Detailed Project Report (DPR) on corn dry milling plant

CORN DRY MILLING PLANT

[CODE NO 4122] 

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                                      100 MT/Day

Land & Building (12,000 sq.mt.)    Rs. 5 Cr

Plant & Machinery                              Rs. 2 Cr

Working Capital for 1 Month             Rs. 4.48 Cr

Total Capital Investment                  Rs. 11.80 Cr

Rate of Return                                 28%

Break Even Point                             59%

• INTRODUCTION
• USES AND APPLICATION
• GRITS/CONES
• FLOUR
• GERM
• MAIZE KERNEL ANATOMY AND COMPOSITION
• MAIZE KERNEL COMPOSITION
• MAIZE OUTLOOK IN INDIA
• INTERNATIONAL GRAIN COUNCIL’S WORLD CORN PROJECTIONS (IN MILLION METRIC TONNES)
• INTERNATIONAL GRAIN COUNCIL’S INDIAN CORNPROJECTIONS (IN MILLION METRIC TONNES)
• MONTH-WISE AVERAGE PRICES OF MAIZE AT VARIOUS MARKETS
• MAIZE ARRIVALS AND PRICES IN WARANGAL MARKET FOR THE MONTH OF JUNE 2020
• MAIZE PRICE OUTLOOK
• MARKET OVERVIEW OF MAIZE DRY MILLING
• PRESENT MANUFACTURERS/SUPPLIERS
• COMPOSITION OF YELLOW DENT CORN
• SAMPLING PROBE
• CORN TESTING
• GRAIN STORAGE
• CLEANING
• TEMPERING CONVEYOR
• DEGERMINATOR
• DRY MILLING OF GRAIN
• PROCESS OVERVIEW OF CORN DRY MILLING
• TEMPERING
• DEGERMINATION
• ASPIRATION
• GRAVITY SEPARATION
• ROLLER MILLING AND SIFTING
• MILLING SYSTEM OF MAIZE
• PROCESSING OF MAIZE
• DESTONING
• CONDITIONING
• TEMPERING
• CONDITIONING
• DEBRANNING AND DEGERMING
• HORIZONTAL ABRASIVE POLISHER
• HORIZONTAL FRICTION POLISHER
• SIFTING
• SPECIFIC GRAVITY SEPARATOR
• DRYING
• DETAILS OF MAIZE DRY MILLING
• COMPARISON OF PRODUCT YIELD FOR LABORATORY DRY-MILLED MEDIUM-HARD ENDOSPERM AND MEDIUM SOFT ENDOSPERM DENT MAIZE DRIED AT TWO TEMPERATURES
• INDUSTRIAL MAIZE PROCESSES
• TYPES OF DRY GRINDERS
• 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
• 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
• EXPERIMENTAL DRY MILLING OF CORN
• MATERIALS AND METHODS
• MATERIALS
• EXPERIMENTAL METHODS
• ANALYTICAL METHODS
• RAW MATERIALS & FINISHED PRODUCTS
• PRINCIPLES OF PLANT LAYOUT
• STORAGE LAYOUT
• EQUIPMENT LAYOUT
• SAFETY
• PLANT EXPANSION
• FLOOR SPACE
• UTILITIES SERVICING
• BUILDING
• MATERIAL-HANDLING EQUIPMENT
• RAILROADS AND ROADS
• PLANT LOCATION FACTORS
• PRIMARY FACTORS
• SPECIFIC FACTORS
• EXPLANATION OF TERMS USED IN THE PROJECT REPORT
• PROJECT IMPLEMENTATION SCHEDULES
• INTRODUCTION
• PROJECT HANDLING
• PROJECT SCHEDULING
• PROJECT CONSTRUCTION SCHEDULE
• TIME SCHEDULE
• 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