MAIZE PROCESSING UNIT
[CODE NO.4259]
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.
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 nvaries 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.
Natural Starches
Starch occurs naturally in the plants and its percentage varies with the plant and also in different parts of the same plant. Corn (maize) sorghum grain wheat, rice, potato, tapioca, arrowroot and sago are among the important sources of natural starches. The grains of barley, rye, oat and the millets are also employed in the production of starches.
Cereal Starches
The cereal starches such as maize wheat, rice and sorghum are recovered by several processes, of which the wet-milling is by far the most important. Other processes commercially employed in the manufacture of unmodified starches are that alkali, Martin and batter in the order of decreasing importance. Of the material methods earlier used for the production of starch and which has now become obsolete, mention may be made of the Hakka, Alsation and Fescas processes. In all the above processes, Starch is recovered in five stages:
a. Softening or steeping of the grains, after thorough washing in water.
b. Tabling or centrifugation of the ground mass.
c. Dewatering and drying of the final products.
d. The recovery of important by products.
COST ESTIMATION
Plant Capacity 150 MT/Day
Land & Building (40,000 sq.mt.) Rs. 33.04 Cr
Plant & Machinery Rs. 63.40 Cr
Working Capital for 2 Months Rs. 18.69 Cr
Total Capital Investment Rs. 117.50 Cr
Rate of Return 27%
Break Even Point 53%
- INTRODUCTION
- STARCH INDUSTRY IN INDIA
- BYPRODUCTS FROM MAIZE
- STARCHES
- NATURAL STARCHES
- CEREAL STARCHES
- OVERVIEW OF MAIZE IN INDIA
- FIGURE: PERCENTAGE SHARE OF MAJOR PRODUCING COUNTRIES IN WORLD MAIZE PRODUCTION
- TABLE: INDIAN EXPORTS AND IMPORTS OF MAIZE
- FIGURE: PERCENTAGE OF EXPORT SHARE TO PRODUCTION OF MAIZE.
- TABLE: BALANCE SHEET OF MAIZE
- TABLE: CONSUMPTION BREAKUP
- TABLE: AREA AND PRODUCTION OF MAJOR PRODUCING STATES OF MAIZE (AREA- LAKH HA, PRODUCTION-LAKH TONNES)
- TABLE: AREA AND PRODUCTION OF MAJOR MAIZE GROWING DISTRICTS OF ANDHRA PRADESH
- TABLE: GROWTH PARAMETERS OF MAIZE BEFORE AND AFTER BIFURCATION OF ANDHRA PRADESH
- TABLE: SEASONAL INDICES OF ARRIVALS AND PRICES OF MAIZE IN KURNOOL MARKET
- FIGURE: TRENDS IN ARRIVALS AND PRICES OF MAIZE KURNOOL MARKET
- FIGURE: AVERAGE MONTHLY PRICES OF MAIZE IN KURNOOL MARKET
- FEATURES AND APPLICATION OF LIQUID GLUCOSE
- APPLICATIONS OF LIQUID GLUCOSE
- SWEETENER:
- PHARMACEUTICAL:
- SPECIFICATION
- HANDLING AND STORAGE
- SPECIFICATION OF STARCH
- MAIZE STARCH SPECIFICATION
- USES OF STARCH:
- A) TEXTILE INDUSTRY:
- B) FOOD INDUSTRY:
- C) PAPER INDUSTRY:
- D) PHARMACEUTICAL INDUSTRY:
- E) MANUFACTURE OF GLUCOSE AND DEXTROSE BY HYDROLYSIS:
- F) MANUFACTURE OF MODIFIED STARCHES, SUCH AS:
- G) MISCELLANEOUS OTHER USES:
- A) CONCENTRATED STEEP LIQUOR:
- B) GERM OIL AND GERM AND CAKE:
- C) GLUTEN:
- PHYSICAL AND CHEMICAL MODIFICATION OF STARCH
- COMPONENTS OF YELLOW DENT CORN
- MARKET OVERVIEW OF MAIZE STARCH
- ECONOMIC SIZE UNIT AND PRODUCTION PATTERN
- FOLLOWING THE AVERAGE ANALYSIS OF MAIZE IN INDIA:
- PHASED PRODUCTION PROGRAMME
- USES OF LIQUID GLUCOSE:-
- LIQUID GLUCOSE SYRUP USES AND APPLICATIONS:
- IN CONFECTIONERY:
- LIQUID GLUCOSE USES
- OTHER FOODS:
- BAKERY PRODUCTS:
- IN ICE CREAMS:
- PHARMACEUTICALS:
- IN TOBACCO:
- IN LEATHER PRODUCTS:
- OTHER USES:
- USES OF DEXTROSE:-
- CONSTITUENTS AND VARIETY OF MAIZE
- PROPERTIES OF LIQUID GLUCOSE
- PROPERTIES OF STARCH
- PHYSICAL PROPERTIES
- CHEMICAL PROPERTIES
- STARCH GIVES A CHARACTERISTIC BLUE COLOR WITH IODINE.
- CORN AND CORN OIL
- A. PARTS OF CORN KERNEL, B. NUTRIENT COMPOSITION OF CORN KERNELS
- CORN OIL VALUE
- OVERVIEW OF CORN WET MILLING
- CORN-WET MILLING MARKET – NOTABLE DEVELOPMENTS
- CORN-WET MILLING MARKET DYNAMICS
- CONSUMPTION PATTERN OF MAIZE IN INDIA
- SEGMENT WISE CONSUMPTION OF MAIZE IN INDIA
- STARCH INDUSTRY IN INDIA: SUPPLY AND DEMAND SCENARIO
- MANUFACTURERS/SUPPLIERS
- MAIZE STARCH
- LIQUID GLUCOSE
- SPECIFICATION
- REQUIREMENT FOR MAIZE, TAPIOCA & ARROW ROOT STARCHES, EDIBLE GRADE*
- REQUIREMENTS FOR MAIZE AND TAPIOCA STARCHES FOR USE IN COTTON TEXTILE INDUSTRY*
- REQUIREMENTS OF TAMARIND STARCH FOR USE IN COTTON TEXTILE AND JUTE INDUSTRIES*
- SEQUENCES IN STARCH AND LIQUID GLUCOSE
- IT CONSISTS OF FOLLOWING STEPS:-
- MIXING AND LIQUEFYING PROCESS:
- SACCHARIFY:
- LIQUID GLUCOSE DECOLORIZING:
- FILTRATION:
- ION EXCHANGE SYSTEM:
- LIQUID GLUCOSE EVAPORATION:
- PROCESS DESCRIPTION OF CORN STARCH
- 1. CORN CLEANING AND STEEPING
- 2. MILLING, GERM SEPARATION AND DRYING
- 3. GRIT MILLING AND FIBER WASHING
- 4. STARCH AND GLUTEN SEPARATION AND STARCH WASHING
- 5. GLUTEN DEWATERING AND DRYING
- 6. STARCH DEWATERING AND DRYING
- METHODS OF MAIZE PROCESSING
- MAIZE IS USUALLY PROCESSED BY TWO PROCESSES:
- DRY MILLING PROCESS FLOW
- WET MILLING PROCESS FLOW
- STARCH MANUFACTURING PROCESS FLOW DIAGRAM
- DETAILS OF CORN WET MILLING
- VARIOUS USES OF CORN
- MAIZE STARCH MANUFACTURING
- CLEANING:
- STEEPING:
- WET MILLING:
- GERM SEPARATION:
- MILLING (FINE GRINDING):
- STARCH GLUTEN SEPARATION
- STARCH REFINING
- DRYING:
- MODIFICATION
- MANY TECHNIQUES ARE APPLIED FOR MODIFICATION FOR EXAMPLE:
- MAIZE STARCH PRODUCTION TECHNOLOGY
- MAIZE STARCH PROCESSING TECHNOLOGY
- MAIZE CLEANING
- MAIZE SOAKING
- MAIZE COARSE CRUSHING
- GERM SEPARATION
- MAIZE GRINDING
- MAIZE STARCH SIEVING
- PROTEIN SEPARATION AND MAIZE STARCH CLEANING
- CENTRIFUGAL SEPARATION AND DRYING
- SEQUENCES IN CORN WET MILLING
- PROCESSING STEPS
- CLEANING
- STEEPING
- MILLING & SEPARATION
- FINE GRINDING AND SCREENING
- SEPARATION OF STARCH AND GLUTEN
- PROCESS FLOW DIAGRAM OF WET CORN MILLING PROCESSES
- LIQUID GLUCOSE MANUFACTURE
- SEQUENCES IN MAIZE STARCH
- CORN STARCH PRODUCTION
- PRODUCTION OF STARCH SLURRY
- PRODUCTION OF STARCH SLURRY
- PRODUCTION OF STARCH AND DEXTRINS:
- PRODUCTION OF STARCH
- PROCESSING DETAILS OF MAIZE STARCH
- RECEIVING
- CLEANING
- STEEPING
- GRINDING
- GERM SEPARATION (DEGERMINATION)
- FIBRE WASHING SECTION
- THICKENING
- PRIMARY SEPARATION
- GLUTEN THICKENING
- ROTARY VACUUM FILTER
- HYDROCLONE SYSTEM
- DRYING
- PROCESS DESCRIPTION OF CORN WET MILLING
- CLEANING AND SOAKING
- STEEP LIQUOR CONCENTRATION
- CRUDE GEM OIL RECOVERY
- FIBRE SEPARATION
- GLUTEN SEPARATION AND CONCENTRATION
- MIXED FEED PROCESSING
- STARCH WASHING DEWATERING AND DRYING
- RAW MATERIALS AND UTILITIES
- RAW MATERIALS
- A) CORN:
- B) CLASSES:
- I) YELLOW CORN:
- II) MIXED CORN:
- SPECIAL GRADES FOR CORN:
- A) FLINT CORN:
- B) FLINT AND DENT CORN:
- C) WEEVILY CORN:
- MANUFACTURE OF DEXTROSE MONOHYDRATE & 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
- MAIZE GERM
- APPLICATIONS
- SORBITOL
- APPLICATIONS:
- COSMETICS:
- FOOD INDUSTRY:
- PHARMACEUTICAL INDUSTRY:
- TOBACCO INDUSTRY:
- TEXTILE INDUSTRY:
- PAPER INDUSTRY:
- PAINT INDUSTRY:
- TURNKEY SUPPLIERS OF STARCH AND ALLIED PRODUCTS
- SUPPLIERS OF PLANT AND MACHINERY
- SUPPLIERS OF CENTRIFUGE
- SUPPLIERS OF HEAT EXCHANGER
- SUPPLIERS OF LAB TESTING EQUIPMENT
- SUPPLIERS OF BOILERS
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF CORN/MAIZE
- SUPPLIERS OF SULPHUR
- SUPPLIERS OF SULPHURIC ACID
- SUPPLIERS OF CAUSTIC SODA
- SUPPLIERS OF SODA ASH
- LAB TESTING EQUIPMENT:-
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)