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Set up a Production unit for Maize Processing Starch, Glucose, Germs, Fibres, Gluten and Steep Water Business Opportunities in Agriculture products Industry

Capacity 0 Plant and Machinery cost 0.00 Lakhs
Working Capital 0.00 Rate of Return (ROR) 0.00 %
Break Even Point (BEP) 0.00 % TCI 0.00 Lakhs
Cost of Project 0.00Lakhs



Set up a Production unit for Maize Processing (Starch, Glucose, Germs, Fibres, Gluten & Steep Water). Business Opportunities in Agriculture products Industry.



Maize is a domesticated grass that originated in what is now Mexico around 7000 years ago. It's also known as corn, and depending on the source of data or sources consulted, both terms are used as synonyms in this study. Shortly after the European discovery of the Americas, maize spread across the globe. Corn has proved to be one of the most adaptable crops, regardless of its origin. Its evolution appears to have occurred primarily as a result of domestication, and biotypes with adaptations ranging from the tropics to the north temperate zone, from sea level to 12,000 feet altitude, and growing periods (from planting to maturity) ranging from 6 weeks to 13 months have resulted.


Related Book:- Maize (Corn) Products in India (Starch, Glucose, Dextrose, Sorbitol) Trends, Opportunities, Market Analysis and Forecasts (Upto 2017)


Between 1990 and 2011, the number of millions of hectares harvested ranged from 129.1 to 163.9 million in the United States, Brazil, Mexico, Argentina, India, France, Indonesia, South Africa, and Italy, accounting for 79 percent of global maize output. Over the same time period, maize production increased from 3.7 to 5.1 metric tonnes per hectare, and total maize production increased from 482.0 to 832.5 million metric tonnes. Domestically, 60–70 percent of maize production is used as livestock feed, while the remaining 30–40 percent is used to provide food for humans. Corn is the most widely produced cereal crop, but it ranks third in terms of staple foods after wheat and rice. The reasons for this are numerous, but some are linked to cultural or social preferences, as well as the fact that corn is grown for livestock feed in some countries. More recently, the use of corn as a biofuel has sparked widespread concern about rising corn market prices, the need to expand cultivable land, as well as water quality and other environmental consequences. According to some models, large-scale corn ethanol production may result in lower food exports, higher prices, and more global deforestation.


Related Projects:- Maize, Corn and its By Products , Derivatives, Maize Processing Industry, Corn Starch, Dextrose, Liquid Glucose, Sorbitol, Oil, Gluten, Germ Oil, Wet Milling, Maize Starch Plant & related Products, High-Fructose Corn Syrup (HFCS)Projects 


Maize Processing

Various maize milling machinery is used in the maize flour milling process, primarily for maize cleaning and flour milling. Automation of a scientific and fair corn flour processing process will minimise labour costs and energy consumption while still ensuring the quality of the final maize products.


Impurities Removal Process

A baffle controls the flow rate of maize kernels fed from the material inlet. When maize kernels are transported into the De-stoner by bucket elevator, they first pass through a fine sieve, where sand and other impurities smaller than maize are screened out and discharged through the taphole. Following fine sieving, maize kernels pass through a coarse filter to remove impurities larger than rice, such as corn cob flakes, which are often discharged through the taphole. It is also connected to a fan, which is located above the sieve. The aim of Fan 1 is to suck out any light impurities that may still be present in maize kernels; these impurities will be removed by centrifugal sedimentation.


Preliminary Breaking & Embryo Selection

A baffle is mounted on the storage barrel's outlet to regulate the discharge flow. When maize kernels are extracted, they are fed into a slag mill for preliminary splitting, which separates some maize skin from the embryo. The elevator then transports the damaged maize to the Embryo Selection Machine. Maize skin and embryo are split inside and expelled via various outlets. Fan 2 is attached to the top of the embryo selection machine at the same time. Some light impurities are sucked out by the fan, while the embryos discharged from the selection machine's outlet are supplied to Maize Flour Mill 1 by Suction Fan 3. The maize skins and some broken embryos that were discharged from the selection machine will be shipped to Maize Flour Mill 2.


Related Videos:- How to Manufacture Maize, Corn and its By Products


Finished Maize Flour Classification

Suction Fan 3 suctions maize flour milled by maize flour mill machine into Double Bin Sieve 1 for sieving, and Suction Fan 4 ejects the maize flour that meets requirements for weighing and packaging. While maize flour that does not meet crushing standards will be screened out of the Double Bin Sieve and delivered to Flour Mill 3 via Suction Fan 3 for further grinding. Suction Fan 3 delivers the discharged material to Double Bin Sieve 2 for sieving: Fan 4 ejects the corn flour that meets the norm, while Fan 3 delivers the substandard corn flour to Maize Flour Mill 4. Maize flour is supplied to Double Bin Sieve 2 for screening after milling.


Profile- Project Reports & Profiles



Maize is the world's most popular feed grain, particularly in developing countries. It is widely used in animal feeding and feed formulation as the primary source of calories. In comparison to other cereal grains, maize converts the driest matter to meat, milk, and eggs. Maize is a valuable feed grain because it has a high net energy content while being low in protein and fibre. It appeals to animals, who readily consume it. Maize is either fed directly or is roasted, milled, and thoroughly mixed with other ingredients. The mixture is then fed or transformed into the types that individual animals prefer. Industrial wet- and dry-milling byproducts are also used as feed.


Market Outlook

The United States, China, and Brazil are the top three producers, with the United States accounting for approximately 36% of total global production. The United States is also the leading exporter of the crop, accounting for over 36% of global exports, with Brazil, Argentina, Ukraine, and Russia following closely behind. The United States, China, the European Union, Mexico, and Brazil are all major corn-consuming countries. End-use markets such as animal feed and corn starch are supporting this rising demand in these regions. Due to the strong presence of most end-use sectors in these areas, the United States and China are among the largest consumers.


Market Research: - Market Research Report


Mexico, Japan, South Korea, the European Union, and Egypt are among the countries that depend on imports. Corn demand is increasing in the United States due to the growing feed and industrial sectors. Animal feed is the most common application in the field, followed by fuel ethanol. Corn demand is being driven by the rising corn starch processing industries in China, which is the world's leading producer of corn starch. Other application sectors where the country has a large market share include HFCS and polyols.

Capacity expansions by major key players in the industry are driving the global corn market. To increase their output, major players such as Archer Daniels Midland Co (NYSE: ADM) and Tate & Lyle Plc are expanding their production capacity and investing in mergers and acquisitions. In 2020, the global corn market will hit 1118 million metric tonnes. Between 2021 and 2026, the corn market is projected to expand at a CAGR of 5.3 percent, reaching a volume of nearly 1524 million metric tonnes.


Related projects:-  Maize, Corn and its By Products , Derivatives, Maize Processing Industry


In 2020, the global corn glucose market will be worth US$ 2.1 billion. Corn glucose, also known as glucose syrup, is a food syrup made from corn starch hydrolysis. It's primarily a concentrated calorie source with no nutritional benefit. Corn glucose has become a common sugar substitute over the last few years. Corn glucose demand in the food processing industry has also increased significantly in recent years. It is primarily used as a main ingredient in commercially prepared foods to enhance flavour, improve colour, add volume, and give the food a smooth texture. Corn glucose is widely used in confectionery, preserves, tinned fruits, ice cream, sorbets, juices, dairy cakes, cookies, pastry, cereals, ketchup, sauces, vitamin tonics, and cough medicine since it prevents sugar crystallization.

In 2018, the Indian corn starch market was estimated to be worth $1.37 billion, and it is expected to expand at a CAGR of 3.9 percent from 2019 to 2024. The easy availability of corn and its wide range of applications in various industries such as food and beverage, pharmaceutical, animal feed, textile industry, paper industry, and others are driving the growth of the India Corn Starch market. The application segment of the India Corn Starch Market was dominated by the food and beverage industry. The rapid growth of India's population, as well as its rapid industrialization, has fueled the demand for corn starch.


Few Major Players:

·         Aksharchem (India) Ltd.

·         Amaravati Agro Ltd.

·         Cargill India Pvt. Ltd.

·         Devi Corn Products Ltd.

·         Gayatri Bioorganics Ltd.

·         Gujarat Ambuja Exports Ltd.

·         Gulshan Polyols Ltd.


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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)


Ø  Manufacturing Process and Formulations

·         Detailed Process of Manufacture with Formulation

·         Packaging Required

·         Process Flow Sheet Diagram


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


                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


                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 


  •   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