Detailed Project Report on MAIZE STARCH, LIQUID GLUCOSE AND OTHER BY-PRODUCTS MANUFACTURING PLANT

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.

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ENGINEERS INDIA RESEARCH INSTITUTE
4/54, Roop Nagar, Delhi-110007 (India)
Phone: [phone]
E-mail: [email protected]
Website: www.eiriindia.org




MAIZE STARCH, LIQUID GLUCOSE AND OTHER BY -
PRODUCTS MANUFACTURING PLANT
[EIRI/EDPR/4772] J.C.: 2992BDT,2992INR,2992US$
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.
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.

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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.
Starches
Starch is a group of polysaccharides, composed of glucopyranose units joined
together by-glucosidric linkages. It conforms to the molecular formula, (C6-
H10O5)u, where 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.
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.
Cereal Starches
The cereal starches such as maize wheat, rice and sorghum are recovered by
several processes, of which the wet-milling is by far the most important. Other
processes commercially employed in the manufacture of unmodified starches are
that alkali, Martin and batter in the order of decreasing importance. Of the
material methods earlier used for the production of starch and which has now

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become obsolete, mention may be made of the Hakka, Alsation and Fescas
processes. In all the above processes, Starch is recovered in five stages:
a. Softening or steeping of the grains, after thorough washing in water.
b. Tabling or centrifugation of the ground mass.
c. Dewatering and drying of the final products.
d. The recovery of important by products

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CONTENTS

INTRODUCTION

STARCH INDUSTRY

BYPRODUCTS FROM MAIZE

STARCHES

NATURAL STARCHES

CEREAL STARCHES

OVERVIEW OF MAIZE GLOBALLY

MAIZE MARKET TRENRS (GLOBAL)

INCREASE IN DEMAND FOR ANIMAL-BASED PROTEIN SOURCES

DEMAND- WORLD WIDE

CORN SCENARIO IN BANGLAGESH

BANGLADESH’S PRODUCTION, SUPPLY, AND DISTRIBUTION OF CORN

PRODUCTION

PRICES

CORN PRICE RISES

TRADE

CORN IMPORTS DECLINE

INDIA IS THE PREFERRED EXPORTER

CONSUMPTION

FEED AND RESIDUAL USE

FEED DEMAND SHRINKS DUE TO HIGH PRICES

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FSI CONSUMPTION

STOCKS

CONSTITUENTS AND VARIETY OF MAIZE

SPECIFICATION OF CORN STARCH

CORN STARCH SPECIFICATION

USES OF STARCH:

STARCH HAS MANY INDUSTRIAL APPLICATIONS. THESE INCLUDE:

A) TEXTILE INDUSTRY:

B) FOOD INDUSTRY:

C) PAPER INDUSTRY:

D) PHARMACEUTICAL INDUSTRY:

E) MANUFACTURE OF GLUCOSE AND DEXTROSE BY HYDROLYSIS:

F) MANUFACTURE OF MODIFIED STARCHES, SUCH AS:

G) MISCELLANEOUS OTHER USES:

IN ADDITION TO THESE USES, BY PRODUCTS OF STARCH ARE ALSO OBTAINED DURING THE WET MILLING OF
MAIZE.

A) CONCENTRATED STEEP LIQUOR:

B) GERM OIL AND GERM AND CAKE:

C) GLUTEN:

PHYSICAL AND CHEMICAL MODIFICATION OF STARCH

COMPONENTS OF YELLOW DENT CORN

ECONOMIC SIZE UNIT AND PRODUCTION PATTERN

FOLLOWING THE AVERAGE ANALYSIS OF MAIZE

PHASED PRODUCTION PROGRAMME

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USES OF LIQUID GLUCOSE:-

LIQUID GLUCOSE SYRUP USES AND APPLICATIONS:

LIQUID GLUCOSE USES

USES OF DEXTROSE:-

PROPERTIES OF LIQUID GLUCOSE

PROPERTIES OF STARCH

PHYSICAL PROPERTIES

CHEMICAL PROPERTIES

STARCH GIVES A CHARACTERISTIC BLUE COLOR WITH IODINE.

CORN AND CORN OIL

A. PARTS OF CORN KERNEL, B. NUTRIENT COMPOSITION OF CORN KERNELS

CORN OIL VALUE

OVERVIEW OF CORN WET MILLING

CORN-WET MILLING MARKET – NOTABLE DEVELOPMENTS

FEW ARE PROMINENT COMPETITORS OPERATING IN THE COMPETITIVE

LANDSCAPE OF GLOBAL CORN-WET MILLING MARKET INCLUDE:

CORN-WET MILLING MARKET DYNAMICS

CONSUMPTION PATTERN OF MAIZE

SEGMENT WISE CONSUMPTION OF MAIZE IN INDIA

SPECIFICATION

REQUIREMENT FOR MAIZE, TAPIOCA & ARROW ROOT STARCHES, EDIBLE GRADE*

REQUIREMENTS FOR MAIZE AND TAPIOCA STARCHES FOR USE IN COTTON TEXTILE INDUSTRY

REQUIREMENTS OF TAMARIND STARCH FOR USE IN COTTON TEXTILE AND JUTE INDUSTRIES*

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SEQUENCES IN STARCH AND LIQUID GLUCOSE

IT CONSISTS OF FOLLOWING STEPS:-

METHOD OF MAIZE PROCESSING

MAIZE IS USUALLY PROCESSED BY TWO PROCESSES:

DRY MILLING PROCESS FLOW

WET MILLING PROCESS FLOW

STARCH MANUFACTURING PROCESS FLOW DIAGRAM

PROCESSING CORN BY WET MILLIING

DETAILS OF CORN WET MILLING

VARIOUS USES OF CORN

MAIZE STARCH MANUFACTURING

STARCH GLUTEN SEPARATION

STARCH REFINING

MODIFICATION

MANY TECHNIQUES ARE APPLIED FOR MODIFICATION FOR EXAMPLE:

MAIZE STARCH PRODUCTION TECHNOLOGY

MAIZE STARCH PROCESSING TECHNOLOGY

MAIZE CLEANING

MAIZE SOAKING

MAIZE COARSE CRUSHING

GERM SEPARATION

MAIZE GRINDING

MAIZE STARCH SIEVING

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PROTEIN SEPARATION AND MAIZE STARCH CLEANING

CENTRIFUGAL SEPARATION AND DRYING

SEQUENCES IN CORN WET MILLING

PROCESSING STEPS

CLEANING

STEEPING

MILLING & SEPARATION

FINE GRINDING AND SCREENING

SEPARATION OF STARCH AND GLUTEN

PROCESS FLOW DIAGRAM OF WET CORN MILLING PROCESSES

MANUFACTURING PROCESS OF LIQUID GLUCOSE

PROCESS DESCRIPTION OF LIQUID GLUCOSE MANUFACTURE

SEQUENCES IN MAIZE STARCH

CORN STARCH PRODUCTION

PRODUCTION OF STARCH SLURRY

PROCESSING DETAILS OF MAIZE STARCH

RECEIVING

CLEANING

STEEPING

GRINDING

GERM SEPARATION (DEGERMINATION)

FIBRE WASHING SECTION

THICKENING

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PRIMARY SEPARATION

GLUTEN THICKENING

ROTARY VACUUM FILTER

HYDROCLONE SYSTEM

DRYING

PROCESS DESCRIPTION OF CORN WET MILLING

CLEANING AND SOAKING

STEEP LIQUOR CONCENTRATION

CRUDE GEM OIL RECOVERY

FIBRE SEPARATION

GLUTEN SEPARATION AND CONCENTRATION

MIXED FEED PROCESSING

STARCH WASHING DEWATERING AND DRYING

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

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MAIZE GERM

APPLICATIONS

SORBITOL

APPLICATIONS:

COSMETICS:

FOOD INDUSTRY:

PHARMACEUTICAL INDUSTRY:

TOBACCO INDUSTRY:

TEXTILE INDUSTRY:

PAPER INDUSTRY:

PAINT INDUSTRY:

QUALITY CONTROL

FINAL PRODUCTS PHOTOGRAPHS

CORN STARCH

LIQUID GLUCOSE

LIST OF LAB TESTING EQUIPMENTS

MANUFACTURERS/SUPPLIERS

MAIZE STARCH

TURNKEY SUPPLIERS OF STARCH AND ALLIED PRODUCTS

SUPPLIERS OF CENTRIFUGE

SUPPLIERS OF HEAT EXCHANGER

SUPPLIERS OF LAB TESTING EQUIPMENT

SUPPLIERS OF BOILERS

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SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF CORN/MAIZE

SUPPLIERS OF SULPHUR

SUPPLIERS OF SULPHURIC ACID

SUPPLIERS OF CAUSTIC SODA

SUPPLIERS OF SODA ASH

MATERIAL HANDLING EQUIPMENTS

PRINCIPLES OF PLANT LAYOUT

STORAGE LAYOUT:

EQUIPMENT LAYOUT:

SAFETY:

PLANT EXPANSION:

FLOOR SPACE:

UTILITIES SERVICING:

BUILDING:

MATERIAL-HANDLING EQUIPMENT:

RAILROADS AND ROADS:

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

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4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION:

2. FIXED ASSETS:

3. WORKING CAPITAL:

4. BREAK-EVEN POINT:

5. OTHER FIXED EXPENSES:

6. MARGIN MONEY:

7. TOTAL LOAD:

8. LAND AREA/MAN POWER RATIO:

PROJECT IMPLEMENTATION SCHEDULES

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INTRODUCTION

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

TIME SCHEDULE

MANPOWER

GENERAL

BASIS OF ESTIMATION

UTILITIES

UTILITIES

STEAM

POWER

WORKING

SWOT ANALYSIS

PLANT LOCATION COUNTRY BANGLADESH

ORGANIZATION CHART

IMPLEMENTATION SCHEDULE

PLANT LAYOUT

MANUFACTURERS AND SUPPLIERS

SUPPLIERS OF STARCH

SUPPLIERS OF LIQUID GLUCOSE

LIST OF MANUFACTURERS OF RAW MATERIAL-OTHER

LIST OF SOME STARCH PROCESSING INDUSTRIES

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COMPLETE PLANT AND MACHINERY SUPPLIERS FOR MAIZE PROCESSING

IMPORTED COMPLETE PLANT & MACHINERY SUPPLIERS

FOREIGN COLLABORATORS

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF HYDROCHLORIC ACID

SUPPLIERS OF SULPHURIC ACID

SUPPLIERS OF SODA ASH

SUPPLIERS OF CAUSTIC SODA

SUPPLIERS OF ACTIVATED CARBON

SUPPLIERS OF PLANT & MACHINERY

STARCH MAKING PLANT AND EQUIPMENTS

SUPPLIERS OF BOILER

SUPPLIERS OF TANKS

SUPPLIERS OF HEAT EXCHANGER

SUPPLIERS OF CENTRIFUGES

SUPPLIERS OF TRAY DRIER

SUPPLIERS OF DISINTEGRATORS

SUPPLIERS OF PULVERISER/GRINDER

SUPPLIERS OF INDUSTRIAL ETP PLANT

SUPPLIERS OF INDUSTRIAL ETP PLANT

SUPPLIERS OF LABORATORTY EQUIPMENTS

SUPPLIERS OF D.G. SET

SUPPLIERS OF WEIGHING BREIDGE

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TURNKEY CONSULTANT FOR SETTINGUP MAIZE PROCESSING PLANT

ANNEXURE -1

LIST OF PLANT & MACHINERY

PROJECT: 150 TPD MAIZE PROCESSING PLANT

PRODUCTION CAPACITY

TECHNICAL DATA

1. SPECIFICATION OF RAW MATERIAL

2. SPECIFICATION OF THE FINAL PRODUCTS

3. SPECIFICATION OF CHEMICALS AND UTILITIES

SPECIFICATION OF UTILITIES

STEAM

ELECTRICITY

AIR SUPPLY

WATER

PROCESS WATER (FRESH WATER)

1. CAPACITY

2. QUALITY

3. CONSUMPTION FIGURES

CONSUMPTION OF RAW MATERIAL

TECHNICAL SPECIFICATION

150 M.T./MAIZE WET MILLING PLANT COVERING

SECTION: 1.00

MAIZE STEEPING

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SECTION: 2.00

SULPHUR DIOXIDE PLANT

DEGERMINATION AND GERM WASHING

SECTION: 4.00

FIBRE MILLING AND WASHING

SECTION: 5.00

STARCH SEPARATION AND REFINING

MAIZE STARCH: 6.00

GLUTEN CONCENTRATION

SECTION: 7.00

GERM DEWATERING AND DRYING

SECTION: 8.00

STEEPING WATER CONCENTRATION

SECTION: 9.00

SECTION: 10.00

ANIMAL FEED DEWATERING AND DRYING

SECTION: 11.00

STARCH DEWATERING AND DRYING

MISCELLANEOUS EQUIPMENT FOR THE MAIZE PROCESSING PLANT SECTION 12.00

ELECTRICAL EQUIPMENT

FIELD & PANEL INSTRUMENTATION

PIPING, DUCTS, VALVES LINE FITTINGS

INSULATION MATERIAL

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UTILITY AND ELECTRICAL WORK RELATED TO MAIZE PROCESSING PLANT

ANEXURE- 2

STANDARD FOR MAIZE (CORN) CXS

SCOPE

1. DESCRIPTION

1. CONTAMINANTS

2. HYGIENE

3. PACKAGING

4. LABELLING

5. LABELLING

6. METHODS OF ANALYSIS AND SAMPLING

ANEXURE


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

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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)



COST ESTIMATION
Plant Capacity 150 MT/Day
Land & Building (48,000 sq.mt.) Rs. 10.96 Cr
Plant & Machinery Rs. 29.84 Cr
Working Capital for 1 Month Rs. 23.13 Cr
Total Capital Investment Rs. 65.54 Cr
Rate of Return 10%
Break Even Point 51%