Corn Processing Plant (for Glucose Syrup & Fructose)

Glucose Syrup is a clear, colourless, viscous solution making it compatible with the
physical properties desired in the end products chemically, glucose syrup has functional
properties such as high fermentability, viscosity, humectancy hygroscopicity,
sweetness, colligative properties and its role in maillards reaction. Glucose syrup is
one of the main products of photosynthesis and starts cellular respiration in both
bacteria and archaea. Fructose is a simple monosaccharide found in many foods. It is a
white solid that dissolves readily in water. Honey, tree fruits, barriers, melons, and
some root vegetables, contain significant amounts of the fructose derivative sucrose.
Sucrose is a disaccharide derived from the condensation of glucose & Fructose. Fructose
corn syrup is a sweetener made from corn and can be found in numerous foods and
beverages on grocery store shelves. High fructose corn syrup is composed of either 42
or 55 percent fructose with the remaining sugars being primarily glucose and higher
sugar. It terms of composition, high fructose corn syrup is nearly identical to table
sugar, which is composed of 50 percent fructose and 50 percent glucose. Glucose is one
of the simplest forms of sugar that serves as a building block for most carbohydrates.
Fructose is a simple sugar commonly found in fruits and honey. High fructose corn
syrup is used in foods and beverages because of the many benefits it offers. In addition
to providing sweetness at a level equivalent to sugar, high fructose corn syrup
enhances fruit & spice flavours in foods. Such as yogurt and spaghetti sauces, gives
chewy breakfast bars their soft texture and also protects freshness. Fructose corn syrup
keeps products fresh by maintaining consistent moisture. In Indian food market is
poised to grow two fold by in the coming years. At a compound annual grow rate of
4.1%. The steady growth of the Indian economy & the improving life style of Indians
have been instrumental in this growth. So, there is good scope in future for these type
of plants.
Plant capacity: 42000 MT/Annum
(Corn Processing), 125 MT Glucose
Syrup Per Day., 125 MT Fructose
Per Day.
Plant & machinery: 430 Lakhs
Working capital: - T.C.I: 1 Million
Return: 39.00% Break even: 46.00%
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Sweet syrup produced by breaking down (hydrolyzing) cornstarch (a product of corn). Corn
syrup contains dextrins, maltose, and dextrose and is used in baked goods, jelly and jam, and
candy. High-fructose corn syrup is widely used in the manufacture of soft drinks and other
foods because it is considerably cheaper than sucrose.
For more information on corn syrup, visit Britannica.com.
Gale's How Products Are Made:
How is corn syrup made?
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Home > Library > Science > How Products are Made
Background
Corn syrup is one of several natural sweeteners derived from corn starch. It is used in a wide
variety of food products including cookies, crackers, catsups, cereals, flavored yogurts, ice
cream, preserved meats, canned fruits and vegetables, soups, beers, and many others. It is
also used to provide an acceptable taste to sealable envelopes, stamps, and aspirins. One
derivative of corn syrup is high fructose corn syrup, which is as sweet as sugar and is often
used in soft drinks. Corn syrup may be shipped and used as a thick liquid or it may be dried
to form a crystalline powder.
The use of corn as a food product dates to about 4000 B.C. when it was grown near what is
now Oaxaca in Mexico. Because of its natural hardiness, corn was successfully cultivated by
people in much of the Western Hemisphere. It was imported to Spain from the West Indies in
about 1520 A.D. and soon became a popular food throughout Europe.
As the use of corn as a food product spread, various machines were developed to help process
it. Water-powered mills, which had been used to grind wheat and other grains for thousands
of years, were adapted to grind dried corn. By the early 1700s, a device to shell corn
remove the dried corn kernels from the cobhad been patented. The refining process used to
separate corn starch from corn kernels is called the wet milling process. It was patented by
Orlando Jones in 1841, and Thomas Kingsford established the first commercial wet milling
plant in the United States in 1842.
The process for converting starches into sugars was first developed in Japan in the 800s using
arrowroot. In 1811, the Russian chemist G.S.C. Kirchoff rediscovered this process when he
heated potato starch in a weak solution of sulfuric acid to produce several starch-derived
sweeteners, including dextrose. In the United States, this acid conversion method was
adapted to corn starch in the mid-1800s and the first corn sweeteners were produced in a
plant in Buffalo, New York, in 1866. This process remained the principal source of corn
syrup until 1967, when the enzyme conversion method for producing high fructose corn
syrup was commercialized. At first, this was a batch process requiring several days. In 1972,
a continuous enzyme conversion process was developed that reduced the time to several
minutes or hours.
Today, corn syrups are an important part of many products. In 1996, there were 28 corn-
refining plants in the United States that processed a total of about 72 billion lb (33 billion kg)
of corn. Of that amount, about 25 billion lb (11.4 billion kg) were converted into corn syrups
and other corn sweeteners. These corn-based products supplied more than 55% of the
nutritive sweetener market in the United States.
Raw Materials
There are several thousand varieties of corn, but the variety known as yellow #2 dent corn is
the primary source of corn syrup. It is a common variety grown in the Midwestern portion of
the United States and elsewhere in the world. It belongs to a family of corn that derive their
name from the small dent in the end of every kernel.
Other materials used during the process of converting corn to corn syrup include sulfur
dioxide, hydrochloric acid or various enzymes, and water.
The Manufacturing
Process
Corn syrup is produced in processing plants known as wet corn mills. In addition to corn
syrup, these mills produce many other corn products including corn oil, corn starch, dextrose,
soap stock, animal feed, and several chemicals used in other industrial processes.
Separating corn starch from corn
Dried, shelled corn kernels are transported to the mill in trucks, railcars, or barges.
The corn is unloaded into a storage pit where it is weighed and sampled.
The kernels are taken from the pit on conveyors and are passed over a set of vibrating
screens or perforated metal grates to remove any sticks, husks, stones, and pieces of
cob. A controlled blast of air blows away any chaff and dust, while electromagnets
capture any nails, screws, or bits of metal that may have fallen in among the kernels
during harvesting, shelling, or shipping.
The cleaned kernels are placed in a series of large stainless steel tanks called steep
tanks. Each tank holds about 168,000 lb (76,000 kg) of kernels. Warm water with a
small amount of sulfur dioxide is circulated through the tanks. The sulfur dioxide
reacts with the water to form a weak sulfurous acid solution. This process continues
for about 20-40 hours and is used to soften the kernels and make it easier to separate
the starch.
The softened kernels are passed through coarse grinding mills to remove the inner
portion of the kernel, called the germ, which contains most of the corn oil. Each mill
has one stationary and one rotating disk. The clearance between the two disks is
adjusted to tear the kernel apart without crushing the germ.
The resulting pulp is transferred to a set of cyclone separators called germ separators
or hydroclones. The germs, which are less dense than the other parts of the kernel, are
spun out of the pulp by centrifugal force. The germs are then pumped onto a series of
screens and washed several times to remove any remaining starch. The cleaned germs
are heated and pressed to extract the corn oil for further processing into food products
and soap stock.
The remaining material from the germ separators is a slurry composed of starch,
protein, and fiber. This slurry passes through another set of mills to tear the starch
lose from the fiber. The fiber is then trapped on a set of washing screens and is dried
to become animal feed or corn bran fiber for use in cereals.
The starch and protein mixture, called mill starch, is pumped into a set of centrifugal
separators that spin the mixture at high speeds. Because of a difference in specific
gravity between the two materials, the heavier starch can be separated from the lighter
protein, which is called the gluten. The gluten is dried and sold as animal feed.
The starch is diluted with water before being washed and filtered 8-14 times to
remove any remaining protein. It is then rediluted and run through a second set of
centrifugal separators. The resulting starch is more than 99.5% pure. Some of this
corn starch is dried and packaged for use in food products, building materials, or to
produce various chemicals. The rest of it, usually the majority, is converted into corn
sweeteners including corn syrup.
Converting corn starch into corn syrup
Corn starch is converted into ordinary corn syrup through a process called acid
hydrolysis. In this process, the wet starch is mixed with a weak solution of
hydrochloric acid and is heated under pressure. The hydrochloric acid and heat break
down the starch molecules and convert them into a sugar. The hydrolysis can be
interrupted at different key points to produce corn syrups of varying sweetness. The
longer the process is allowed to proceed, the sweeter the resulting syrup.
This syrup is then filtered or otherwise clarified to remove any objectionable flavor or
color. It is further refined and evaporated to reduce the amount of water.
To produce a corn syrup powder, also called corn syrup solids, the liquid corn syrup is
passed through a drum or spray dryer to remove 97% of the water. This produces a
crystalline corn syrup powder.
Converting corn syrup into high fructose corn syrup
Ordinary corn syrup contains dextrose sugar which is about three-quarters as sweet as
the sucrose sugar in cane or beet sugar. In many sweetener applications this is an
advantage because it does not overpower the other flavors in the food. Howev-. er, in
some applications, such as soft drinks, a sweeter taste is desired. To improve the
sweetness of ordinary corn syrup, it undergoes a further process called enzyme
conversion. In this process, the dextrose sugars in the syrup are converted into sweeter
fructose sugars by the action of an enzyme in a series of steps under carefully
controlled temperatures, pressures, and acidity. This produces a high fructose corn
syrup with a 42% fructose content. It is used in canned fruits and condiments.
To produce corn syrups with a fructose level above 50%, syrupsthe 42% fructose
syrup is passed through a series of fractionation columns, which separate and hold the
fructose content. The separated portion is about 80-90% fructose and is flushed from
the columns with deionized water. A portion of this is retained and sold for use in
"light" foods where only a small amount of liquid sweetener is needed. The remainder
is blended with other 42% fructose syrup to produce a 55% fructose syrup, which is
used in soft drinks, ice cream, and frozen desserts.
Powdered high fructose corn syrups can be produced by evaporating the water from
the syrup and then encapsulating the powder grains to prevent them from reabsorbing
moisture. Pure fructose crystals may be obtained by further processing the 80-90%
fructose syrup. It is used in cake mixes and other food products where a highly
concentrated, dry sweetener is desired.
Quality Control
Corn syrup is primarily used as a food product. In the United States, its production and use
falls under the control of the federal Food and Drug Administration (FDA), which sets rigid
quality standards. The corn refiners, working through the Corn Refiners Association, have
developed comprehensive analytical procedures for testing the properties of corn products,
including corn syrup. Some of the important properties of corn syrup are dextrose or fructose
content, carbohydrate composition, solids content, sweetness, solubility, viscosity, and
acidity. In addition to monitoring the materials and processes used to make corn syrup,
manufacturers also take frequent samples of the finished product for analysis.
The Future
Because of the ready supply of corn in the United States, it is expected that corn syrup and
other corn sweeteners will continue to be used extensively in food products.
Corn is also expected to be a source of many other products in the future. Ethanol can be
derived from corn and offers a cleaner-burning fuel than gasoline for use in motor vehicles.
Corn starch can be used as a raw material to replace petroleum in the production of chemicals
and plastics. Corn products may also find applications in the production of drugs and
antibiotics


Read more: http://www.answers.com/topic/corn-syrup#ixzz2sinM5hMw

Corn wet milling
Corn wet milling is the process by which we refine corn (maize) to manufacture products that are used by
millions of people around the world each day. During this process, which we have outlined below, none
of the corn is wasted every part of every kernel is used in some way to produce the quality ingredients
that our customers want.

Tate & Lyle uses two types of corn: dent and waxy. Dent corn is the most common, and is used to make
high fructose corn syrup, food starch, ethanol and animal feed. Waxy corn is used primarily for creating
stabilisers, thickeners and emulsifiers for the food industry.
The process

The corn wet milling process - click the image above to enlarge
Cleaning
First we clean the shelled corn shipments to ensure that they are free from dust and foreign bodies.
Steeping
Once clean, the corn is soaked in water, called steepwater, at 50C for between 20 and 30 hours, during which
time it doubles in size. Sulphur dioxide is added to the water to prevent excessive bacterial growth. As the corn
swells and softens, the mildly acidic steepwater starts to loosen the gluten bonds with the corn, and to release
the starch. The corn goes on to be milled.
The steepwater is not wasted. We concentrate it in an evaporator to capture nutrients, which are used for animal
feed and fermentation.
Milling and separation
The corn is coarsely milled in the cracking mills to separate the germ from the rest of the components (including
starch, fibre and gluten). Now in a form of slurry, the corn flows to the germ or cyclone separators to separate
out the corn germ.
The corn germ, which contains about 85% of the corns oil, is removed from the slurry and washed. It is then
dried and sold for further processing to recover the oil.
Fine grinding and screening
The remaining slurry then leaves the separation step for fine grinding. After the fine grinding, which releases the
starch and gluten from the fibre, the slurry flows over fixed concave screens which catch the fibre but allow the
starch and gluten to pass through. The starch-gluten suspension is sent to the starch separators.
The collected fibre is dried for use in animal feed.
Separating the starch and gluten
The starch-gluten suspension passes through a centrifuge where the gluten, which is less dense than starch, is
easily spun out.
The gluten is dried and used in animal feed.
The starch, which still has a small percentage of protein remaining, is washed to remove the last traces of protein
and leave a 99.5% pure starch. The starch can either be dried and sold as corn starch, or it can be modified to
turn into other products, such as corn sweeteners, corn syrups, dextrose and fructose.
Further processing
Starch to syrup conversion
To convert starch to syrup, the starch, suspended in water, is liquefied in the presence of an enzyme to convert it
into a low-dextrose solution. Another enzyme is added to continue the conversion process. At any time the
enzyme treatment can be halted to produce the right mixture of sugars (like dextrose or maltose) for syrups to
meet different needs. In some syrups, the conversion of starch to sugars is halted at an early stage to produce
low-to-medium sweetness syrups. In others, the process is allowed to proceed until the syrup is nearly all
dextrose. The syrup is refined in filters, centrifuges and ion-exchange columns, and excess water is evaporated.
The syrups produced are sold directly, crystallised into pure dextrose, or processed further to create high fructose
corn syrup or crystalline fructose.
Fermentation
Dextrose is most commonly used for fermentation, although other sugars can be used. Dextrose is sent to the
fermentation facilities to be converted into ethanol by traditional yeast fermentation, or into other bioproducts
through either yeast or bacterial fermentation. The nutrients that remain after fermentation are used in animal
feed.

NABARD
MAIZE PROCESSING WET

Dry milling in small scale level

Wet milling for value added products

Maize average yield is more than 3.2 t/ha to 3.5 t/ha

Has potential of 5-6 t/ha

Can be grown in 3 seasons

Plants in India vary 100 to 400 TPD capacities

NABCONS did extensive study

Plant of 100 TPD is optimum for new centre

The cost of the project vary depending up on the cost of land

Technology is readily available

Critical machinery are imported and supplied by companies like Alfa Laval

Plant of 30,000 tpa cost around Rs 15 Cr to 20 Cr


Plant & machinery: about 8 Cr

Working capital needs are high: 10-11 cr

IRR is quite impressive: +33%

BEP: around 40%

Employment to 30-35 technical/skilled and 40 casual workers per day

Critical point: needs fairly large quantity of water, around 4 cum/t

Large requirement of working capital for stocking maize grain

Seasonal availability of grain needs crop development, which also offers other
potentials

Products expected from wet milling:


Starch


Glutenk


Germ


Husk
http://www.nabcons.com/maize.aspx