Detailed Project Report on Modified Starch
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MODIFIED STARCH
[EIRI/EDPR/3522] J.C.: 1608INR, 1609US$
INTRODUCTION
According to Visakh and Yu (2016), starch is an abundant, inexpensive, renewable, and biodegradable polymer. Polymers are made up of numerous molecules strung together to form long chains. Starch is the second most abundant natural polymer after cellulose. Starch can be obtained mainly from the roots, stalks and seeds of staple crops such as maize, wheat, potato, cassava and rice. In these plants, starch is produced in the form of granules, and the size, shape, morphology, and composition of these granules vary from plant to plant.
Maize, or maize starch, makes up the majority of the world market for starch, and most of this is produced in the United States of America. Europe is the major producer of wheat and potato starches, whereas cassava starch is mainly produced in Asia. Other starches, such as those from rice and sweet potato, make up only a minor proportion of the total. The common industrial starches are typically derived from cereals (maize, wheat, rice, sorghum), tubers (potato, sweet potato), roots (cassava) and legumes (mung bean, green pea). Sago palm and sugar palm starch are examples of commercial starch derived from another source, the palm stem.
It has been reported that the USA, followed by Europe, are the two largest producers of starch in the world and contribute about half of the globally produced commercial starch. Worldwide, the main sources of starch are maize (82%), wheat (8%), potatoes (5%) and cassava (5%) (Visakh and Yu, 2016).
Starch is a versatile polymer and therefore an important industrial material in both the food and non-food industries. Approximately, 60 million tons are extracted annually worldwide from various cereals, tubers and root crops, of which roughly 60% is used in the food industry (for example, bakery products, sauces, soups, confectionery, sugar syrups, ice cream, snack foods, meat products, baby foods, fat replacers, coffee whitener, beer, soft drinks) and 40% is used in pharmaceuticals and other industries, such as fertilizers, seed coatings, paper, cardboard, packing materials, adhesives, textiles, fabrics, diapers, bioplastics, building material, cement, and oil drilling (Visakh and Yu, 2016).
In terms of its chemical composition, starch is a polysaccharide consisting of D-glucose units, referred to as homoglucan or glucopyranose, and has two major biomacromolecules namely amylose and amylopectin. Amylopectin is generally the major component of starch and constitutes 65–85% of the matter in the starch granules (Fredriksson et al. 1998; Gérard et al. 2001; Hoover 2001, as cited by Bertoft, 2015). Amylopectin is a much larger molecule than amylose and is a heavily branched structure.
Modified starch is a food additive which is prepared by treating starch or starch granules, causing the starch to be partially degraded. The purposes of this modification are to enhance its properties particularly in specific applications such as to improve the increase in water holding capacity, heat resistant behavior, reinforce its binding, minimized syneresis of starch and improved thickening.
Modified starches consist of starch with low to very low level of substituent group. Enzymatic modification of starch is hydrolysis of some part of starch into a low molecular weight of starch called maltodextrin, or dextrin using amylolytic enzymes. They are widely used for food and pharmaceutical industries.
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.
COST ESTIMATION
Plant Capacity 200 MT/Day
Land & Building (5 Acres) Rs. 9.10 Cr
Plant & Machinery Rs. 5.36 Cr
Working Capital for 2 Months Rs. 27.11 Cr
Total Capital Investment Rs. 42.63 Cr
Rate of Return 26%
Break Even Point 45%
CONTENTS
INTRODUCTION
BYPRODUCTS FROM MAIZE
SPECIFICATION OF STARCH
PHYSICAL AND CHEMICAL MODIFICATION OF STARCH
TYPES OF DEXTRIN
DEXTRINS AND ITS USES
WHITE DEXTRINS ARE USED AS:
ADHESIVE INDUSTRY
CHEMICAL & DYES INDUSTRY
FOUNDRIES
TEXTILE INDUSTRY
COLOUR INDUSTRY
APPLICATION - ADHESIVES
OTHER APPLICATIONS
USES AND APPLICATION
IN GENERAL, MODIFIED FOOD STARCHES ARE USED FOR THREE REASONS:
LIQUID GLUCOSE SYRUP USES AND APPLICATIONS:
LIQUID GLUCOSE USES
USES OF DEXTROSE:-
PROPERTIES OF LIQUID GLUCOSE
PROPERTIES OF STARCH
PHYSICAL PROPERTIES
CHEMICAL PROPERTIES
STARCH GIVES A CHARACTERISTIC BLUE COLOR WITH IODINE.
MODIFIED STARCHES
PROPERTIES OF PREGELATINIZED STARCH
MAIZE STARCH AND ALLIED PRODUCTS AND THEIR APPLICATIONS
MAIZE STARCH
LIQUID GLUCOSE
MALTODEXTRIN
DEXTROSE MONOHYDRATE
MAIZE GLUTEN
MAIZE GERM
APPLICATIONS
SORBITOL
COSMETICS:
FOOD INDUSTRY:
PHARMACEUTICAL INDUSTRY:
TOBACCO INDUSTRY:
PAPER INDUSTRY:
PAINT INDUSTRY:
STARCH AND STARCH DERIVATION
FIGURE: STARCH AND STARCH DERIVATIVES
MACRONUTRIENTS
CARBOHYDRATES
GLUCOSE
STARCH
TABLE 1: STARCH CONTENT AND COMPOSITION IN DIFFERENT SOURCES
NATIVE STARCH
HYDROLYSED STARCH
MODIFIED STARCH
PHYSICAL MODIFICATION
CHEMICAL MODIFICATION
ENZYMATIC MODIFICATION
GENETIC/BIOTECHNOLOGICAL MODIFICATION
STARCH AND STARCH DERIVATIVE CLASSIFICATIONS
STARCH CLASSIFICATION BASED ON HARMONIZED SYSTEM (HS) CODES
MAIZE PRODUCTION IN SOUTH AFRICA
FIGURE: MAIZE PRODUCTION IN SOUTH AFRICA
FIGURE: MAIZE YIELD IN SOUTH AFRICA
STARCH AND STARCH DERIVATIVE APPLICATIONS
FOOD INDUSTRIES
NON-FOOD INDUSTRIES
STRUCTURE OF THE SOUTH AFRICAN
STARCH INDUSTRY
TONGAAT HULETT STARCH
INTRODUCTION
TONGAAT HULETT’S INPUTS
TONGAAT HULETTS PRODUCTION AND CAPACITY
GERMISTON
KLIPRIVIER
MEYERTON
BELLVILLE
TABLE 7: TONGAAT HULETT’S STARCH AND GLUCOSE VOLUMES
TONGAAT HULETT’S STARCH PRODUCTS
MODIFIED WAXY MAIZE STARCHES
FIGURE 26: SUMMARY OF TONGAAT HULETT’S STARCH VALUE CHAIN
OTHER MANUFACTURERS
WFM STARCH PRODUCTS
ITS PRODUCT LIST INCLUDES:
FIGURE 27: SUMMARY OF WFM STARCH PRODUCTS VALUE CHAIN
CHARKA
THE PRODUCTION PROCESS:
FIGURE 28: SUMMARY OF CHARKA’S VALUE CHAIN
NATAL STARCH
TOP PRODUCTS
POTENTIAL SOLUTIONS TO THIS DILEMMA ARE:
FIGURE 29: SUMMARY OF TOP PRODUCTS VALUE CHAIN
NOUKLOOF STORE
CONSOLIDATED STARCH INDUSTRIES
POTENTIAL NEW ENTRANTS
LIST OF STARCH DISTRIBUTORS IN SOUTH AFRICA
IMPORT ANALYSIS OF STARCH AND STARCH DERIVATION
TRADE ANALYSIS
SOUTH AFRICA’S STARCH IMPORT VOLUMES
MAIZE STARCH
FIGURE 31: MAIZE STARCH IMPORT VOLUMES INTO SOUTH AFRICA
WHEAT STARCH
FIGURE 32: WHEAT STARCH IMPORT VOLUMES INTO SOUTH AFRICA
POTATO STARCH
FIGURE 33: POTATO STARCH IMPORT VOLUMES INTO SOUTH AFRICA
CASSAVA STARCH
FIGURE 34: CASSAVA STARCH IMPORT VOLUMES INTO SOUTH AFRICA
OTHER STARCHES
FIGURE 35: OTHER STARCHES IMPORT VOLUMES INTO SOUTH AFRICA
DEXTRINS AND OTHER MODIFIED STARCH
FIGURE 36: DEXTRINS AND OTHER MODIFIED STARCH IMPORT VOLUMES
INTO SOUTH AFRICA
SUMMARY OF SOUTH AFRICA’S IMPORT VOLUMES
FIGURE 37: SUMMARY OF SOUTH AFRICA’S STARCH IMPORT VOLUMES
SOUTH AFRICA’S STARCH IMPORT VALUES
SUMMARY OF SOUTH AFRICA’S IMPORT VALUES
FIGURE 38: SOUTH AFRICA’S IMPORT VALUES OF VARIOUS STARCHES
TABLE 8: SOUTH AFRICA’S STARCH IMPORT VALUES IN RANDS 2009 - 2016
SOUTH AFRICA’S STARCH IMPORTS PER REGION
MAIZE STARCH
FIGURE 39: MAIZE STARCH IMPORT VALUES PER REGION
WHEAT STARCH
FIGURE 40: WHEAT STARCH IMPORT VALUES PER REGION
POTATO STARCH
FIGURE 41: POTATO STARCH IMPORT VALUES PER REGION
CASSAVA STARCH
FIGURE 42: CASSAVA STARCH IMPORT VALUES PER REGION
OTHER STARCHES
FIGURE 43: OTHER STARCHES IMPORT VALUES PER REGION
DEXTRINS AND OTHER MODIFIED STARCHES
FIGURE 44: DEXTRINS AND OTHER MODIFIED STARCHES IMPORT VALUES
PER REGION
TECHNOLOGY/CAPITAL UTILISED
MARKET POTENTIAL OF STARCHES AND DERIVATIONS IN SOUTH AFRICA
FIGURE 45: NON-FOOD APPLICATIONS OF MODIFIED STARCH
A SUMMARY OF THE MAIN APPLICATIONS OF STARCHES:
TRADE ANALYSIS
SOUTH AFRICA’S STARCH EXPORT VOLUMES
MAIZE STARCH
WHEAT STARCH
FIGURE 47: WHEAT STARCH EXPORT VOLUMES
POTATO STARCH
FIGURE 48: POTATO STARCH EXPORT VOLUMES
CASSAVA STARCH
FIGURE 49: CASSAVA STARCH EXPORT VOLUMES
OTHER STARCHES
FIGURE 50: OTHER STARCHES EXPORT VOLUMES
DEXTRINS AND OTHER MODIFIED STARCHES
FIGURE 51: DEXTRINS AND OTHER MODIFIED STARCH EXPORT VOLUMES
SUMMARY OF SOUTH AFRICA’S EXPORT VOLUMES
FIGURE 52: SUMMARY SOUTH AFRICA’S STARCH EXPORT VOLUMES
5.2.2. SOUTH AFRICA’S STARCH EXPORT VALUES
FIGURE 53: SOUTH AFRICA’S EXPORT VALUES OF VARIOUS STARCHES
MORE DETAILS ON THE EXPORT VALUES ARE PROVIDED IN TABLE 9.
SOUTH AFRICA’S STARCH EXPORT VALUES PER REGION
MAIZE STARCH
WHEAT STARCH
POTATO STARCH
CASSAVA STARCH
OTHER STARCHES
DEXTRINS AND OTHER MODIFIED STARCHES
SUMMARY OF SOUTH AFRICA’S EXPORT VALUES
EXPORT VALUES IN 2016, THE SOUTH AFRICAN STARCH INDUSTRY EXPORTED:
EXISTING AND POTENTIAL DEMAND FOR STARCH LOCALLY
FIGURE 60: ESTIMATED STARCH CONSUMPTION IN SOUTH AFRICA IN 2016
TONGAAT HULETT’S CUSTOMERS
INVESTMENTS
IN TERMS OF SUPPLY OF MAIZE:
OVERALL GROWTH TRENDS IN THE MAIN APPLICATION INDUSTRY’S
INTERNATIONAL COMPETITION OF STARCH AND DERIVATION
STARCHES AND INULIN
DEXTRINS AND OTHER MODIFIED STARCHES
TRADE BALANCES OF VARIOUS STARCHES
THE TRADE BALANCE FIGURES SHOW THAT SOUTH AFRICA IS A:
COMPETITIVE AND COMPARATIVE ADVANTAGE
DEXTRINS AND OTHER MODIFIED STARCHES
FIGURE 80: SOUTH AFRICA’S EXPORT MARKET FOR DEXTRINS AND OTHER MODIFIED STARCHES
INDUSTRY CAPACITY ANALYSIS
SOUTH AFRICA’S STARCH POTENTIAL
FIGURE 81: STARCH POTENTIAL
SOUTH AFRICA’S CURRENT STARCH CAPABILITIES
THE THREE BEST OPPORTUNITIES ARE:
SWOT ANALYSIS OF SOUTH AFRICAN STARCH INDUSTRY
MANUFACTURERS/SUPPLIERS OF MODIFIED STARCH
MANUFACTURING PROCESS OF DEXTRIN
PROCESS FLOW DIAGRAM
MANUFACTURING PROCESS OF MALTODEXTRIN
MANUFACTURING PROCESS OF GLUCOSE/CORN SYRUP
PROCESS FLOW DIAGRAM
MANUFACTURE OF CORN SYRUP
MANUFACTURE OF HIGH FRUCTOSE CORN SYRUP
PROCESS FLOW DIAGRAM OF FRUCTOSE SYRUP
MANUFACTURING PROCESS FOR LIQUID GLUCOSE-G
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
MANUFACTURING PROCESS OF PREGALATINIZED STARCH
MANUFACTURING PROCESS OF CATIONIC STARCH
PROCESS FLOW DIAGRAM
MANUFACTURING PROCESS OF OXIDIZED STARCH
ENZYME TECHNOLOGY
THERE ARE THREE STAGES IN THE CONVERSION OF STARCH:
TABLE ENZYMES USED IN STARCH HYDROLYSIS
STARCH OXIDATION
OXIDIZED STARCH PRODUCTION
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF PLANT AND 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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