POTATO PROCESSING UNIT

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Native Potato Starch is basically a carbohydrate, consisting of amylose and amylopectin.

Potato is widely consumed as food all over the world. It contains the starch as a major carbohydrate. Surplus and cull potatoes are used as feed for live stock and also as raw material for the manufacture of starch, ethyl-alcohal and a few other industrial products like, dextrose, liquid Glucose etc.

The potato contains approximately 18-21% of carbohydrates. The major carbohydrate is starch. This starch is comprising 65-80% of the dry weight of the tuber, is calorifically the most important nutritional component. In the raw tuber, it is present as microscopic granules in levcoplasts lining the interior cell walls of parenchyma tissue. The granule is ellipsoidal in shape, 100N*60N, with striations like an oyster shell. Under polarized light, the granule shows an irregular black cross.

Electron micrographs reveal a surprising smooth surface structure. The ratio of amylase to amylopectine in potato starch is 24:76 and the gelatinization temperature ranges from 56oC to 69oC with water this starch forms a translucent paste of high viscosity. Freshly harvested mature tubers contain more sugars than the large ones. A slight rise in total sugars is observed when tubers are stored at 20-30oC. However when the storage temperature is 4o or less., the total reducing sugars increase, the rate and extent of increase being greater when lower the temperature down to the freezing point. The maximum sugar concentration (3 to 10%) is reached after 4-8 weeks.

Potato starch is produced from varieties selected and grown for their high starch, low protein and low fibre contains. In USA and elsewhere, only surplus potatoes and tubes unsuitable for table use are used for starch production.

For starch manufacture, potatoes are washed and milled in a rasp or hammer mill to disintegrate the cells and liberate starch. Sulphur dioxide is added to inhibit the action of oxidizing enzymes and the slurry is passed through centrifugal separator to remove ‘protein water’. The residual cake is mixed with water and the suspension pumped on to starch tables, where starch settles and major part of the fibre and soluble salts pass off. The cake is scrap off the table, mixed with water and passed through rotary vacuum filters. The cake obtained is the pure starch.

The raw material required for the manufacture potato starch is selected varieties of potato having high starch and low protein and low fibre contents.

• Potato starch is starch extracted from potatoes. The cells of the root tubers of the potato plant contain starch grains (leucoplasts).

• To extract the starch, the potatoes are crushed; the starch grains are released from the destroyed cells. The starch is then washed out and dried to powder.

• Potato starch contains typical large oval spherical granules; their size ranges between 5 and 100 μm.

• Potatoes contain around 20% starch, 2% fibres and 1% protein.

• Potato starch is a very refined starch, containing minimal protein or fat. This gives the powder a clear white colour.

• Potato starch absorbs and retains moisture to a far greater degree than wheat flour.

• The cooked starch typical characteristics of neutral taste, good clarity, high binding strength, long texture and a minimal tendency to foaming or yellowing of the solution.

• Potato starch and potato starch derivatives are used in many recipes, for example in noodles, wine gums, cocktail nuts, potato chips, hot dog sausages, bakery cream and instant soups and sauces, in gluten-free recipes.

• Potato starch is also used in technical applications as wallpaper adhesive, for textile finishing and textile sizing, in paper coating and sizing and as an adhesive in paper sacks and gummed tape.

• Potato starch was also used in one of the earlier color photography processes.

• Potato starch also lowers plasma cholesterol and triglyceride concentrations, increases satiety, and possibly even reduces fat storage.

• Potato starch is gluten free, it is very useful for people with gluten intolerance or wheat sensitivity. It is also a good source of energy.

• The granule size of potato starch is definitely larger than other starches.

• Compared to other starches, potato starch has a higher phosphorus content. Due to higher phosphorus content, potato starch exhibits extremely high viscosity.

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Description

INTRODUCTION
PROPERTIES
ADVANTAGE OF POTATO STARCH
USES AND APPLICATION
POTATO STARCH IN FOOD APPLICATIONS
USES AND APPLICATION OF POTATO FLAKES
INDUSTRIAL PROTEIN
THE MAJOR POTATO PROTEINS
POTATO JUICE
DETAILS OF POTATO PROTEIN
NUTRITIONAL QUALITY
CURRENTLY AVAILABLE PROTEIN INGREDIENT FORMS
POTENTIAL FUNCTIONALITY AND APPLICATIONS
PRESENT CONSUMPTION PATTERN
CATEGORY‐WISE ESTIMATED CONSUMPTION PATTERN OF POTATO
USES OF STARCH
A) TEXTILE INDUSTRY:
B) FOOD INDUSTRY:
C) PAPER INDUSTRY:
D) PHARMACEUTICAL INDUSTRY:
B.I.S. SPECIFICATION
MARKET SCENARIO OF POTATO STARCH
SWEET RICE FLOUR:
CORN STARCH:
ARROWROOT STARCH:
TAPIOCA STARCH:
COCONUT FLOUR:
RICE FLOUR:
OPPORTUNITIES
CONCERNS
MAJOR CHALLENGES
NATIVE POTATO STARCH IS SUITABLE FOR USE IN PET FOODS AND ANIMAL NUTRITION
INCREASED PRODUCTION IN LESSER TIME BOOSTING THE INDUSTRIAL USAGE OF MICROBIAL ENZYMES
KEY MARKET PLAYERS
BUYERS OF POTATO STARCH, FLAKES & POWDER
POTATO STARCH PRODUCTION IN INDIA
POTATO & POTATO STARCH
ROTARY WASHING MACHINE
FLASH DRYING MACHINE
GROWTH IN PROCESSED FOOD INDUSTRY VIS-A-VIS STARCH INDUSTRY
STARCH INDUSTRY IN INDIA;
PRESENT STATUS:
CONSUMPTION:
SYNTHESIS OF RAW MATERIAL SPECIFICITIES AND USES
USES OF STARCH PRODUCTS
MAJOR STARCH END-USE SECTORS BY STARCH PRODUCT
PRESENT CONSUMPTION PATTERN
CATEGORY‐WISE ESTIMATED CONSUMPTION PATTERN OF POTATO
OVERALL ORGANISATION OF THE POTATO STARCH
SUPPLY CHAIN
STARCH INDUSTRY: AN OVERVIEW
INDIAN STARCH INDUSTRY
POLYMERIC USED OF STARCH IN: STARCH INDUSTRY IN INDIA
STATE-WISE LIST OF STARCH INDUSTRIES IN INDIA
MAJOR END – USERS OF STARCH AND STARCH BASED PRODUCTS
GLOBAL STARCH MARKET
PROMISING FUTURE
FUTURE BEHOLDS FOR MODIFIED STARCH MARKET
MODIFIED STARCH MARKET
MANUFACTURERS/EXPORTERS/SUPPLIERS OF POTATO STARCH
RAW MATERIALS
GLOBAL MARKET OF POTATO STARCH
BREAKUP BY CATEGORY:
BREAKUP BY APPLICATION:
REGIONAL INSIGHTS:
OVERVIEW OF POTATO FLAKES
OVERVIEW OF INDIAN SNACKS MARKET
PROCESS OVERVIEW OF POTATO STARCH
PROCESS OVERVIEW FOR PRODUCTION OF POTATO STARCH
DE-SANDING CYCLONE
RASPER
PROTEIN DEWATERING
MANUFACTURE OF POTATO STARCH
POTATO STARCH:-
IS THIS COMPANY CAN PROVIDE MACHINE (GELGOOG)
PROCESS FLOW SHEET FOR MANUFACTURE OF STARCH
OCCURRENCE OF STARCH
THE BASIS FOR STARCH QUALITY IS LAID IN THE POTATO CLAMP
REFINING BEGINS ALREADY DURING RAW MATERIAL INTAKE
EFFICIENT WASHING MAKES REFINING EASIER
RASPING
USE OF SULPHUR
EXTRACTION
OPERATING PRINCIPLE OF A STARCH EXTRACTOR
CONCENTRATING THE CRUDE STARCH SLURRY
REFINING
HYDROCYCLONES
COOLING
CIP – CLEANING IN PLACE
DRYING AND SIFTING
COMPOSITION OF POTATO STARCH
SIZE DISTRIBUTION.
PROPERTIES OF STARCH
SPECIFICATIONS OF POTATO STARCH
NUTRITIONAL VALUE OF POTATO PROTEIN
NUTRITIONAL VALUE OF POTATO PROTEINS
USES AND APPLICATION OF POTATO PROTEIN
MANUFACTURING PROCESS OF POTATO PROTEIN
FOOD GRADE COAGULATED POTATO PROTEIN
STEPS IN POTATO STARCH MANUFACTURE
DESCRIPTION OF POTATO STARCH MANUFACTURING PROCESS FOR YOUR REFERENCE
(1) RAW MATERIAL RECEIVING UNIT:
(2) WATER TRANSPORT:
(3) DE-STONE AND WASHING UNIT OF POTATO STARCH MANUFACTURING PROCESS:
(4) RASPER UNIT OF POTATO STARCH MANUFACTURING PROCESS:
(5) DE-SANDING CYCLONE UNIT OF POTATO STARCH MANUFACTURING PROCESS:
(6) CENTRIFUGAL EXTRACTING UNIT:
(7) POTATO RESIDUE DEWATERING UNIT OF POTATO STARCH MANUFACTURING PROCESS:
(8) CONCENTRATION AND REFINING UNIT:
(9) VACUUM DEWATERING UNIT OF POTATO STARCH MANUFACTURING PROCESS:
(10) AIR DRYING UNIT OF POTATO STARCH MANUFACTURING PROCESS:
(11) SIEVING AND STORAGE UNIT:
POTATO STARCH EXTRACTION DETAILS
FIG. 6 – POTATO STARCH EXTRACTION PROCESS
POTATO STARCH PRODUCTION METHOD
DELIVERY AND UNLOADING POTATOES
CLEANING
RASPING OF TUBERS
POTATO JUICE SEPARATION
STARCH EXTRACTION
STARCH MILK RAFFINATION
DEWATERING OF REFINED STARCH MILK AND STARCH DRYING
TABLE: POTATO STARCH PRODUCTION CHARACTERISTIC.
WASTE PRODUCTS
MANUFACTURE OF POTATO FLAKES
WASHING & SORTING
PEELING
COOKING
PULPING AND DRUM DRYING OF PULP TO PRODUCE FLAKES
CONTINUOUS PROCESS TO MANUFACTURE POTATO FLAKES
A POTATO FLAKE PRODUCTION LINE
FIRST PHASE OF PRODUCTION
CUTTING, PRE-COOKING AND COOLING
DRYING, SIZING AND PACKING.
EFFLUENT TREATMENT AND DISPOSAL
EFFLUENT TREATMENT PLANT SPECIFICATION AND NORMS
STANDARDS
TOLERANCE LIMITS FOR INDUSTRIAL EFFLUENT DISCHARGE
WASTE TREATMENT
PRIMARY TREATMENT
ANAEROBIC TREATMENT
SECONDARY TREATMENT
TERTIARY TREATMENT
SOLIDS CONCENTRATION
TYPICAL WASTE SOLIDS CHARACTERISTICS
EQUIPMENT REQUIREMENT
EQUIPMENT REQUIREMENTS
MANPOWER
GENERAL
BASIS OF ESTIMATION
GENERAL PLANT LAYOUT
GMP/GHP CRITERIA FOR STARCH
2.1 LOCATION
2.2 PREMISES AND ROOMS
DESIGN AND LAYOUT
INTERNAL STRUCTURES & FITTINGS
2.3 EQUIPMENT
2.4 CONTAINERS FOR WASTE AND INEDIBLE SUBSTANCES
2.5 FACILITIES
WATER SUPPLY
DRAINAGE AND WASTE DISPOSAL
CLEANING
PERSONNEL HYGIENE FACILITIES AND TOILETS
TEMPERATURE CONTROL
AIR QUALITY AND VENTILATION
LIGHTING
STORAGE
3. CONTROL OF OPERATION
3.1 TIME AND TEMPERATURE CONTROL
3.2 CONTROL OF OTHER SPECIFIC PROCESS STEPS
3.3 SPECIFICATIONS
3.4 MICROBIOLOGICAL CROSS CONTAMINATION
3.5 PHYSICAL AND CHEMICAL CONTAMINATION
3.6 INCOMING MATERIALS REQUIREMENTS
3.7 PACKAGING
3.8 WATER
WATER, ICE AND STEAM IN CONTACT WITH FOOD
WATER, ICE AND STEAM NOT IN CONTACT WITH FOOD
3.9 MANAGEMENT AND SUPERVISION
3.10 DOCUMENTATION AND RECORDS
3.11 PRODUCT RECALL & TRACEABILITY
3.12 STORAGE
4 MAINTENANCE AND SANITATION
4.2 PEST CONTROL
4.3 WASTE MANAGEMENT
5. PERSONAL HYGIENE
6. QUALITY CONTROL
7. TRANSPORTATION
8. PRODUCT INFORMATION AND CONSUMER AWARENESS
9. COMPETENCE & TRAINING
10. TEMPORARY / MOBILE PREMISES; VENDING MACHINES
TURNKEY CONSULTANT FOR SETTING-UP STARCH PROCESSING UNIT
LIST OF SOME STARCH PROCESSING INDUSTRIES
SUPPLIERS OF COMPLETE PLANT AND MACHINERY FOR POTATO STARCH [GLOBAL]
SUPPLIERS OF PLANT AND MACHINERY (INDIAN)
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF HYDROCHLORIC ACID
SUPPLIERS OF SULPHURIC ACID
SUPPLIERS OF SODA ASH
SUPPLIERS OF CAUSTIC SODA
SUPPLIERS OF ACTIVATED CARBON
OTHER PLANT AND EQUIPMENTS SUPPLIERS
SUPPLIERS OF BOILER
SUPPLIERS OF TANKS
SUPPLIERS OF TRAY DRIER
SUPPLIERS OF DISINTEGRATORS
SUPPLIERS OF PULVERISER/GRINDER
SUPPLIERS OF INDUSTRIAL ETP PLANT MANUFACTURE/SUPPLIER
SUPPLIERS OF MIXER
SUPPLIERS OF REACTOR
SUPPLIERS OF WEIGHING MACHINES
SUPPLIERS OF LIST OF FOOD AND AGRO PROCESSING CONSULTANTS
IMPLEMENTATION SCHEDULE
DETAILS OF PLANT & MACHINERY SECTION:
POTATO STARCH FACTORY
SECTION: 1.00
POTATO STEEPING
POTATO STARCH FACTORY
SECTION: 2.00
SULPHUR DIOXIDE PLANT
POTATO STARCH FACTORY
SECTION: 3.00
WASHING
POTATO STARCH FACTORY
SECTION: 4.00
FIBRE MILLING AND WASHING
POTATO STARCH FACTORY
SECTION: 5.00
STARCH SEPARATION AND REFINING
TO FILTER OUT PARTICLES THAT COULD BLOCK SEPARATOR NOZZLES.
POTATO STARCH FACTORY
SECTION: 6.00
JUICE CONCENTRATION
POTATO STARCH FACTORY
SECTION: 7.00
DEWATERING AND DRYING
POTATO STARCH FACTORY
SECTION: 8.00
STEEPING WATER CONCENTRATION
POTATO STARCH FACTORY
SECTION: 12.00
HANDLING/HOLDING & STORAGE EQUIPMENTS

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

53.4 MT/Day
Land & Building

(3000 sq.yard)
Plant & Machinery

US$ 1164285
Rate of Return

59%
Break Even Point

36%

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