                            :    Rs. 164.85 Cr
Rate of Return                                             :    23%
Break Even Point                                         :    55%

INTRODUCTION    
STARCH INDUSTRY IN INDIA    
BYPRODUCTS FROM MAIZE    
SPECIFICATION OF STARCH    
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:-    
PROPERTIES    
PROPERTIES OF STARCH    
PHYSICAL PROPERTIES    
CHEMICAL PROPERTIES    
STARCH GIVES A CHARACTERISTIC BLUE COLOR WITH IODINE.    
OVERVIEW OF CORN WET MILLING    
STARCH INDUSTRY IN INDIA: SUPPLY    
AND DEMAND SCENARIO    
SUPPLY    
DEMAND    
MARKET SURVEY    
INSTALLED CAPACITY, CAPACITY UTILIZATION & PRODUCTION
    OF MAIZE STARCH & ALLIED PRODUCTS    
APPRENT CONSUMPTION OF MAIZE STARCH AND ALLIED PRODUCTS    39
ESTIMATED DEMAND    
DETAILED EXPORT DATA OF CORN STARCH    
DETAILED EXPORT DATA OF LIQUID GLUCOSE    
DETAILED EXPORT DATA OF CORN OIL    
MANUGFACTURERS/SUPPLIERS    
MAIZE STARCH    
LIQUID GLUCOSE    
SPECIFICATION    
REQUIREMENT FOR MAIZE, TAPIOCA & ARROW ROOT STARCHES,
    EDIBLE GRADE    
TABLE III REQUIREMENTS FOR MAIZE AND TAPIOCA STARCHES
    FOR USE IN COTTON TEXTILE INDUSTRY    
REQUIREMENTS OF TAMARIND STARCH FOR USE IN COTTON TEXTILE
    AND JUTE INDUSTRIES    
CORN WET MILLING PROCESS    
PROCESSING STEPS    
CLEANING    
STEEPING    
MILLING & SEPARATION    
FINE GRINDING AND SCREENING    
SEPARATION OF STARCH AND GLUTEN    
PROCESS FLOW DIAGRAM OF WET CORN MILLING PROCESSES    
MANUFACTURES OF STARCH AND ALLIED PRODUCTS    
MAIZE STARCH    
TAPIOCA STARCH    
AMYLOSE MOLECULE OF STARCH    
AMYLOPECTIN MOLECULE    
DETAILS OF CORN WET MILLING    
PROCESS DESCRIPTION    
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    
SPECIAL GRADES FOR 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    
AND DEXTROSE ANHYDROUS    
DEXTROSE MANUFACTURE    
MANUFACTURING DIAGRAM OF LIQUID GLUCOSE    
MANUFACTURING DIAGRAM OF ANHYDROUS DEXTROSE    
MAIZE STARCH AND ALLIED PRODUCTS AND THEIR APPLICATIONS    
MAIZE STARCH    
APPLICATIONS    
LIQUID GLUCOSE    
APPLICATIONS    
MALTODEXTRIN    
DEXTROSE MONOHYDRATE    
MAIZE GLUTEN    
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    
                          
        
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