Detailed Project Report on liquid glucose from rice

LIQUID GLUCOSE FROM RICE

[CODE NO.4243]  

Glucose is a commercially import ant product widely used by the food and pharmaceutical industries. In general, glucose is used in the food industry as a partial or complete substitute for sucrose. Glucose is the common name for the syrup which is used in large quantities in fruit canning, confectioneries, jams, jellies, preserves, ice cream, bakery products, pharmaceuticals, beverages and alcoholic fermentation. The functional purpose of glucose in the confectionery industry is to prevent crystallization of the sucrose while in the bakery products industry it is to supply fermentable carbohydrates. In the icecream and fruitpreserves, it used to increase the solidswithout causing an undue increase in the total sweetness. In pharmaceutical industry, glucose is used as a precursor to make vitamin C in the Reichstein process, to make citric acid, gluconic acid, polylactic acid and sorbitol. Currently, glucose is utilized as an intermediate raw material for bioethanol production.

Commonly, glucose is prepared commercially via the enzymatic hydrolysis of starchinstead of acid hydrolysis. Many crops can be used as the source of the initial starch. Maize, rice, wheat, potato, cassava, arrowroot and sago are all used in various parts of the world. Nevertheless, using the starch needs to compete with their primary use as food crops. Due to the abundant of nonfood energy crops like cellulosic material, they are use to reduce the utilization of starch as raw material for production of glucose. Cellulosic materials including agricultural, agroindustrial and forestry lignocellulosic residues have potential as cheap and renewable feedstocks for large scale production of fuels and chemicals. Currently, bioprocessing of lignocellulosics is focused on enzymatic hydrolysis of the cellulose fraction to glucose, followed by fermentation to fuelgrade ethanol. However, enzymatic hydrolysis of cellulosic materials to produce fermentable sugars has also enormous potential in meeting global food and energy demand via biological route.

In lignocellulosic materials cellulose is physically associated with hemicellulose and physically and chemically associated with lignin. The presence of these two fractions is reported to make the access of cellulase enzymes to cellulose difficult, thus reducing the efficiency of the hydrolysis. There are several kinds of pretreatment able to disrupt the lignocellulosic structure for increasing the efficiency of the hydrolysis which have been investigated but are not within the scope of this study. However, the effect of temperature and pH are also significant in cellulose hydrolysis which will be stud ying in this study. The temperature and pH influence the efficiency of cellulase to degrade the cellulose for producing glucose.

In order to produce glucose, cellulose is essential to break it down first.By using acid hydrolysis, conversion of cellulose to glucose only produces low glucose concentration because acid is no selectivity. Furthermore, by using acid causes the cost production of glucose is highdue to demand of neutralization after hydrolysis which can contribute to corrosion problem if there is no neutralization process. Other that, the need of high temperature during acid hydrolysis process also contribute s to the cost of production because high energy is consumed. Waste from acid hydrolysis also gives the bad effect to the environment which is using high concentration of acid can cause harmful to the environment. Therefore, the investigation attempted to determine the glucose production by using enzymatic hydrolysis process inorder to replace acid hydrolysis process.

Nevertheless by using enzymatic hydrolysis need highly specific and very sensitive. Their environmental condition such temperature and pH influence the activity of the enzymes in the system. Hence, the effect of temperature and pH is investigated to determine the maximum conditions of enzymatic hydrolysis process in glucose production.

Glucose is a simple monosaccharide sugar also known as grape sugar, blood sugar or corn sugar which is a very important carbohydrate in biology. The living cell uses it as a source of energy and metabolic intermediate. Glucose is one of the main products of photosynthesis and starts cellular respiration in both prokaryotes and eukaryotes. Glucose (C6H12O6) contains six carbon atoms, one of which is part of an aldehyde group (Figure). Therefore, glucose is an aldohexose. Glucose is commonly available in the form of a white powder or as a solid crystal, called dextrose. It can also be dissolved in water as an aqueous solution, glucose syrups.

Its solubility level is very high.

 Glucose can be forms disaccharide when two of monosaccharide are linked together such sucrose, the combination of glucose with fructose. Sucrose is the most common sweetener in the modern, industrialized world, although it has been displaced in industrial food production by some other sweeteners such as glucose syrups or combinations of functional ingredients and high intensity sweeteners. 

In lactose, another important disaccharide, glucose is joined to galactose (Figure ). It used as the predominant sugar in milk. For maltose, a product of starch digestion is glucose glucose disaccharide. Glucose also can be forms polysaccharides when the units (either mono or disaccharides) are repeated and joined together by glycosidic bonds like cellulose. Cellulose is yet a third polymer of the monosaccharide glucose.

Structure of Lactose

COST ESTIMATION

Plant Capacity                          75 MT/Day

Land & Building (6 Acres)  Rs. 13.73 Cr

Plant & Machinery                      Rs. 16.16 Cr

Working Capital for 1 Month    Rs. 5.92 Cr

Total Capital Investment          Rs. 36.83 Cr

Rate of Return                            26%

Break Even Point                        59%

• INTRODUCTION
  
• STRUCTURE OF LACTOSE
• TYPES OF GLUCOSE SYRUP
• CONFECTIONER'S SYRUP
• HIGH-MALTOSE GLUCOSE SYRUPS
• MALTO DEXTRIN
• DEALING WITH DE
• BROWNING (DUE TO THE INCREASED LEVEL OF REDUCING SUGARS);
• AS DE DECREASES, THE FOLLOWING CHARACTERISTICS INCREASE:
• PRODUCT DESCRIPTION AND APPLICATION
• GLUCOSE AS ENERGY SOURCE IN LIVING CELL
• CULINARY APPLICATIONS
• HEALTH BENEFITS OF LIQUID GLUCOSE
• LIQUID GLUCOSE USES
• IN FOODS
• CHEMICAL AND PHARMACEUTICAL USES
• OTHER INDUSTRIAL USES
• LEATHER INDUSTRY
• PHARMACEUTICAL INDUSTRY
• AGRICULTURE/ANIMAL FEED
• USES AND APPLICATION OF MALTODEXTRIN
• CARRIERS AND BULKING
• CALORIE REDUCTION
• FROZEN ASSETS
• SPORTS AND NUTRITION
• PROPERTIES & CHARACTERISTICS
• PROPERTIES OF STARCH
• PHYSICAL PROPERTIES
• CHEMICAL PROPERTIES
• COMPOSITION OF RICE
• COMPOSITION OF RAW AND PARBOILED RICE.
• CHEMICAL COMPOSITION OF DIFFERENT KINDS OF RICE
• SYNONYMS
• PROPERTIES
• AVERAGE ANALYSIS OF RICE IN INDIA
• PROPERTIES AND CHARACTERISTICS OF MALTODEXTRIN
• SACCHARIDE COMPOSITION OF COMMERCIAL MALTODEXTRINS
• MALTODEXTRIN
• MARKET OVERVIEW OF LIQUID GLUCOSE
• PRESENT MANUFACTURERS/SUPPLIERS
• SPECIFICATIONS
• SPECIFICATION FOR LIQUID GLUCOSE
• 3. GRADES
• 4. REQUIREMENTS
• COLOUR
• REQUIREMENTS FOR LIQUID GLUCOSE (ALL GRADES)
• 5. PACKING & MARKING
• PACKING
• MARKING
• COMMERCIAL PRODUCTION OF GLUCOSE
• USAGE OF GLUCOSE IN FOOD INDUSRIES
• SUBSTRATE FOR GLUCOSE PRODUCTION
• THE COMPARISON STRUCTURE OF STARCH AND CELLULOSE
• SEQUENCES IN GLUCOSE PREPARATION
• PREPARATION
• SOAKING
• GELATINIZATION
• HYDROLYSIS
• CLARIFICATION
• EVAPORATION
• RICE GLUCOSE PROCESSING [ENZYME HYDROLYSIS]
• 1. RICE POWDER MAKING PROCESS IN RICE GLUCOSE SYRUP PROCESSING PLANT
• 2. RICE POWER SLURRY MAKING PROCESS IN RICE GLUCOSE SYRUPPROCESSING PLANT
• 3. LIQUEFACTION PROCESS IN RICE GLUCOSE SYRUP PROCESSING PLANT
• 4. DEPROTEINIZATION PROCESS IN RICE GLUCOSE SYRUP PROCESSINGPLANT
• 5. SACCHARIFICATION PROCESS IN RICE GLUCOSE SYRUP PROCESSINGPLANT
• 6. DECOLORIZATION PROCESS IN RICE GLUCOSE SYRUP PROCESSING PLANT
• 7. DECARBURIZATION PROCESS IN RICE GLUCOSE SYRUP PROCESSINGPLANT
• 8. ION EXCHANGE PROCESS IN RICE GLUCOSE SYRUP PROCESSING PLANT
• 9. EVAPORATION PROCESS IN RICE GLUCOSE SYRUP PROCESSING PLANT
• 10. FINAL PRODUCT STORAGE IN RICE GLUCOSE SYRUP PROCESSING PLANT
• PROCESS FLOW CHART
• SYRUP PROCESSING LINE
• SYRUP PROCESSING LINE FLOW CHART
• HIGH FRUCTOSE SYRUP PRODUCTION DETAILS:
• 1. MIXING AND LIQUEFYING PROCESS:
• 2. SACCHARIFY:
• 3. LIQUID GLUCOSE DECOLORIZING:
• 4. FILTRATION:
• 5. ION EXCHANGE SYSTEM DURING HIGH FRUCTOSE SYRUP PRODUCTION:
• 6. CONCENTRATION:
• 7. ISOMERISM PROCESS:
• 8. HIGH FRUCTOSE SYRUP REFINING PROCESS:
• GLUCOSE SYRUP MAKING MACHINE TECHNOLOGY:
• 1. MIXING AND LIQUEFACTION:
• 2. FILTRATION SECTION DURING THE GLUCOSE SYRUP MAKING MACHINE:
• 3. SACCHARIFICATION:
• 4. DECOLORIZATION BY GLUCOSE SYRUP MAKING MACHINE:
• 5. FILTRATION PROCESS/DECARBURIZATION:
• 6. ION EXCHANGE SECTION:
• 7. EVAPORATION:
• MALTOSE SYRUP PROCESS MACHINE TECHNOLOGY DESCRIPTION:
• 1. MIXING SLURRY UNIT DURING THE MALTOSE SYRUP PROCESS:
• 2. EJECTOR LIQUEFACTION UNIT:
• 3. FILTER PRESS DEPROTEINIZATION:
• 4. SACCHARIFICATION:
• 5. DECOLORIZATION:
• 6. FILTER PRESS DECARBURIZATION:
• 7. ION EXCHANGE PROCESS:
• 8. CONCENTRATION AND EVAPORATION:
• MANUFACTURING PROCESS OF LIQUID GLUCOSE BY ACID HYDROLYSIS
• PROCESS FLOW DIAGRAM
• MANUFACTURING PROCESS FOR LIQUID GLUCOSE
• RAW MATERIALS
• CONFECTIONERY GLUCOSE-D:
• LOW CONVERSION
• REGULAR CONVERSION
• INTERMEDIATE CONVERSION
• HIGH CONVERSION
• PROCESS FLOW DIAGRAM OF LIQUID GLUCOSE USING STARCH
• MANUFACTURING PROCESS IN DETAILS OF LIQUID GLUCOSE USING ENZYME HYDROLYSIS
• THERE ARE THREE STAGES IN CONVERSION OF STARCH:
• STARCH MILK ADJUSTMENT:
• LIQUEFACTION:
• RICE GLUTEN FEED MAKING.
• SACCHARIFICATION:
• FILTERATION AND DECOLORING:
• ION EXCHANGE:
• EVAPORATION:
• FILTRATION OF LIQUID GLUCOSE
• GENERAL INFORMATION
• EQUIPMENT DESIGN
• PURIFICATION OF GLUCOSE SYRUPS USING ACTIVATED CARBON
• STANDARD DESIGN CONDITIONS
• PROCESS FLOW DIAGRAM
• MANUFACTURING PROCESS OF RICE STARCH
• ALKALI STEEPING PROCESS:
• SEPARATION OF THE STARCH:
• CRYSTALLIZING AND DRYING OF RICE STARCH:
• MANUFACUTRING PROCESS OF MALTODEXTRIN FROM BROKEN RICE
• PROCESS FLOW DIAGRAM OF MALTODEXTRIN FROM RICE STARCH OBTAINED FROM BROKEN RICE
• TECHNICAL DETAILS AND OBTIMIZATION OF LIQUID GLUCOSE AND MALTO DEXTRIN
• TYPICAL CARBOHYDRATE PROFILE OF COMMERCIAL MALTODEXTRIN
• GLUCOSE
• ACID-CATALYZED HYDROLYSIS
• TYPICAL GLUCOSE SYRUP PROCESS
• COMPOSITION OF TYPICAL STARCH DERIVED SWEETERS
• TYPICAL ACID CONVERTER
• CARBON TREATMENT AND REGENERATION SYSTEM
• ACID–ENZYME PROCESSES
• SYRUP DEMINERALIZATION SEQUENCE
• MULTIPLE EFFECT EVAPORATORS
• SEPARATION OF PROTEINS AND PRODUCTION OF MALTODEXTRIN
• ASSAY METHOD OF MALTO DEXTRIN (REDUCING SUGAR)
• MATERIAL
• METHOD
• WET MILLING PROCESS
• CLEANING AND STEEPING
• STEEP LIQUOR CONCENTRATION
• FIBRO SEPARATION
• GLUTEN SEPARATION
• STARCH WASHING, DEWATERING AND DRYING OR CONCENTRATION
• CONCLUSION & COMPARISON
• TECHNICAL PARAMETER IN LIQUID GLUCOSE PLANT
• FOR ENZYMES BASED HYDROLYSIS
• FOR ACID BASED HYDROLYSIS
• RICE VARIETY AND PARTICLE SIZE OF RICE FLOUR AT MILLING
• ENZYMES PROCUREMENT ANALYSIS DETAILS OF ALPHA AMYLASE ENZYMES
• CHARACTERISTIC AND PROCESS PARAMETERS
• SPECIFICATION:
• STORAGE:
• SHELF LIFE:
• SAFETY:
• MATERIAL SAFETY DATA SHEET FOR ALPHA AMYLASE ENZYMES
• DESCRIPTIONS
• STORAGE AND SHELF LIFE
• PACKAGING
• USING THE PRODUCT
• GUIDELINES FOR USE
• SPECIFICATIONS
• OVERVIEW OF ANIMAL FEED INDUSTRY
• OPTIMIZATION OF BYPRODUCT OF THE PROCESS (GLUTEN)
• FORMULATION OF ANIMAL FEED
• EQUIPMENT FOR MAKING CATTLE FEED PELLETS
• DESCRIPTION OF PLANT & MACHINERY
• DESCRIPTION
• RAW MATERIALS & YIELD
• FROM 1 TON OF BROKEN RICE
• FROM 1 TON OF BROKEN RICE
• CONSULTANTS FOR GLUCOSE PLANT
• ADDRESSES OF PLANT AND MACHINERY SUPPLIERS
• SUPPLIERS OF BROKEN RICE
• SUPPLIERS OF PLANT & MACHINERY (IMPORTED)
• ANNEXURE-A
• SUPPLIERS OF LIQUID GLUCOSE 
• SUPPLIERS OF RICE GLUTEN 

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)