Detailed Project Report on Liquid Glucose from Broken Rice Cap: 40 Ton/Day

LIQUID GLUCOSE FROM BROKEN RICE

[EIRI/EDPR/1536] J.C.: 254INR, 742US$

INTRODUCTION

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 n varies from a few hundred to over one million. Starch is found as the reserve carbonhydrate in various parts of plants and is enzymatically broken down to gluose to other erbohydrates according to the metabollic 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, dialdehyde 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.

Maltodextrins are products with a low Dextrose Equivalent (DE) from 3 to 20, obtained by enzyme Conversion (usually Alpha-amylase). They are usually spray dried powders (less than 5 percent moisture) as the corresponding liquids have extremely high viscosities and tend to become cloudy on storage. Among Maltodextrins, the very low DE product is prepared from waxy corn starch, a natural starch that is almost entirely the amylopectin Polymer.

Maltrodextrin is a purified concentrated aqueos solution of nutritive saccharides obtained from edible starch, or the dried product derived from said solution and having a dextrose equivalent (DE) less than 20.

Maltodextrin (C6H10O5)n H2O is a mixture of saccherides with a molecuelar weight between poly saccharides and oligosaccharides with DE lower than 20 (not sweet) which is available as white powder mostly or concentrated solution. It physical and functional properties such as sweetners. Compressibility and viscosity vary depending upon the extent of starch hydrolyses which is characterized by DE determination.

It is used in food industry, bulking agent fat replacer, medical/nutritional purpose.

The U.S. Food and Drug Administration has defined maltodextrins as a "nonsweet nutritive saccharide polymer that consists of D-glucose units linked primarily by (alpha)-1,4 bonds and that has a dextrose equivalent (DE) of less than 20. It is prepared as a white powder or concentrated solution by partial hydrolysis of corn starch or potato starch with safe and suitable acids and enzymes.

The food industry usually refers to corn-based products when referring to maltodextrins. But in addition to the legally defined corn and potato versions, some ingredient manufacturers also produce "maltodextrins" from other starchy sources, such as rice and tapioca. The current labeling status of these products is unresolved, so they might require the term "hydrolyzed (starch/source).

COST ESTIMATION

Plant Capacity                                            40 MT/Day                   
Land & Building (16,000 Sq.Mtr)               Rs. 13.37 Cr
Plant & Machinery                                        Rs. 4.59 Cr         
W.C. for 2 Months                                         Rs. 4.93 Cr         
Total Capital Investment                              Rs. 24.42Cr              
Rate of Return                                              35%   
Break Even Point                                         46%

CONTENTS

INTRODUCTION

PRODUCT DESCRIPTION AND USE

USES AND APPLICATION OF MALTODEXTRIN

PROPERTIES

PROPERTIES AND CHARACTERISTICS OF MALTODEXTRIN

B.I.S. SPECIFICATION

MARKET SURVEY

FUTURE EXPANSION PLANNING OF KBRL LTD INTO LIQUID GLUCOSE

PRESENT MANUFACTURERS

SPECIFICATIONS

MANUFACTURES OF STARCH AND ALLIED PRODUCTS

MANUFACTURING PROCESS

PROCESS FLOWSHEET FOR STARCH MANUFACTURING FROM BROKEN RICE

MANUFACTURING PROCESS FOR LIQUID GLUCOSE

MANUFACTURING DIAGRAM MANUFACTURS OF LIQUID GLUCOSE

MANUFACUTRING PROCESS OF MALTODEXTRIN FROM BROKEN RICE

PROCESS FLOW DIAGRAM OF MALTODEXTRIN FROM RICE STARCH

OBTAINED FROM BROKEN RICE

SEPARATION OF PROTEINS AND PRODUCTION OF MALTODEXTRIN

ASSAY METHOD OF MALTO DEXTRIN (REDUCING SUGAR)

WET MILLING PROCESS

RAW MATERIALS & YIELD

CONSULTANTS FOR GLUCOSE PLANT

SUPPLIERS OF RAW MATERIALS

COMPLETE PLANT SUPPLIERS FOR LIQUID GLUCOSE

SUPPLIERS OF BROKEN RICE

SUPPLIERS OF PLANT & MACHINERY

LIST OF THE BUYERS OF LIQUID GLUCOSE

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)