Detailed Project Report (DPR) on liquid glucose from broken rice

LIQUID GLUCOSE FROM BROKEN RICE
 [CODE NO. 2052]

Glucose is a commercially import ant product widely used by the food and pharmaceutical industries. In general, glucose is used in the food industry as a partial or complete substitute for sucrose. Glucose is the common name for the syrup which is used in large quantities in fruit canning, confectioneries, jams, jellies, preserves, ice cream, bakery products, pharmaceuticals, beverages and alcoholic fermentation. The functional purpose of glucose in the confectionery industry is to prevent crystallization of the sucrose while in the bakery products industry it is to supply fermentable carbohydrates. In the icecream and fruitpreserves, it used to increase the solidswithout causing an undue increase in the total sweetness. In pharmaceutical industry, glucose is used as a precursor to make vitamin C in the Reichstein process, to make citric acid, gluconic acid, polylactic acid and sorbitol. Currently, glucose is utilized as an intermediate raw material for bioethanol production.

Commonly, glucose is prepared commercially via the enzymatic hydrolysis of starchinstead of acid hydrolysis. Many crops can be used as the source of the initial starch. Maize, rice, wheat, potato, cassava, arrowroot and sago are all used in various parts of the world.Nevertheless, using the starch needs to compete with their primary use as food crops. Due to the abundant of nonfood energy crops like cellulosic material, they are use to reduce the utilization of starch as raw material for production of glucose. Cellulosic materials including  agricultural,  agroindustrial and  forestry  lignocellulosic residues have potential as   cheap   and   renewable feedstocks for large scale production of fuels and chemicals. Currently, bioprocessing of lignocellulosics is focused on enzymatic hydrolysis of the cellulose fraction to glucose, followed by fermentation to fuelgrade ethanol. However, enzymatic  hydrolysis  of  cellulosic  materials  to  produce fermentable  sugars  has  also enormous potential in meeting global food  and  energy  demand  via  biological  route.

In    lignocellulosic    materials    cellulose    is    physically    associated    with hemicellulose, and physically and chemically associated with lignin.   The  presence of  these  two  fractions  is  reported  to  make  the  access  of  cellulase  enzymes  to cellulose  difficult,  thus  reducing  the  efficiency  of  the  hydrolysis.  There  are  several  kinds  of  pretreatment  able  to  disrupt  the  lignocellulosic structure for increasing the efficiency of the hydrolysis which have been investigated but are not within the scope of this study. However, the effect of temperature and pH are also significant in cellulose hydrolysis which will be stud ying in this study.  The temperature and pH influence the efficiency of cellulase to degrade the cellulose for
producing glucose.    

In order to produce  glucose, cellulose is essential to break it down first.By using acid hydrolysis, conversion of cellulose to glucose only produces low glucose concentration  because  acid  is  no  selectivity.   Furthermore, by  using  acid  causes the cost production  of  glucose  is highdue  to demand  of  neutralization  after  hydrolysis which  can  contribute  to  corrosion  problem  if  there is no  neutralization  process .  Other that, the need of high temperature during acid hydrolysis process also contribute s to the cost of production because high energy is consume d.  Waste from a cid  hydrolysis  also  gives  the  bad  effect  to  the  environment  which  is  using  high concentration  of  acid   can  cause  harmful  to  the  environment.   Therefore, the investigation attempted  to  determine  the glucose  production  by  using enzymatic hydrolysis process inorder to replace acid hydrolysis process.

Nevertheless by using enzymatic hydrolysis need highly specific and very sensitive.   Their  environmental  condition  such  temperature  and  pH  influence  the activity  of the  enzymes  in  the  system. Hence,  the  effect of  temperature  and  pH  is investigated to  determine  the  maximum conditions  of  enzymatic  hydrolysis  process in glucose production.


COST ESTIMATION

Plant Capacity                                               70.00 MT/day                           
Land & Building (24,000 Sq.Mtr)                Rs.16.76 Cr
Plant & Machinery                                         Rs.8.50  Cr
W.C. for 1 Month                                           Rs. 5.58 Cr
Total Capital Investment                             Rs.32.89 Cr
Rate of Return                                              26%
Break Even Point                                          55%


INTRODUCTION    
TYPES OF GLUCOSE SYRUP    
PRODUCT DESCRIPTION AND USE    
USES AND APPLICATION OF MALTODEXTRIN    
PROPERTIES & CHARACTERISTICS    
CHEMICAL COMPOSITION OF DIFFERENT KINDS OF RICE    
PROPERTIES AND CHARACTERISTICS OF MALTODEXTRIN    
B.I.S. SPECIFICATION    
OVERVIEW AND AVAILABILITY OF RICE IN INDIA    
MARKET SURVEY    
IMPORT DATA OF LIQUID GLUCOSE    
EXPORT DATA OF LIQUID GLUCOSE    
PRODUCTION OF LIQUID GLUCOSE IN INDIA    
MARKET SURVEY (GLOBAL)    
PRESENT MANUFACTURERS    
SPECIFICATIONS    
COMMERCIAL PRODUCTION OF GLUCOSE    
SEQUENCES IN GLUCOSE PREPARATION    
MANUFACTURING PROCESS OF LIQUID GLUCOSE BY ACID HYDROLYSIS    
PROCESS FLOW DIAGRAM    
MANUFACTURING PROCESS FOR LIQUID GLUCOSE    
PROCESS FLOW DIAGRAM OF LIQUID GLUCOSE    
USING STARCH    
MANUFACTURING PROCESS OF LIQUID GLUCOSE USING
ENZYME HYDROLYSIS    
FILTERATION OF LIQUID GLUCOSE    
PURIFICATION OF GLUCOSE SYRUPS USING ACTIVATED CARBON    
PROCESS FLOW DIAGRAM    
MANUFACTURING PROCESS OF RICE STARCH    
MANUFACUTRING PROCESS OF MALTODEXTRIN FROM BROKEN RICE    
PROCESS FLOW DIAGRAM OF MALTODEXTRIN FROM RICE STARCH
OBTAINED
FROM BROKEN RICE    
TECHNICAL DETAILS AND OBTIMIZATION OF LIQUID
GLUCOSE AND MALTO DEXTRIN    
SEPARATION OF PROTEINS AND PRODUCTION OF MALTODEXTRIN    
ASSAY METHOD OF MALTO DEXTRIN (REDUCING SUGAR)    
WET MILLING PROCESS    
TECHNICAL PARAMETER IN LIQUID GLUCOSE PLANT    
ENZYMES PROCUREMENT ANALYSIS DETAILS OF ALPHA
AMYLASE ENZYMES    
MATERIAL SAFETY DATA SHEET FOR ALPHA AMYLASE ENZYMES    
OVEVIEW OF ANIMAL FEED INDUSTRY    
OPTIMIZATION OF BYPRODUCT OF THE PROCESS (GLUTEN)    
RAW MATERIALS & YIELD    
CONSULTANTS FOR GLUCOSE PLANT    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF BROKEN RICE    
SUPPLIERS OF PLANT & MACHINERY (IMPORTED)    
LIST OF THE BUYERS OF LIQUID GLUCOSE    


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