MAIZE PROCESSING PLANT
(WET MILLING) CORN OIL, CORN SYRUP,
HFCS DEXTRIN, MALTO DEXTRIN, CORN STARCH, LIQUID GLUCOSE ETC. CAP: 300 TON/DAY INPUT
[CODE NO.3485]
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.
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 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.
COST ESTIMATION
Plant Capacity : 300.00 MT./day
land & Building (15 Acres) : Rs. 34.22 Cr
Plant & Machinery : Rs. 95.00 Cr
Working Capital for 2 Months : Rs. 29.63 Cr
Total Capital Investment : Rs. 164.85 Cr
Rate of Return : 23%
Break Even Point : 55%
INTRODUCTION
STARCH INDUSTRY IN INDIA
BYPRODUCTS FROM MAIZE
SPECIFICATION OF STARCH
PHYSICAL AND CHEMICAL MODIFICATION OF STARCH
COMPONENT OF YELLOW DENT CORN
ECONOMIC SIZE UNIT AND PRODUCTION PATTERN
PHASED PRODUCTION PROGRAMME
USES OF LIQUID GLUCOSE:-
LIQUID GLUCOSE SYRUP USES AND APPLICATIONS:
LIQUID GLUCOSE USES
USES OF DEXTROSE:-
PROPERTIES
PROPERTIES OF STARCH
PHYSICAL PROPERTIES
CHEMICAL PROPERTIES
STARCH GIVES A CHARACTERISTIC BLUE COLOR WITH IODINE.
OVERVIEW OF CORN WET MILLING
STARCH INDUSTRY IN INDIA: SUPPLY
AND DEMAND SCENARIO
SUPPLY
DEMAND
MARKET SURVEY
INSTALLED CAPACITY, CAPACITY UTILIZATION & PRODUCTION
OF MAIZE STARCH & ALLIED PRODUCTS
APPRENT CONSUMPTION OF MAIZE STARCH AND ALLIED PRODUCTS 39
ESTIMATED DEMAND
DETAILED EXPORT DATA OF CORN STARCH
DETAILED EXPORT DATA OF LIQUID GLUCOSE
DETAILED EXPORT DATA OF CORN OIL
MANUGFACTURERS/SUPPLIERS
MAIZE STARCH
LIQUID GLUCOSE
SPECIFICATION
REQUIREMENT FOR MAIZE, TAPIOCA & ARROW ROOT STARCHES,
EDIBLE GRADE
TABLE III REQUIREMENTS FOR MAIZE AND TAPIOCA STARCHES
FOR USE IN COTTON TEXTILE INDUSTRY
REQUIREMENTS OF TAMARIND STARCH FOR USE IN COTTON TEXTILE
AND JUTE INDUSTRIES
CORN WET MILLING PROCESS
PROCESSING STEPS
CLEANING
STEEPING
MILLING & SEPARATION
FINE GRINDING AND SCREENING
SEPARATION OF STARCH AND GLUTEN
PROCESS FLOW DIAGRAM OF WET CORN MILLING PROCESSES
MANUFACTURES OF STARCH AND ALLIED PRODUCTS
MAIZE STARCH
TAPIOCA STARCH
AMYLOSE MOLECULE OF STARCH
AMYLOPECTIN MOLECULE
DETAILS OF CORN WET MILLING
PROCESS DESCRIPTION
PROCESS FLOW DIAGRAM FOR THE MFG. OF STARCH
MANUFACTURE OF CORN SYRUP
MANUFACTURE OF HIGH FRUCTOSE CORN SYRUP
PROCESS FLOW DIAGRAM OF FRUCTOSE SYRUP
RAW MATERIALS AND UTILITIES
RAW MATERIALS
SPECIAL GRADES FOR CORN:
MAIZE PROCESSING PROCESS SHEET
MANUFACTURING PROCESS FOR LIQUID GLUCOSE
RAW MATERIALS
CONFECTIONERI GLUCOSE-D:
LOW CONVERSION:
REGULAR CONVERSION
INTERMIDIATE CONVERSION
HIGH CONVERSION
MANUFACTURE OF DEXTROSE MONOHYDRATE
AND 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
COSMETICS:
FOOD INDUSTRY:
PHARMACEUTICAL INDUSTRY:
TOBACCO INDUSTRY:
TEXTILE INDUSTRY:
PAPER INDUSTRY:
PAINT INDUSTRY:
SUPPLIERS OF PLANT AND MACHINERY
CENTRIFUGE
HEAT EXCHANGER
LAB TESTING EQUIPMENT
BOILERS
SUPPLIERS OF RAW MATERIALS
CORN/MAIZE
SULPHUR
SULPHURIC ACID
CAUSTIC SODA
SODA ASH
PLANT & MACHINERY SECTION WISE
LIST OF MACHINERY AND EQUIPMENT
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