MAIZE/CORN AND ITS BY PRODUCTS LIKE STARCH, CORN OIL, CORN SYRUP, DEXTROSE MONOHYDRATE, DEXTRIN, MALTODEXTRIN, MAIZE GERM, SORBITOL POWDER, HIGH FRUCTOSE CORN SYRUP, GLUTEN, ANIMAL FEED
[CODE NO.3816]
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.
1.1 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.
1.1 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.
1.3 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 have now 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.
1.4 Raw Materials
The principal raw materials, used by the Indian Starch Industry are maize and tapioca.
1.4.1 Maize
Maize is grown in Uttar Pradesh, Bihar, Rajasthan, Punjab, Madhya Pradesh, Himachal Pradesh, Gujarat, Jammu and Kashmir, Andhra Pradesh, Mysore, and Haryana.
COST ESTIMATION
Plant Capacity 60 MT/Day
Land & Building (16,000 sq.mt.) Rs. 10.17 Cr
Plant & Machinery Rs. 19.60 Cr
Working Capital for 2 Months Rs. 6.47 Cr
Total Capital Investment Rs. 37.49 Cr
Rate of Return 16%
Break Even Point 67%
INTRODUCTION
STARCH INDUSTRY IN INDIA
BYPRODUCTS FROM MAIZE
1.0 STARCHES
1.1 NATURAL STARCHES
1.1 NATURAL STARCHES
1.3 CEREAL STARCHES
1.4 RAW MATERIALS
1.4.1 MAIZE
SPECIFICATION OF STARCH
MAIZE STARCH SPECIFICATION
USES OF STARCH:
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 :
A) CONCENTRATED STEEP LIQUOR:
B) GERM OIL AND GERM AND CAKE:
C) GLUTEN:
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
CONSTITUENTS AND VARIETY OF MAIZE
PROPERTIES
PROPERTIES OF STARCH
PHYSICAL PROPERTIES
CHEMICAL PROPERTIES
STARCH GIVES A CHARACTERISTIC BLUE COLOR WITH IODINE.
OVERVIEW OF CORN WET MILLING
OVERVIEW OF MAIZE IN INDIA
MAIZE PRICE OUTLOOK
MARKET OVERVIEW
CONSUMPTION PATTERN OF MAIZE IN INDIA
IMPORT & EXPORT DATA OF MAIZE STARCH
STARCH INDUSTRY IN INDIA: SUPPLY AND DEMAND SCENARIO
SUPPLY
DEMAND
DETAILED EXPORT DATA OF CORN STARCH
DETAILED EXPORT DATA OF LIQUID GLUCOSE
DETAILED EXPORT DATA OF CORN OIL
MANUFACTURERS/SUPPLIERS
MAIZE STARCH
LIQUID GLUCOSE
SPECIFICATION
CORN WET MILLING
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
PROCESSING DETAILS OF MAIZE STARCH
RECEIVING
CLEANING
STEEPING
GRINDING
GERM SEPARATION (DEGERMINATION)
FIBRE WASHING SECTION
THICKENING
PRIMARY SEPARATION
GLUTEN THICKENING
ROTARY VACUUM FILTER
HYDROCLONE SYSTEM
DRYING
MANUFACTURES OF STARCH AND ALLIED PRODUCTS
MAIZE STARCH
AMYLOSE MOLECULE OF STARCH
TABLE NO.2.1
AMYLOPECTIN MOLECULE
DETAILS OF CORN WET MILLING
PROCESS DESCRIPTION
5.1 CLEANING AND SOAKING
5.2 STEEP LIQUOR CONCENTRATION
5.3 CRUDE GEM OIL RECOVERY
5.4 FIBRE SEPARATION
5.5 GLUTEN SEPARATION AND CONCENTRATION
5.6 MIXED FEED PROCESSING
5.7 STARCH WASHING DEWATERING AND DRYING
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
A) CORN:
B) CLASSES:
I) YELLOW CORN:
II) MIXED CORN:
SPECIAL GRADES FOR CORN:
A) FLINT CORN:
B) FLINT AND DENT CORN:
C) WEEVILY 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 & DEXTROSE ANHYDROUS
DEXTROSE MANUFACTURE
MANUFACTURING DIAGRAM OF LIQUID GLUCOSE
MANUFACTURING DIAGRAM OF ANHYDROUS DEXTROSE
MAIZE STARCH
APPLICATIONS
LIQUID GLUCOSE
APPLICATIONS
MALTODEXTRIN
DEXTROSE MONOHYDRATE
MAIZE GLUTEN
MAIZE GERM
APPLICATIONS
SORBITOL
APPLICATIONS:
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
1. MAIZE STEEPING
3. DEGERMINATION AND GERM WASHING
4. FIBRE MILLING AND WASHING
6. GLUTEN CONCENTRATION
7. GERM DEWATERING AND DRYING
8. STEEPING WATER CONCENTRATION
10. DRYER FOR ANIMAL FEED
11. STARCH DEWATERING AND DRYING
12. SORBITOAL AND MALTODEXTRIN MANUFACTURING SECTION
B. HANDLING/HOLDING & STORAGE EQUIPMENTS
LAB TESTING EQUIPMENT
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)
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