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MAIZE PROCESSING UNIT

Capacity 200 MT Maize Processing/Day Products, Starch 133 MT, Glucose 20 MT, Gluten 18 MT, Germ 8 MT, Fiber Plant and Machinery cost 2913.00 Lakhs
Working Capital 0.00 Rate of Return (ROR) 41.00 %
Break Even Point (BEP) 58.00 % TCI 6084.00 Lakhs
Cost of Project 6084.00Lakhs

Description:

Maize is one of the best cereals after paddy and wheat. It is largely cultivated in the north and west India, though there is cultivation of maize in the eastern and southern India. There are basic commercial product maize hull, maize oil, zein, maize starches are obtained directly from maize. Starch is the main product of a maize processing unit, which is consumed in various other industries like food, pharmaceuticals, textiles, papers, hotels and restaurants etc. Maize is one of the most important cereal crops in the world agricultural economy and is grown in many countries in each of the continents of the world. Few new entrants can join the industry without any hesitation. 

 

Tags

 

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Maize Processing Unit

Capacity 60,900 MT/Annum Plant and Machinery cost 420.00 Lakhs
Working Capital 0.00 Rate of Return (ROR) 28.00 %
Break Even Point (BEP) 59.00 % TCI 1229.00 Lakhs
Cost of Project 1229.00Lakhs

Description:

Maize is one of the cereal grains which has been produced throughout India and is placed 3rd position in agricultural base production. Maize is constituted by hull, germ, protein, starch and moisture. There is dry and wet milling process of manufacturing of starch, zein, germ and hulls. Starch is the basic constituent of maize and it is converted to liquid glucose by adopting series of digestion steps on starch. It will be basically enzyme and acid digestion system. It may be enzyme - enzyme system or only acid digestion system. In the production of liquid glucose there is some production of dextrose anhydride. Starch is a tasteless, odorless, white amorphous powder, insoluble in water. All green plants store Starch as nourishment for the future. Starch is one of the fundamental substances in the vegetable kingdom and is in existence abundantly in the natural world. Starch is produced from various sources such as corn (maize), tapioca etc. Starch is a mixture of two polymers namely amylase and amylopectine. Uses Pure Starches can be physically modified into various products of varied characteristics. Starch can be potentially used in large number of preparations. Its major applications are in textiles and paper manufacture and in food and pharmaceutical industries. Starch is used in the manufacture of number of products such as starch esters, starch phosphates, glucose, dextrose, sorbitol, ethyl alcohol etc. Glucose syrup is used in hard boiled sweets and many dairy products, as a granulating agent for tablet coating and as a vehicle for orally administered medical syrups in pharmaceuticals. Glucose syrup is used in the manufacture of canned foods, confectionery, bakery products, ice-creams, chewing tobacco, shoe polish and leather chemicals. Sorbitol is used as raw material for the manufacture of Vitamin-C and also as basic additive material in toothpaste, creams, cosmetics, paper and numerous food products. It can also be used as stabilizer and antioxidant in PVC resins, protective coatings, urethane rigid foams, elastomers etc. Market survey 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. Karnataka, AP, Bihar, MP. UP and Rajasthan are the main maize producing areas. It is also produced in Assam, Chhattisgarh, Haryana, Jharkhand, Tamil Nadu, Uttarakhand, Gujarat, HP, Jammu Kashmir, and Orissa. Punjab, West Bengal etc. Expiry rate of maize is fixed according to Nizamabad mandi. Apart from Nizamabad, Karimnagar in AP is also a delivery centre. In Maharashtra, Jalna and Jalgaon are the delivery centres while in Karnataka, Davengere is a delivery centre. Nimbaheda in Rajasthan, Ratlam in MP and Bahraich in UP are the delivery centres which are approved by the NCDEX. Maize is also produced in Assam, Chhattisgarh, Haryana, Jharkhand, Tamil Nadu, Uttarakhand, Gujarat, HP, Jammu & Kashmir, Orissa, Punjab and West Bengal. Starch is the key ingredient in Food Industry, Pharma Industry, Cattle Feed, Paper and Textile Industry. Starch market is driven mainly by the dynamics in Pharma, Food, Paper and Textile Industries. Apart from the above, starch and starch derivates are increasingly used in manufacture of ethanol to be blended with petroleum products. The wet milling industry in India is limited to certain pockets such as Gujarat, Maharashtra, Madhya Pradesh, Punjab, Karnataka and Chattisgarh. There are about 17 wet milling units with a crushing capacity of about 3400 MT of maize/day. The average processing capacity of the units in India is 200 MT of maize/day. There are plants with as high crushing capacity as 400 MT/day. The starch is the main product of a maize processing unit, which is consumed in various other industries like food, pharmaceuticals, textiles, paper, hotels and restaurants, etc. The other products include Gluten, Germ, Fibre (husk) and Corn Steep Liquor. Gluten has great demand in animal feed industry because of its high protein content (70%). Germ is expressed to extract germ oil which is a low cholesterol containing edible oil. Fibre, mainly the husk, is used by animal feed manufacturers. It has demand in wet form itself for animal feed. Corn Steep Liquor is one of the substrates for culture media for manufacturing of antibiotics and other microbial production systems. In India, Mumbai, Delhi, Ahmedabad and Kolkata are the major markets for processed maize products. Other important markets include Bhopal, Hyderabad, Chandigarh, Lucknow, Bangalore etc. Hence, Ahmedabad and Mumbai are the major trading centres for corn starch in India. As the supply demand gap is about 60% the starch can very easily be marketed in the Country and also Starch and Gluten have good Export Potential as well. India exports these products to Sri Lanka, South East Asian countries, Bangladesh and South Africa. The husk can be sold locally, the steep liquor which produce antibiotics and microbial products and corn oil can be marketed outside the state as there is good demand for it. Hence the maize processing unit if set up in the State, will flourish and catch up the market very easily. Glucose and Dextrose are the most important end uses of the product. The growth of liquid glucose in terms of its production has been at an annual compound growth of 6.3%. As regard Dextrose, the production of the same registered an annual compound growth rate of 8%. With such as appreciable growth rate of production of dextrose it is expected that the demand for starch would also substantially go up in the future. The paper industry also accounts for about 10% of the total consumption of starch. In this respect the growth of paper, and paperboard and also paper grade pulp in terms of installed capacity production and capacity utilization have been as under. Apart from these, food products industry is also growing appreciably over a period of time, which would also an increasing demand for starch.

Few Indian Major Players are as under

 

  • Amaravati Agro Ltd.
  • Bharat Starch Inds. Ltd.
  • E I C L Ltd.
  • Gayatri Bioorganics Ltd.
  • Gujarat Ambuja Proteins Ltd.
  • Gulshan Polyols Ltd.
  • Hindustan Maize Products Ltd.
  • Indian Maize & Chemicals Ltd.
  • International Bestfoods Ltd.
  • Jayant Vitamins Ltd.
  • K G Gluco Biols Ltd.
  • Kamala Sugar Mills Ltd.
  • Laxmi Starch Ltd.
  • Origin Agrostar Ltd.
  • Rai Agro Inds. Ltd.
  • Riddhi Siddhi Gluco Biols Ltd.
  • Santosh Starch Ltd.
  • Santosh Starch Products Ltd.
  • Sayaji Industries Ltd.
  • Starch & Chemicals Ltd.
  • Sukhjit Starch & Chemicals Ltd.
  • Tan India Ltd.
  • Tirupati Starch & Chemicals Ltd.
  • Unicorn Organics Ltd.
  • Unique Sugars Ltd.
  • Universal Starch-Chem Allied Ltd.
  • Wockhardt Health Care Ltd.

 

Tags

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Information

  • One Lac / Lakh / Lakhs is equivalent to one hundred thousand (100,000)
  • One Crore is equivalent to ten million (10,000,000)
  • T.C.I is Total Capital Investment
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  • Caution: The project's cost, capacity and return are subject to change without any notice. Future projects may have different values of project cost, capacity or return.

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Our Market Survey cum Detailed Techno Economic Feasibility Report Contains following information:

 

 

Ø  Introduction

·         Project Introduction

·         Project Objective and Strategy

·         Concise History of the Product

·         Properties

·         BIS (Bureau of Indian Standards) Provision & Specification

·         Uses & Applications

 

Ø  Market Study and Assessment

·         Current Indian Market Scenario

·         Present Market Demand and Supply

·         Estimated Future Market Demand and Forecast

·         Statistics of Import & Export

·         Names & Addresses of Existing Units (Present Players)

·         Market Opportunity

 

Ø  Raw Material

·         List of Raw Materials

·         Properties of Raw Materials

·         Prescribed Quality of Raw Materials

·         List of Suppliers and Manufacturers

 

Ø  Personnel (Manpower) Requirements

·         Requirement of Staff & Labor (Skilled and Unskilled) Managerial, Technical, Office Staff and Marketing Personnel

 

Ø  Plant and Machinery

·         List of Plant & Machinery

·         Miscellaneous Items

·         Appliances & Equipments

·         Laboratory Equipments & Accessories

·         Electrification

·         Electric Load & Water

·         Maintenance Cost

·         Sources of Plant & Machinery (Suppliers and Manufacturers)

 

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·         Detailed Process of Manufacture with Formulation

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Ø  Infrastructure and Utilities

·         Project Location

·         Requirement of Land Area

·         Rates of the Land

·         Built Up Area

·         Construction Schedule

·         Plant Layout and Requirement of Utilities

 

Project at a Glance

Along with financial details as under:

 

  •     Assumptions for Profitability workings

  •    Plant Economics

  •    Production Schedule

  •    Land & Building

            Factory Land & Building

            Site Development Expenses

  •    Plant & Machinery

             Indigenous Machineries

            Other Machineries (Miscellaneous, Laboratory etc.)

  •    Other Fixed Assets

            Furniture & Fixtures

            Pre-operative and Preliminary Expenses

            Technical Knowhow

            Provision of Contingencies

  •   Working Capital Requirement Per Month

             Raw Material

            Packing Material

            Lab & ETP Chemical Cost

           Consumable Store

  •   Overheads Required Per Month And Per Annum

         Utilities & Overheads (Power, Water and Fuel Expenses etc.)

             Royalty and Other Charges

            Selling and Distribution Expenses

  •    Salary and Wages

  •    Turnover Per Annum

  •   Share Capital

            Equity Capital

            Preference Share Capital

 

  •    Annexure 1:: Cost of Project and Means of Finance

  •    Annexure 2::  Profitability and Net Cash Accruals

                Revenue/Income/Realisation

                Expenses/Cost of Products/Services/Items

                Gross Profit

                Financial Charges     

                Total Cost of Sales

                Net Profit After Taxes

                Net Cash Accruals

  •   Annexure 3 :: Assessment of Working Capital requirements

                Current Assets

                Gross Working. Capital

                Current Liabilities

                Net Working Capital

                Working Note for Calculation of Work-in-process

  •    Annexure 4 :: Sources and Disposition of Funds

  •    Annexure 5 :: Projected Balance Sheets

                ROI (Average of Fixed Assets)

                RONW (Average of Share Capital)

                ROI (Average of Total Assets)

  •    Annexure 6 :: Profitability ratios

                D.S.C.R

                Earnings Per Share (EPS)

               

             Debt Equity Ratio

        Annexure 7   :: Break-Even Analysis

                Variable Cost & Expenses

                Semi-Var./Semi-Fixed Exp.

                Profit Volume Ratio (PVR)

                Fixed Expenses / Cost 

                B.E.P

  •   Annexure 8 to 11:: Sensitivity Analysis-Price/Volume

            Resultant N.P.B.T

            Resultant D.S.C.R

   Resultant PV Ratio

   Resultant DER

  Resultant ROI

          Resultant BEP

  •    Annexure 12 :: Shareholding Pattern and Stake Status

        Equity Capital

        Preference Share Capital

  •   Annexure 13 :: Quantitative Details-Output/Sales/Stocks

        Determined Capacity P.A of Products/Services

        Achievable Efficiency/Yield % of Products/Services/Items 

        Net Usable Load/Capacity of Products/Services/Items   

       Expected Sales/ Revenue/ Income of Products/ Services/ Items   

  •    Annexure 14 :: Product wise domestic Sales Realisation

  •    Annexure 15 :: Total Raw Material Cost

  •    Annexure 16 :: Raw Material Cost per unit

  •    Annexure 17 :: Total Lab & ETP Chemical Cost

  •    Annexure 18  :: Consumables, Store etc.,

  •    Annexure 19  :: Packing Material Cost

  •    Annexure 20  :: Packing Material Cost Per Unit

  •    Annexure 21 :: Employees Expenses

  •    Annexure 22 :: Fuel Expenses

  •    Annexure 23 :: Power/Electricity Expenses

  •    Annexure 24 :: Royalty & Other Charges

  •    Annexure 25 :: Repairs & Maintenance Exp.

  •    Annexure 26 :: Other Mfg. Expenses

  •    Annexure 27 :: Administration Expenses

  •    Annexure 28 :: Selling Expenses

  •    Annexure 29 :: Depreciation Charges – as per Books (Total)

  •   Annexure 30   :: Depreciation Charges – as per Books (P & M)

  •   Annexure 31   :: Depreciation Charges - As per IT Act WDV (Total)

  •   Annexure 32   :: Depreciation Charges - As per IT Act WDV (P & M)

  •   Annexure 33   :: Interest and Repayment - Term Loans

  •   Annexure 34   :: Tax on Profits

  •   Annexure 35   ::Projected Pay-Back Period And IRR