MAIZE PROCESSING PLANT (300 TON/DAY MAIZE PROCESSING PLANT) STARCHES/MODIFIED STARCHES/LIQUID GLUCOSE/DEXTROSE MONOHYDRATE/GLUCOSE SYRUPS/CORN SYRUP SOLIDS/HIGH MALTOSE CORN SYRUPS/MALTO DEXTRINE POWDER/CORN GLUTEN MEAL (60%) MAIZE OIL/SORBITOL
[EIRI/EDPR/1605] J.C.:405
INTRODUCTION
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 is 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.
1.0 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 cerbonhydrate in various parts of plants and is enzymatically broken down to glucose to other carbohydrates 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 simpluy 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, dialdehyde starches and cationic starches.
COST ESTIMATION
Plant Capacity 300 MT/Day
Land & Building (20 Acres) Rs. 21.87 Cr
Plant & Machinery Rs. 64.55 Cr
Working Capital for 2 Months Rs. 26.07 Cr
Total Capital Investment Rs. 113.92 Cr
Rate of Return 58%
Break Even Point 34%
CONTENTS
INTRODUCTION
PRODUCT DESCRIPTION AND USE
ECONOMIC SIZE UNIT AND PRODUCTION PATTERN
PROPERTIES
MARKET SURVEY
NAME AND ADDRESS OF MANUFACTURERS
OF LIQUID GLUCOSE
LIQUID GLUCOSE AND DEXTROSE - AN ASSESSMENT
OF MARKET
ESTIMATED DEMAND FOR DEXTROSE
LIST OF MANUFACTURERS OF
RAW MATERIAL-DEXTROSE
SPECIFICATION
INDIAN STANDARDS
SPECIFICATIONS
MANUFACTURES OF STARCH AND ALLIED PRODUCTS
PROCESS DESCRIPTION
PROCESS FLOW DIAGRAM FOR THE MFG. OF STARCH
RAW MATERIALS AND UTILITIES
MANUFACTURING PROCESS FOR LIQUID GLUCOSE-G
MANUFACTURE OF DEXTROSE MONOHYDRATE
AND DEXTROSE ANHYDROUS
MANUFACTURING DIAGRAM OF LIQUID GLUCOSE
MANUFACTURING DIAGRAM OF
ANHYDROUS DEXTROSE
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF PLANT & MACHINERY
PLANT AND MACHINERY
IMPLEMENTATION SCHEDULE
LIST OF FOOD AND AGRO PROCESSING
CONSULTANTS
MANUAL ON STANDARDS OF MAIZE
PLANT ECONOMICS
PLANT & MACHINERY
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)