LIQUID GLUCOSE FROM RICE

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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 consumed. Waste from acid 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.

Glucose is a simple monosaccharide sugar also known as grape sugar, blood sugar or corn sugar which is a very important carbohydrate in biology. The living cell uses it as a source of energy and metabolic intermediate. Glucose is one of the main products of photosynthesis and starts cellular respiration in both prokaryotes and eukaryotes. Glucose (C6H12O6) contains six carbon atoms, one of which is part of an aldehyde group (Figure). Therefore, glucose is an aldohexose. Glucose is commonly available in the form of a white powder or as a solid crystal, called dextrose. It can also be dissolved in water as an aqueous solution, glucose syrups.

Its solubility level is very high.

Glucose can be forms disaccharide when two of monosaccharide are linked together such sucrose, the combination of glucose with fructose. Sucrose is the most common sweetener in the modern, industrialized world, although it has been displaced in industrial food production by some other sweeteners such as glucose syrups or combinations of functional ingredients and high intensity sweeteners.

In lactose, another important disaccharide, glucose is joined to galactose (Figure ). It used as the predominant sugar in milk. For maltose, a product of starch digestion is glucose glucose disaccharide. Glucose also can be forms polysaccharides when the units (either mono or disaccharides) are repeated and joined together by glycosidic bonds like cellulose. Cellulose is yet a third polymer of the monosaccharide glucose.

Structure of Lactose

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Description

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 PROCESSINGPLANT
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 – 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)

Additional information

Plant Capacity

75 MT/Day
Land & Building

(6 Acres)
Plant & Machinery

US$ 2308571
Rate of Return

26%
Break Even Point

59%

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