MAIZE DRY MILLING PLANT
[CODE NO.3200]
Maize/corn dry milling process is a less versatile, less capital intensive process that focuses primarily on the production of grain ethanol. In this process, the corn kernel are hammer milled into a medium to fine grind meal for introduction to the ethanol production process. The products of a traditional dry grind ethanol facility and dried distillers grain (DDG) a low value animal feed product.
Dry milling technology has been standardized by Central Food Technological Research Institute (CFTRI) Mysore.
The grits is the main product of dry milling process, which is used as porridge by boiling domestically. The processing units, use grits for manufacture of products like ready to eat snacks (Corn flakes), manufacture of glucose by direct hydrolysis etc.
Maize is one of the staple foods in India. The annual maize production in India is around 21 million tons with the highest maize cultivation in Karnataka, Andhra
Pradesh and Rajasthan.
India is one of the largest cultivators of maize in the world, and it is a crop suitable for all the growing seasons in nearly every agro-climatic zone within the country’s borders. India has seen a dramatic increase in maize cultivation over the past few years, which explains its pre-eminence as a starch source among processors.
Traditionally, the grain is converted into flour in mill for making bread immature cobs are roasted and eater all over the country. It is an important material for animal and poultry feed, corn flakes etc.
The quantity of maize utilized by this unit, is limited as the existing units are of small scale nature. They make only a few products having limited demand where as a large scale unit can process a large quantity of maize to different value added products.
COST ESTIMATION
Plant Capacity : 32.00 Tons/day
land & Building (8000 Sq.Mtr) : Rs. 1.46 Cr
Plant & Machinery : Rs. 65.00 Lacs
Working Capital for 2 Months : Rs. 2.70 Cr
Total Capital Investment : Rs. 5.11 Cr
Rate of Return : 16%
Break Even Point : 61%
INTRODUCTION
GRITS/CONES
FLOUR
GERM
MAIZE KERNEL ANATOMY AND COMPOSITION
MAIZE KERNEL COMPOSITION
OVERVIEW OF MAIZE PRODUCTION AND TRENDS IN INDIA
TABLE: MAIZE AREA, PRODUCTION AND YIELD STATISTICS IN INDIAN
STATES FROM 2012-13 TO 2014-15
MARKET SURVEY
PRODUCTION OF MAIZE IN INDIA HAS INCREASED AT A CAGR OF 5.5 PER
CENT FROM 14 MNMT IN 2004-05 TO 23 MNMT IN 2013-14
MAIZE CONSUMPTION HAS INCREASED AT A CAGR OF 3.6 PER CENT
OVER THE LAST FIVE YEARS; POULTRY FEED ACCOUNTS FOR ~50
PER CENT OF MAIZE CONSUMPTION
END-USE FOR MAIZE
EXPORT OF MAIZE HAS INCREASED SIGNIFICANTLY OVER THE YEARS; INDONESIA, VIETNAM & MALAYSIA ARE THE KEY EXPORT
DESTINATION
THE GOVERNMENT HAS BEEN PROVIDING PRICE SUPPORT MECHANISM
TO ENCOURAGE FARMERS TO GROW MAIZE
ANNUAL MAIZE PRICES HAVE BEEN FOLLOWING THE MSP DECLARED
BY THE GOVERNMENT, AS CAN BE SEEN FROM THE GRAPH BELOW.
STOCK TO CONSUMPTION RATIO FOR INDIA INCREASED FROM 3.7 PER
CENT IN 2004-05 TO 6.6 PER CENT IN 2013-14 VIS-À-VIS GLOBAL
AVERAGE OF 16.3 PER CENT IN 2013-14
IMPORT & EXPORT DATA OF CORN FLAKES
DETAILED EXPORT DATA OF MAIZE GRITS
PRESENT MANUFACTURERS/SUPPLIERS
COMPOSITION OF YELLOW DENT CORN
SAMPLING PROBE
CORN TESTING
GRAIN STORAGE
CLEANING
TEMPERING CONVEYOR
DEGERMINATOR
INDUSTRIAL MAIZE PROCESSES
TYPES OF DRY GRINDERS
THERE ARE THREE METHODS USED FOR CORN DRY MILLING:
PROCESS OVERVIEW
TEMPERING
DEGERMINATION
ASPIRATION
GRAVITY SEPARATION
ROLLER MILLING AND SIFTING
MANUFACTURING PROCESS
CLEANING:
CONDITIONING:
DEGERMINATION:
DRYING:
COOLING:
GRADING:
MILLING:
DRY CORN MILLER’S PROCESS CORN IN ONE OF THREE WAYS:
PROCESS FLOW DIAGRAM
TEMPERING DEGERMING PROCESS
TECHNOLOGICAL PROCESS OF CORN GRITS
AND FLOUR PRODUCTION LINE
CORN GRITS AND FLOUR PRODUCTION LINE
WITH DRY METHOD
TECHNOLOGY INTRODUCTION OF CORN GRITS AND FLOUR PRODUCTION
LINE:
DETAILS OF DRY MILLING PROCESS OF MAIZE
DRY MILLING AND FRACTIONATION OF GRAIN
THE DRY MILLING PROCESS INCLUDES A NUMBER OF UNIQUE FEATURE
THE TABLE BELOW IS A COMPILATION OF PARTICLE SIZE AND YIELD
OF MILLED MAIZE PRODUCTS.
EXPERIMENTAL DRY MILLING OF CORN
MATERIALS AND METHODS
MATERIALS
EXPERIMENTAL METHODS
ANALYTICAL METHODS
RAW MATERIALS & FINISHED PRODUCTS
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE
SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
SPECIFIC FACTORS
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
PROJECT IMPLEMENTATION SCHEDULES
PLANT LAYOUT
SUPPLIERS OF RAW MATERIALS
HDPE WOVEN BAGS
SUPPLIERS OF PLANT AND MACHINERY
BUCKET ELEVATOR
CYCLONE
SCREW CONVEYORS
APPENDIX – A:
1. COST OF PLANT ECONOMICS
2. LAND & BUILDING
3. PLANT AND MACHINERY
4. FIXED CAPITAL INVESTMENT
5. RAW MATERIAL
6. SALARY AND WAGES
7. UTILITIES AND OVERHEADS
8. TOTAL WORKING CAPITAL
9. COST OF PRODUCTION
10. PROFITABILITY ANALYSIS
11. BREAK EVEN POINT
12. RESOURCES OF FINANCE
13. INTEREST CHART
14. DEPRECIATION CHART
15. CASH FLOW STATEMENT
16. PROJECTED BALANCE SHEET