Industry Overview
Glucose is an important commercial product widely used across the food, pharmaceutical, beverage, confectionery, bakery, ice cream, fruit-preserve and fermentation industries. It is commonly used as a partial or complete substitute for sucrose. In confectionery applications, glucose helps prevent sucrose crystallization; in bakery products, it provides fermentable carbohydrates; and in ice cream and fruit preserves, it increases solids without causing an excessive increase in sweetness. Pharmaceutical applications include its use as a precursor for vitamin C, citric acid, gluconic acid, polylactic acid and sorbitol production. Glucose is also used as an intermediate raw material for bioethanol production.
Commercial glucose is commonly produced through enzymatic hydrolysis of starch. Sources include maize, rice, wheat, potato, cassava, arrowroot and sago, although food-crop utilization creates competition with food applications. Lignocellulosic agricultural, agroindustrial and forestry residues offer an alternative renewable feedstock because cellulose can be hydrolyzed into fermentable glucose.
Effective enzymatic hydrolysis of lignocellulosic materials is affected by the association of cellulose with hemicellulose and lignin, which can restrict cellulase access. Temperature and pH are particularly important process variables because they influence enzyme activity and hydrolysis efficiency. Compared with acid hydrolysis, enzymatic hydrolysis can avoid issues associated with acid selectivity, neutralization requirements, corrosion, high-temperature energy consumption and acidic waste. Accordingly, the study investigates temperature and pH conditions for optimizing enzymatic hydrolysis for glucose production.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 75 MT/Day |
| Land & Building (6 Acres) | Rs. 13.73 Cr |
| Plant & Machinery | Rs. 16.16 Cr |
| Working Capital for 1 Month | Rs. 5.92 Cr |
| Total Capital Investment | Rs. 36.83 Cr |
| Rate of Return | 26% |
| Break Even Point | 59% |
Content Index
- INTRODUCTION
- STRUCTURE OF LACTOSE
- TYPES OF GLUCOSE SYRUP
- CONFECTIONER'S SYRUP
- HIGH-MALTOSE GLUCOSE SYRUPS
- MALTO DEXTRIN
- DEALING WITH DE
- BROWNING (DUE TO THE INCREASED LEVEL OF REDUCING SUGARS);
- AS DE DECREASES, THE FOLLOWING CHARACTERISTICS INCREASE:
- PRODUCT DESCRIPTION AND APPLICATION
- GLUCOSE AS ENERGY SOURCE IN LIVING CELL
- CULINARY APPLICATIONS
- HEALTH BENEFITS OF LIQUID GLUCOSE
- LIQUID GLUCOSE USES
- IN FOODS
- CHEMICAL AND PHARMACEUTICAL USES
- OTHER INDUSTRIAL USES
- LEATHER INDUSTRY
- PHARMACEUTICAL INDUSTRY
- AGRICULTURE/ANIMAL FEED
- USES AND APPLICATION OF MALTODEXTRIN
- CARRIERS AND BULKING
- CALORIE REDUCTION
- FROZEN ASSETS
- SPORTS AND NUTRITION
- PROPERTIES & CHARACTERISTICS
- PROPERTIES OF STARCH
- PHYSICAL PROPERTIES
- CHEMICAL PROPERTIES
- COMPOSITION OF RICE
- COMPOSITION OF RAW AND PARBOILED RICE.
- CHEMICAL COMPOSITION OF DIFFERENT KINDS OF RICE
- SYNONYMS
- PROPERTIES
- AVERAGE ANALYSIS OF RICE IN INDIA
- PROPERTIES AND CHARACTERISTICS OF MALTODEXTRIN
- SACCHARIDE COMPOSITION OF COMMERCIAL MALTODEXTRINS
- MALTODEXTRIN
- MARKET OVERVIEW OF LIQUID GLUCOSE
- PRESENT MANUFACTURERS/SUPPLIERS
- SPECIFICATIONS
- SPECIFICATION FOR LIQUID GLUCOSE
- 3. GRADES
- 4. REQUIREMENTS
- COLOUR
- REQUIREMENTS FOR LIQUID GLUCOSE (ALL GRADES)
- 5. PACKING & MARKING
- PACKING
- MARKING
- COMMERCIAL PRODUCTION OF GLUCOSE
- USAGE OF GLUCOSE IN FOOD INDUSRIES
- SUBSTRATE FOR GLUCOSE PRODUCTION
- THE COMPARISON STRUCTURE OF STARCH AND CELLULOSE
- SEQUENCES IN GLUCOSE PREPARATION
- PREPARATION
- SOAKING
- GELATINIZATION
- HYDROLYSIS
- CLARIFICATION
- EVAPORATION
- RICE GLUCOSE PROCESSING [ENZYME HYDROLYSIS]
- 1. RICE POWDER MAKING PROCESS IN RICE GLUCOSE SYRUP PROCESSING PLANT
- 2. RICE POWER SLURRY MAKING PROCESS IN RICE GLUCOSE SYRUPPROCESSING PLANT
- 3. LIQUEFACTION PROCESS IN RICE GLUCOSE SYRUP PROCESSING PLANT
- 4. DEPROTEINIZATION PROCESS IN RICE GLUCOSE SYRUP PROCESSINGPLANT
- 5. SACCHARIFICATION PROCESS IN RICE GLUCOSE SYRUP PROCESSINGPLANT
- 6. DECOLORIZATION PROCESS IN RICE GLUCOSE SYRUP PROCESSING PLANT
- 7. DECARBURIZATION PROCESS IN RICE GLUCOSE SYRUP PROCESSING PLANT
- 8. ION EXCHANGE PROCESS IN RICE GLUCOSE SYRUP PROCESSING PLANT
- 9. EVAPORATION PROCESS IN RICE GLUCOSE SYRUP PROCESSING PLANT
- 10. FINAL PRODUCT STORAGE IN RICE GLUCOSE SYRUP PROCESSING PLANT
- PROCESS FLOW CHART
- SYRUP PROCESSING LINE
- SYRUP PROCESSING LINE FLOW CHART
- HIGH FRUCTOSE SYRUP PRODUCTION DETAILS:
- 1. MIXING AND LIQUEFYING PROCESS:
- 2. SACCHARIFY:
- 3. LIQUID GLUCOSE DECOLORIZING:
- 4. FILTRATION:
- 5. ION EXCHANGE SYSTEM DURING HIGH FRUCTOSE SYRUP PRODUCTION:
- 6. CONCENTRATION:
- 7. ISOMERISM PROCESS:
- 8. HIGH FRUCTOSE SYRUP REFINING PROCESS:
- GLUCOSE SYRUP MAKING MACHINE TECHNOLOGY:
- 1. MIXING AND LIQUEFACTION:
- 2. FILTRATION SECTION DURING THE GLUCOSE SYRUP MAKING MACHINE:
- 3. SACCHARIFICATION:
- 4. DECOLORIZATION BY GLUCOSE SYRUP MAKING MACHINE:
- 5. FILTRATION PROCESS/DECARBURIZATION:
- 6. ION EXCHANGE SECTION:
- 7. EVAPORATION:
- MALTOSE SYRUP PROCESS MACHINE TECHNOLOGY DESCRIPTION:
- 1. MIXING SLURRY UNIT DURING THE MALTOSE SYRUP PROCESS:
- 2. EJECTOR LIQUEFACTION UNIT:
- 3. FILTER PRESS DEPROTEINIZATION:
- 4. SACCHARIFICATION:
- 5. DECOLORIZATION:
- 6. FILTER PRESS DECARBURIZATION:
- 7. ION EXCHANGE PROCESS:
- 8. CONCENTRATION AND EVAPORATION:
- MANUFACTURING PROCESS OF LIQUID GLUCOSE BY ACID HYDROLYSIS
- PROCESS FLOW DIAGRAM
- MANUFACTURING PROCESS FOR LIQUID GLUCOSE
- RAW MATERIALS
- CONFECTIONERY GLUCOSE-D:
- LOW CONVERSION
- REGULAR CONVERSION
- INTERMEDIATE CONVERSION
- HIGH CONVERSION
- PROCESS FLOW DIAGRAM OF LIQUID GLUCOSE USING STARCH
- MANUFACTURING PROCESS IN DETAILS OF LIQUID GLUCOSE USING ENZYME HYDROLYSIS
- THERE ARE THREE STAGES IN CONVERSION OF STARCH:
- STARCH MILK ADJUSTMENT:
- LIQUEFACTION:
- RICE GLUTEN FEED MAKING.
- SACCHARIFICATION:
- FILTERATION AND DECOLORING:
- ION EXCHANGE:
- EVAPORATION:
- FILTRATION OF LIQUID GLUCOSE
- GENERAL INFORMATION
- EQUIPMENT DESIGN
- PURIFICATION OF GLUCOSE SYRUPS USING ACTIVATED CARBON
- STANDARD DESIGN CONDITIONS
- PROCESS FLOW DIAGRAM
- MANUFACTURING PROCESS OF RICE STARCH
- ALKALI STEEPING PROCESS:
- SEPARATION OF THE STARCH:
- CRYSTALLIZING AND DRYING 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
- TYPICAL CARBOHYDRATE PROFILE OF COMMERCIAL MALTODEXTRIN
- GLUCOSE
- ACID-CATALYZED HYDROLYSIS
- TYPICAL GLUCOSE SYRUP PROCESS
- COMPOSITION OF TYPICAL STARCH DERIVED SWEETERS
- TYPICAL ACID CONVERTER
- CARBON TREATMENT AND REGENERATION SYSTEM
- ACID–ENZYME PROCESSES
- SYRUP DEMINERALIZATION SEQUENCE
- MULTIPLE EFFECT EVAPORATORS
- SEPARATION OF PROTEINS AND PRODUCTION OF MALTODEXTRIN
- ASSAY METHOD OF MALTO DEXTRIN (REDUCING SUGAR)
- MATERIAL
- METHOD
- WET MILLING PROCESS
- CLEANING AND STEEPING
- STEEP LIQUOR CONCENTRATION
- FIBRO SEPARATION
- GLUTEN SEPARATION
- STARCH WASHING, DEWATERING AND DRYING OR CONCENTRATION
- CONCLUSION & COMPARISON
- TECHNICAL PARAMETER IN LIQUID GLUCOSE PLANT
- FOR ENZYMES BASED HYDROLYSIS
- FOR ACID BASED HYDROLYSIS
- RICE VARIETY AND PARTICLE SIZE OF RICE FLOUR AT MILLING
- ENZYMES PROCUREMENT ANALYSIS DETAILS OF ALPHA AMYLASE ENZYMES
- CHARACTERISTIC AND PROCESS PARAMETERS
- SPECIFICATION:
- STORAGE:
- SHELF LIFE:
- SAFETY:
- MATERIAL SAFETY DATA SHEET FOR ALPHA AMYLASE ENZYMES
- DESCRIPTIONS
- STORAGE AND SHELF LIFE
- PACKAGING
- USING THE PRODUCT
- GUIDELINES FOR USE
- SPECIFICATIONS
- OVERVIEW OF ANIMAL FEED INDUSTRY
- OPTIMIZATION OF BYPRODUCT OF THE PROCESS (GLUTEN)
- FORMULATION OF ANIMAL FEED
- EQUIPMENT FOR MAKING CATTLE FEED PELLETS
- DESCRIPTION OF PLANT & MACHINERY
- DESCRIPTION
- RAW MATERIALS & YIELD
- FROM 1 TON OF BROKEN RICE
- FROM 1 TON OF BROKEN RICE
- CONSULTANTS FOR GLUCOSE PLANT
- ADDRESSES OF PLANT AND MACHINERY SUPPLIERS
- SUPPLIERS OF BROKEN RICE
- SUPPLIERS OF PLANT & MACHINERY (IMPORTED)
- ANNEXURE-A
- SUPPLIERS OF LIQUID GLUCOSE
- SUPPLIERS OF RICE GLUTEN
Appendix
- 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)
Frequently Asked Questions
Glucose syrup is widely used as a functional ingredient across food, pharmaceutical and other industrial applications. In confectionery, it helps control sucrose crystallization, while in bakery products it supplies fermentable carbohydrates. It is also used in ice cream and fruit preserves to increase solids without an undue increase in sweetness. The report also identifies applications in beverages, alcoholic fermentation, pharmaceuticals, leather, agriculture and animal feed, as well as use as an intermediate raw material for bioethanol production.
Commercial glucose can be produced by hydrolyzing starch into glucose through a sequence of processing operations. The report describes preparation, soaking or slurry formation, gelatinization, liquefaction, saccharification, clarification, decolorization, filtration, ion exchange and evaporation. Enzymatic hydrolysis is emphasized as an important alternative to acid hydrolysis. Depending on the raw material and process configuration, starch can be sourced from crops such as rice, maize, wheat, potato, cassava, arrowroot and sago.
Enzymatic hydrolysis is used because it provides a more selective route for converting cellulose or starch into fermentable sugars. The report contrasts it with acid hydrolysis, which can have lower selectivity and may require neutralization, create corrosion concerns, consume substantial energy at high temperatures and generate acidic waste. Enzymatic processing instead relies on enzymes whose activity is strongly influenced by operating conditions. Consequently, controlling temperature and pH is essential for achieving efficient hydrolysis.
Temperature and pH strongly influence enzyme activity and therefore affect the efficiency of enzymatic hydrolysis. Enzymes operate effectively within suitable environmental conditions, while conditions outside their effective range can reduce catalytic performance. In glucose production, appropriate temperature and pH control can improve the conversion of the carbohydrate substrate into glucose. The report specifically investigates these two parameters to determine conditions that maximize enzymatic hydrolysis performance.
Glucose can be produced from starch-containing crops and potentially from lignocellulosic biomass. The report identifies maize, rice, wheat, potato, cassava, arrowroot and sago as starch sources used in different parts of the world. It also discusses agricultural, agroindustrial and forestry lignocellulosic residues as renewable feedstocks. Lignocellulosic materials contain cellulose associated with hemicellulose and lignin, so suitable pretreatment may be necessary to improve cellulase access before enzymatic hydrolysis.
A rice glucose syrup processing plant generally involves preparation of rice powder and slurry followed by conversion and purification stages. The report describes rice powder making, slurry preparation, liquefaction, deproteinization, saccharification, decolorization, decarburization, ion exchange, evaporation and final product storage. These operations are designed to convert the carbohydrate feedstock into glucose syrup and then remove unwanted components while achieving the required concentration and product quality.
The report states a plant capacity of 75 MT/Day and a Total Capital Investment of Rs. 36.83 Cr. The stated cost estimation also includes Land & Building (6 Acres) at Rs. 13.73 Cr, Plant & Machinery at Rs. 16.16 Cr, and Working Capital for 1 Month at Rs. 5.92 Cr. The report further states a Rate of Return of 26% and a Break Even Point of 59%. These figures are reproduced exactly as provided in the project report.
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