MAIZE PROCESSING UNIT

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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.

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 nvaries 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.

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.

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 has 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.

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Description

INTRODUCTION
STARCH INDUSTRY IN INDIA
BYPRODUCTS FROM MAIZE
STARCHES
NATURAL STARCHES
CEREAL STARCHES
OVERVIEW OF MAIZE IN INDIA
FIGURE: PERCENTAGE SHARE OF MAJOR PRODUCING COUNTRIES IN WORLD MAIZE PRODUCTION
TABLE: INDIAN EXPORTS AND IMPORTS OF MAIZE
FIGURE: PERCENTAGE OF EXPORT SHARE TO PRODUCTION OF MAIZE.
TABLE: BALANCE SHEET OF MAIZE
TABLE: CONSUMPTION BREAKUP
TABLE: AREA AND PRODUCTION OF MAJOR PRODUCING STATES OF MAIZE (AREA- LAKH HA, PRODUCTION-LAKH TONNES)
TABLE: AREA AND PRODUCTION OF MAJOR MAIZE GROWING DISTRICTS OF ANDHRA PRADESH
TABLE: GROWTH PARAMETERS OF MAIZE BEFORE AND AFTER BIFURCATION OF ANDHRA PRADESH
TABLE: SEASONAL INDICES OF ARRIVALS AND PRICES OF MAIZE IN KURNOOL MARKET
FIGURE: TRENDS IN ARRIVALS AND PRICES OF MAIZE KURNOOL MARKET
FIGURE: AVERAGE MONTHLY PRICES OF MAIZE IN KURNOOL MARKET
FEATURES AND APPLICATION OF LIQUID GLUCOSE
APPLICATIONS OF LIQUID GLUCOSE
SWEETENER:
PHARMACEUTICAL:
SPECIFICATION
HANDLING AND STORAGE
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
COMPONENTS OF YELLOW DENT CORN
MARKET OVERVIEW OF MAIZE STARCH
ECONOMIC SIZE UNIT AND PRODUCTION PATTERN
FOLLOWING THE AVERAGE ANALYSIS OF MAIZE IN INDIA:
PHASED PRODUCTION PROGRAMME
USES OF LIQUID GLUCOSE:-
LIQUID GLUCOSE SYRUP USES AND APPLICATIONS:
IN CONFECTIONERY:
LIQUID GLUCOSE USES
OTHER FOODS:
BAKERY PRODUCTS:
IN ICE CREAMS:
PHARMACEUTICALS:
IN TOBACCO:
IN LEATHER PRODUCTS:
OTHER USES:
USES OF DEXTROSE:-
CONSTITUENTS AND VARIETY OF MAIZE
PROPERTIES OF LIQUID GLUCOSE
PROPERTIES OF STARCH
PHYSICAL PROPERTIES
CHEMICAL PROPERTIES
STARCH GIVES A CHARACTERISTIC BLUE COLOR WITH IODINE.
CORN AND CORN OIL
A. PARTS OF CORN KERNEL, B. NUTRIENT COMPOSITION OF CORN KERNELS
CORN OIL VALUE
OVERVIEW OF CORN WET MILLING
CORN-WET MILLING MARKET – NOTABLE DEVELOPMENTS
CORN-WET MILLING MARKET DYNAMICS
CONSUMPTION PATTERN OF MAIZE IN INDIA
SEGMENT WISE CONSUMPTION OF MAIZE IN INDIA
STARCH INDUSTRY IN INDIA: SUPPLY AND DEMAND SCENARIO
MANUFACTURERS/SUPPLIERS
MAIZE STARCH
LIQUID GLUCOSE
SPECIFICATION
REQUIREMENT FOR MAIZE, TAPIOCA & ARROW ROOT STARCHES, EDIBLE GRADE*
REQUIREMENTS FOR MAIZE AND TAPIOCA STARCHES FOR USE IN COTTON TEXTILE INDUSTRY*
REQUIREMENTS OF TAMARIND STARCH FOR USE IN COTTON TEXTILE AND JUTE INDUSTRIES*
SEQUENCES IN STARCH AND LIQUID GLUCOSE
IT CONSISTS OF FOLLOWING STEPS:-
MIXING AND LIQUEFYING PROCESS:
SACCHARIFY:
LIQUID GLUCOSE DECOLORIZING:
FILTRATION:
ION EXCHANGE SYSTEM:
LIQUID GLUCOSE EVAPORATION:
PROCESS DESCRIPTION OF CORN STARCH
1. CORN CLEANING AND STEEPING
2. MILLING, GERM SEPARATION AND DRYING
3. GRIT MILLING AND FIBER WASHING
4. STARCH AND GLUTEN SEPARATION AND STARCH WASHING
5. GLUTEN DEWATERING AND DRYING
6. STARCH DEWATERING AND DRYING
METHODS OF MAIZE PROCESSING
MAIZE IS USUALLY PROCESSED BY TWO PROCESSES:
DRY MILLING PROCESS FLOW
WET MILLING PROCESS FLOW
STARCH MANUFACTURING PROCESS FLOW DIAGRAM
DETAILS OF CORN WET MILLING
VARIOUS USES OF CORN
MAIZE STARCH MANUFACTURING
CLEANING:
STEEPING:
WET MILLING:
GERM SEPARATION:
MILLING (FINE GRINDING):
STARCH GLUTEN SEPARATION
STARCH REFINING
DRYING:
MODIFICATION
MANY TECHNIQUES ARE APPLIED FOR MODIFICATION FOR EXAMPLE:
MAIZE STARCH PRODUCTION TECHNOLOGY
MAIZE STARCH PROCESSING TECHNOLOGY
MAIZE CLEANING
MAIZE SOAKING
MAIZE COARSE CRUSHING
GERM SEPARATION
MAIZE GRINDING
MAIZE STARCH SIEVING
PROTEIN SEPARATION AND MAIZE STARCH CLEANING
CENTRIFUGAL SEPARATION AND DRYING
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
LIQUID GLUCOSE MANUFACTURE
SEQUENCES IN MAIZE STARCH
CORN STARCH PRODUCTION
PRODUCTION OF STARCH SLURRY
PRODUCTION OF STARCH SLURRY
PRODUCTION OF STARCH AND DEXTRINS:
PRODUCTION OF STARCH
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
PROCESS DESCRIPTION OF CORN WET MILLING
CLEANING AND SOAKING
STEEP LIQUOR CONCENTRATION
CRUDE GEM OIL RECOVERY
FIBRE SEPARATION
GLUTEN SEPARATION AND CONCENTRATION
MIXED FEED PROCESSING
STARCH WASHING DEWATERING AND DRYING
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:
MANUFACTURE OF DEXTROSE MONOHYDRATE & DEXTROSE ANHYDROUS
DEXTROSE MANUFACTURE
MANUFACTURING DIAGRAM OF LIQUID GLUCOSE
MANUFACTURING DIAGRAM OF ANHYDROUS DEXTROSE
MAIZE STARCH AND ALLIED PRODUCTS AND THEIR APPLICATIONS
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:
TURNKEY SUPPLIERS OF STARCH AND ALLIED PRODUCTS
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF CENTRIFUGE
SUPPLIERS OF HEAT EXCHANGER
SUPPLIERS OF LAB TESTING EQUIPMENT
SUPPLIERS OF BOILERS
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF CORN/MAIZE
SUPPLIERS OF SULPHUR
SUPPLIERS OF SULPHURIC ACID
SUPPLIERS OF CAUSTIC SODA
SUPPLIERS OF SODA ASH
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)

Additional information

Plant Capacity

150 MT/Day
Land & Building

(40,000 sq.mt.)
Plant & Machinery

US$ 9057142
Rate of Return

27%
Break Even Point

53%

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