Maize & By-Products Processing Plant Capacity-100 Mt/Day Starches / Modified Starches/ Liquid Glucose / Dextrose Monohydrate / Glucose Syrups / Corn Syrup Solids / High Maltose Corn Syrups / Malto Dextrine Powder / Corn Gluten/Maize Oil / Sorbitol

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MAIZE & BY-PRODUCTS PROCESSING PLANT CAPACITY-100 MT/DAY STARCHES / MODIFIED STARCHES/ LIQUID GLUCOSE / DEXTROSE MONOHYDRATE / GLUCOSE SYRUPS / CORN SYRUP SOLIDS / HIGH MALTOSE CORN SYRUPS / MALTO DEXTRINE POWDER / CORN GLUTEN MEAL (60%) MAIZE OIL / SORBITOL

[EIRI/EDPR/1396] J.C. 173

INTRODUCTION

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.

COST ESTIMATION

Plant Capacity 1. Starch 15,000 MT.

2. Liquid Glucose 1,500 MT.

3. Dextrose Monohydrate 500 MT.

4. Maize Germ 50 MT.

5. Sorbitol 500 MT.

6. Dextrin 500 MT.

7. Gluten 500 MT.

8. Animal Feed 2,000 MT.

Land & Building (10 Acres) Rs. 11.05 Cr

Plant & Machinery Rs. 41.85 Cr

Working Capital for 3 Months Rs. 18.33 Cr

Total Capital Investment Rs. 72.81 Cr

Rate of Return 26%

Break Even Point 55%

CONTENTS

INTRODUCTION

PRODUCT DESCRIPTION AND USE

ECONOMIC SIZE UNIT AND PRODUCTION PATTERN

PROPERTIES

MARKET SURVEY

NAME AND ADDRESS OF MANUFACTURERS OF LIQUID GLUCOSE

LIQUID GLUCOSE AND DEXTROSE - AN ASSESSMENT OF MARKET

ESTIMATED DEMAND FOR DEXTROSE

LIST OF MANUFACTURERS OF RAW MATERIAL-DEXTROSE

SPECIFICATION

INDIAN STANDARDS

SPECIFICATIONS

MANUFACTURES OF STARCH AND ALLIED PRODUCTS

PROCESS DESCRIPTION

PROCESS FLOW DIAGRAM FOR THE MFG. OF STARCH

RAW MATERIALS AND UTILITIES

MANUFACTURING PROCESS FOR LIQUID GLUCOSE-G

MANUFACTURE OF DEXTROSE MONOHYDRATE AND DEXTROSE ANHYDROUS

MANUFACTURING DIAGRAM OF LIQUID GLUCOSE

MANUFACTURING DIAGRAM OF ANHYDROUS DEXTROSE

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF PLANT & MACHINERY

PLANT AND MACHINERY

IMPLEMENTATION SCHEDULE

LIST OF FOOD AND AGRO PROCESSING CONSULTANTS

MANUAL ON STANDARDS OF MAIZE

PLANT ECONOMICS

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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