STARCH TO SWEETENERS (MALTODEXTRIN, DE40 SYRUP, MALTITOL, DEXTROSE MONOHYDRATE) (CAP: 166.667 MT/DAY)
[EIRI/EDPR/4500] J.C.: 2716INR, 2716US$
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.
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 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 166.667 MT/Day
Land & Building (40,000 sq.mt.) Rs. 27.37 Cr
Plant & Machinery Rs. 55.00 Cr
Working Capital for 1 Month Rs. 27.35 Cr
Total Capital Investment Rs. 110.85 Cr
Rate of Return 43%
Break Even Point 42%
CONTENTS
INTRODUCTION
SPECIFICATION OF STARCH
MAIZE STARCH SPECIFICATION
USES AND APPLICATION OF MALTITOL
CHEMICAL PROPERTIES
USES OF LIQUID GLUCOSE:-
LIQUID GLUCOSE SYRUP USES AND APPLICATIONS:
LIQUID GLUCOSE USES
MAIZE SCENARIO IN INDIA
PROPERTIES
PROPERTIES OF STARCH
PHYSICAL PROPERTIES
CHEMICAL PROPERTIES
STARCH GIVES A CHARACTERISTIC BLUE COLOR WITH IODINE.
PROPERTIES OF MALTITOL
MARKET OVERVIEW OF STARCH BASED SWEETENER
MANUFACTURERS/SUPPLIERS OF STARCH BASED PRODUCTS
MAIZE STARCH
LIQUID GLUCOSE
SEQUENCES IN LIQUID GLUCOSE MANUFACTURING (DE 40)
BLOCK DIAGRAM OF SWEETENER PLANT
PRODUCTION METHOD OF GLUCOSE/CORN SYRUP
ACID-CATALYZED HYDROLYSIS
FIGURE: TYPICAL CORN/GLUCOSE SYRUP PROCESS
FIGURE: TYPICAL ACID CONVERTER
FIGURE: CARBON TREATMENT AND REGENERATION SYSTEM
ACID–ENZYME PROCESSES
FIGURE: SYRUP DEMINERALIZATION SEQUENCE
FIGURE: MULTIPLE-EFFECT EVAPORATOR
PRODUCTION METHOD OF MALTODEXTRIN
FIGURE: GENERAL PROCESS FLOW FOR STARCH-DERIVED SWEETENERS (CORN/GLUCOSE SYRUPS, HIGH FRUCTOSE SYRUPS, DEXTROSE, FRUCTOSE, MALTODEXTRINS AND SYRUP SOLIDS)
MALTITOL PRODUCTION METHOD
LOW DE GLUCOSE SYRUP FROM STARCH
CONDITIONING OF STARCH MILK
RAW MATERIAL PREPARATION
ENZYME HYDROLYSIS
BIOREACTION
PURIFICATION
PRODUCT ISOLATION AND CONCENTRATION
MALTODEXTRIN
SEQUENCES IN CORN SYRUP AND HIGH FRUCTOSE CORN SYRUP
SEPARATING CORN STARCH FROM CORN
CONVERTING CORN STARCH INTO CORN SYRUP
CONVERTING CORN SYRUP INTO HIGH FRUCTOSE CORN SYRUP
HIGH FRUCTOSE CORN SYRUP MANUFACTURING PROCESS
(1) PREPARATION:
(2) ISOMERIZATION:
(3) DECOLORIZATION:
(4) DEMINERALIZATION:
(5) EVAPORATION:
HFCS 55 PROCESS DESCRIPTION
PURE CRYSTALLINE FRUCTOSE (PCF) PROCESS DESCRIPTION
(1) CHROMATOGRAPHIC SEPARATION
(2) BLENDING
(3) POLISHING
(4) EVAPORATION
PROCESS FLOW DIAGRAM OF FRUCTOSE SYRUP
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:
RAW MATERIALS
CONFECTIONERI GLUCOSE-D:
LOW CONVERSION
REGULAR CONVERSION
INTERMIDIATE CONVERSION
HIGH CONVERSION
MANUFACTURE OF DEXTROSE MONOHYDRATE & DEXTROSE ANHYDROUS
DEXTROSE MANUFACTURE
MANUFACTURING DIAGRAM OF LIQUID GLUCOSE
MANUFACTURING DIAGRAM OF ANHYDROUS DEXTROSE
MANUFACTURING PROCESS OF SORBITOL
TURNKEY SUPPLIERS OF STARCH YO SWEETENERS
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 SULPHURIC ACID
SUPPLIERS OF CAUSTIC SODA
SUPPLIERS OF SODA ASH
DETAILS OF PLANT & MACHINERY FOR CORN WET MILLING
LIST OF MACHINERY AND EQUIPMENT
1. MAIZE STEEPING
2. SULPHURDIOXIDE PLANT
3. DEGERMINATION AND GERM WASHING
4. FIBRE MILLING AND WASHING
5. STARCH SEPARATIONS AND REFINING
6. GLUTEN CONCENTRATION
7. GERM DEWATERING AND DRYING
8. STEEPING WATER CONCENTRATION
SECTION: 9.00
10. ANIMAL FEED DEWATERING AND DRYING
11. STARCH DEWATERING AND DRYING
12. SORBITOL AND MALTODEXTRIN MANUFACTURING SECTION
13. DMH SECTION
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)
