2013

Bharat Starch Industry Limited, Yamunanagar, Haryana

SETH JAI PARKASH MUKAND LAL INSTITUTE OF TECHNOLOGY

[ INDUSTRIAL TRAINING REPORT ]

This is practical report on working of BHARAT STARCH INDUSTRY on theoretical basis given by authorities of company.

Submitted To:Mr. S.C Srivastva H.O.D Chemical Engineering Department, JMIT, Radaur

Submitted By:Varun Sharma 1210556 Chemical Engineering Department, JMIT, Radaur

TABLE OF CONTENT:-

Sr. No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

PARTICULARS
Acknowledgement Preface Company profile Introduction Sources of starch Composition and structure of maize Production of starch from maize Finished products/ by products Starch manufacture Applications of starch Glucose Refined oil Structure of starch Properties of starch Modification of starch Reference

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3 4 5 6 7 10 12 14 15 18 20 21 22 23 24 27

ACKNOWLEDGEMENT

It brings us great pleasure for an opportunity to work & submit this industrial training report of Chemical Engineering in BHARAT STARCH INDUSTRY, Yamuna Nagar. For this, I sincerely thank to Director and all the faculty of Department of Chemical Engineering of JMIT, Radaur (Yamuna Nagar) Without whose inspiration & guidance this report would not have had this form. I also want to pay my sincere gratitude to Mr. Mohan Lal Sharma, Production Manager of Bharat Starch Industry, Yamuna Nagar to allow me to perform my practical training in their reputed organization under his able guidance The important guidance & excellent support is key for me you successfully complete the project work. The experience commits and corrections were remarkable.

(VARUN SHARMA)

PREFACE

Project work is an important part of practical and theoretical studies. It covers all what which remains uncovered in the classroom. It offers the technical exposure and experience to us. As we know that the practical work plays an important role in the future building of an individual one can easily over come to fear from that life in which we have to work in an actual practice. Just theoretical knowledge is not sufficient for success of an individual to one should have practical knowledge about each theory of general life. We have given the opportunity to work in the laboratory as well as in home to study of pulp and paper process in this project work. I availed of this opportunity in a very satisfactory manner and I have tried to overcome whatever I know in this report.

COMPANY PROFILE (BHARAT STARCH INDUSTRY)

Bharat starch industry is one of the famous company of the Thapar Group of Industries. It is an ISO-9002 company. It is situated at yamunanagar. The company ahead from the railway station yamunanagar. The company was established in 1937. It is one of the oldest company in the field of manufacturing of starch only but today it is providing whole range of starches like textile starches, paper grade starches, modified starches and also contributing in the manufacturing dextrose, glucose, sorbitol and refined oil. Company has its own research and development centre with complete modern facilities and also a well equipped laboratory. It has a small library also in which books are available for consolation. Its products are of international standard. The production unit of company has four plants with grinding capacity of150 tones of maize per day.

INTRODUCTION:
Starch exists as major source of carbohydrate storage in all plants containing chlorophyll, starch is a polymer of anhydrous glucose units. The starches that are obtained from grains and from rots and tubes are of principal industrial importance. In India, starch is manufactured from maize, tapioca, potato and rice and to some extent jowar. Industrial usage of starch will be greater than normal methods of economic projection would indicate. The birth of enzyme engineering made possible low cost conversion of starch to Dglucose and on to an equilibrium mixture to D-glucose and D-fructose equivalent in invert sugar from cane or beet. A second event that makes projections for starch use difficult but still suggests an upward demand is the increase price of energy. This places new usage requirement on low costs starch to serve as a source of alcohol, component for plastics. A special adsorbents, oil well drilling muds, and as an additive of tertiary oil recovery system. A third large area of starch usage, as a basic food to supply nutritional requirements of the growing world population .traditionally , carbohydrates supply 80% of the calories consumed by human population with 2-3rd of these calories coming from starch. Each of these considerations indicates a firm for starch as a future industrial raw material.

SOURCES OF STARCH:1. Corn or Maize 2. Wheat 3. Rice 4. Potato 5. Tapioca 6. Arrow Root 7. Sago

1. Corn or Maize: The word corn is used in the United State as the common name for the cultivated member of the grass family (Gramineae) known to botanist as Zea mays. More specifically, corn here means the seed produced by this plant. Corn is believed to the produce to domestication in Central Mexico beginning 5000-7000 years. Corn has reached its present state of development through continual mutations, hybridizations, segregations and selection by random, natural processes and conscious selection. By the process a number of types have developed which differ primarily in structure of the seed. Examples are popcorn, sweet corn, dent, flint corn and flour corn. The ready availability of corn at relatively low and steady prices, its storability from season and its high starch content led naturally to development of commercial processes for recovery of corn starch. Maize starch is more uniform in quality than other starches and has become the genetic name for starches. Maize starch is sold as plain maize starch and modified starch. Modified starches are being sold to food/textile/pharmacy industry in addition to wide application in Ice creams/Sindoor/Holi colour/Mattresses/Soaps etc.

2. Wheat: It is most common source of starch due to the value of isolating a viable gluten fraction. Elements of separation process are easily demonstrated by mixing one part of water with 2 parts of flour, allowing the dough to stand for 30 mins. And then kneading the mixture under a stream of water to wash out of starch. Starch settles from the collected washing upon standing from a compact layer of prime. A starch on the bottom of the flask. Next is less compact and slightly off layer of B. The layer floating on the surface contains gluten fragments, bran and fiber.

3. Rice: The material for rice starch is broken grains which may be milled or crush prior to steeping. A alkali steep is used to solublise the protein matrix that surrounds the starch granules. For steeping, rice may be held for 10 hours at 25 c in 0.3-0.5% NaOH, drained and then held for another period of time when sufficiently softened, grains are wet ground using pin mills, hammer mills, a second stage grinding may be used to free additional starch. Fiber removed by screening the dilute starch slurry those posses through the screens is concentrated and purified by centrifugal separations of impurities and by washing. Counter current washing and screening systems have been developed used to save on water usage. 4. Potato: They posses high starch content, ash, protein and fiber depending upon such factors like variety and region of growth. It needs immediate processing, cool conditions (4 C) with air
circulation, are needed during storage to remove heat.

Isolation of starch averages about 17% of total tuber solids is relatively easy to accomplish. After washing, the dirt is removed and shredded using high speed rotating. To increase starch recovery a second stage of grinding can be used. Use of so here, elsewhere in the process, enzymes. Purification of starch includes batch centrifugation the starch to remove remaining dirt or fiber from surface of starch.

5. Tapioca: Tapioca starch is isolated from the tuberous roots of manioc plant. Roots may be bitter or sweet depending upon presence of B-galactoside in the normal manner by screening, centrifuging, washing, de-watering and drying. 6. Arrow Root: Arrow root is isolated from the rhizomes of a tropical plant in much the same manner as tapioca. Removal of the outer skin is necessary to avoid bitter yellow starch. 7. Sago: The pith of sago palms is the usual sources of sago starch. Screens are used to remove fiber and the effluent slurry is filtered to remove the starch. After washing, the starch filter cake is de-watered and dried. Sago production occurs mainly in South Eastern Asia and in tropical South America.

Percentage Composition:Water Sugar Starch Ash Fats Protein Fibers Others 16.2% 2.2% 59.4% 1.2% 4% 8.2% 2.2% 6.6%

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Structure of Maize:Maize starch is more uniform in quality than other starches and has become the genetic name for starches. Maize kernels have three parts:i) The seed coat or pericarp. ii) The starchy endosperm, iii) The embryo or germ. The pericap is the outer skin or hull of the kernel which serves to protect seed. The endosperm and main energy reserves make up about 90% starch and 7% gluten (protein) with the remainder consisting of small amounts of oil minerals and some trace constitutions. The embryo contains high energy oil. In the wet milling process, the kernel is separated into its components parts and those parts are than further sub-divided and refined. 1. Hilas Layer: functions as sealing layer across the base of germ upon kernel maturation, is revealed. 2. Pericarp: Smooth dense covering of kernel. 3. Aleurone: First layer of endosperm single layer having thickness. 4. Dent: flouring endosperm on drying of srinking forms dent. 5. Scuttellum: fuction as storageorgans from which nutrient can be quickly mobilized during intial seedling growth.

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PRODUCTION OF STARCH FROM MAIZE:Composition of mature kernels Endosperm - 82% Germ Peicarp Tip Cap PROCESS: High starch content is a principal reason for dominance of corn for industrial purposes. In course, of maize cultivation different seed structures such as sweet, flint, dent, popcorn and floury corn types have been developed. In dent corn, the benefits of agricultural research are favourably illustrated. Maize can be processed using either:1) 2) Dry milling Wet milling 12% 5.2% 0.8%

1) Dry Milling Process:In dry milling kernels are abraded to remove bran, pericarp & germ while learning the endosperm essentially intact. Endospem is isolated & a fraction goes to flakes. Final products are grits, meals and flours. Dry-milled materials are not suited generally for hydrolysate manufactures because protein adhering to starch can increase refining costs. 2) Wet Milling Process:It is expressly designed to ensure for industrial and food uses and food uses and for hydrolysate production.

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Processing of starch by wet milling process:In the steep tanks maize kernel are softned to optimize milling component separation. Kernels are held in a dilute sulfurous acid solution (0.1-0.2%) for 30-40 hour at 48-520C. A typical counter current steep system is an array of 8-12 tanks in which fresh acid is added to kernels ready for milling steep water is pumped from tank to tank & exists after containing fresh corn. After steeping, kernels are macerated in an attrition mill that frees the germ for separation by centrifugal force. This step is followed by a finer grind and screening to remove null and fiber. The starch slurry at this point is primarily a mixture of starch and gluten protein which are separated by centrifugal Action. Isolated starch is washed to remove residual gluten and soluble using the centrifugal forces in hydro clones separators; the operations is counter current and in multiple stages. At this stage, starch slurries may go to driers, modification tanks or to the refinery for hydrolysis.

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FINISHED PRODUCTS/ BY PRODUCTS: Maize Starch Corn Syrup Refined Corn Oil Maize Starch (Pharma Grade) Amyloplast SMO Papyrox Yellow Dextrine White Dextrine Corn Steep Liquor Malto Dextrine

BY-PRODUCTS:
Corn Gluten Maize Oil Cake Mixed Fiber

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STARCH MANUFACTURE:The following steps are included in the manufacture of starch:1) Cleaning the grain 2) Steeping 3) Grinding and germ separation 4) Fine grinding 5) Centrifugation 1) Cleaning the grain: This is the very first step in the production of starch. The main reason behind this step is the removal of the unwanted particulates which hinder in the normal flow of water during the wet milling process. 2) Steeping: In this step cleaned maize is heated with the sulphur water at the temperature of 40-60 C for about 35-40 hours. Sulphur water weakens the protein matrix so that it can be easily separated. Steeping process is carried out in the large tanks known as the vats. The construction material of the vats is made up of the stainless steel to avoid the corrosive action of SO2 The grain and the sulphur water are pumped into the vats. Here the water is absorbed by the corn SO2 is dissolved in the water so as to increase the rate of water diffusion into the grain. The sulphur water from the vats is finally taken out for vaporization and finally soft maize sent to the grinding section where the water is drained into the effluent. 3) Grinding and germ separation: after the process of steeping, the steeped garin is grinded in the grinding section and the results in the formation of pulp. During this process, the germ separates out and due to its lighter density it floats on the surface of water while rest of the particles of the pulp settle at the bottom of the tank. The floating germ cells are skimmed off from the surface of the water and from these cells crude maize oil is obtained. 4) Fine Grinding: after coarse grinding and separations of the germ cells the residue obtained i.e. the particles which settled at the bottom of the tank during the coarse grinding is finely grinded where the protein, starch and fiber contents of the pulp is separated from the rest of the fractions.

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5) Centrifugation: Centrifugation of the native starch leads to the formation of wet starch cake which is further dried to form the dried starch powder.

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Application of starch: Papermaking Pharmacy Food Clothing Starch or Laundry Starch Printing Industry Oil exploration Body powder Papermaking: It is the largest non food application for starches globally, consuming millions of metric tons annually. In a typically sheet of copy paper for instance, starch content maybe as high as 8%. Both chemically modified and unmodified starch are used in papermaking. Starch also helps get out cleaning stains from dirty washing. Pharma: Starch has a very important application in pharma industry. It is used in making tablets, capsules, syrups (for cough) etc Food: Starch is used in making candies, sweets, honey, chocolates and other bakry products. Clothing starch or laundry starch: It is a liquid that is prepared by mixing a vegetable starch in water and is used in the laundering of clothes. Dirt and sweat from a persons neck and wrists would stick to the starch rather than fibers of the clothing and would easily wash away along with the starch. After each laundering, the starch would be reapplied. Today the product is sold in aerosol cons for home use.

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Printing industry: In the printing industry, food grade starch is used in the manufacture of anti-set-off spray powder used to separate printing sheets of paper to avoid wet ink being set off. Starch is also used in the manufacture of glues for book building. Oil exploration: Starch is used as to adjust the viscosity of drilling fluid which is used to lubricate the drill head in (mineral) oil extraction. Body powder: Powdered corn starch is used as a substitute for talcum powder in many health and beauty products.

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GLUCOSE:Glucose is a typical monosaccharide, what can be said about glucose, can also be said about the other monosaccharide. In laboratory it is prepared by hydrolysis of sucrose with dilute hydrochloric acid Or sulphuric acid in alcoholic medium When mixture of glucose is formed. It is sparingly soluble in alcohol, separates out while fructose remain in solution. On commercial scale, glucose is produced by the hydrolysis of starch with hot dilute mineral acids. When the hydrolysis is complete, the reaction mixture is neutralized with chalk and filtered. The filtrate is decolorized with animal charcoal and concentrated under reduced pressure when glucose crystallizes out. Uses of glucose:1) It is used in pharmaceutical industries. 2) To produce bulk carrier for active ingredients. 3) Used as reducing agent in silvering in mirrors. 4) In manufacture of confectionary like syrups candles, jams etc.

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REFINED OIL:Refined oil is produced by chemical refining of crude corn oil. The steps are phosphoric acid treatment followed by caustic treatment known as neutralization. It is then bleached with activated carbon and bleaching earth. It is filtered and then deodouring under high vaccum and high temperature where elimination of colour material, odorous material and balanced odorous material and balanced free fatty acids are removed. In this process the crude oil becomes clear, colourless, and odourless. Special Features:It is important to note that major selling point for corn oil is high level of essential polysaturated fatty acids, linolenic acid (18:2). Although highly polysaturated corn oil is very stable oil because it contains high level of natural anti-oxidant and very (<0.0%) linolenic acid (18:3). Uses and Applications:Corn oil is considered as a premium vegetable oil because of its flavor, color stability and clarity at refrigerated temperature assuming the dewaxing done in the process. The nutritional benefits are primarily related to its polyunsaturated fatty acid and vitamin E content thus making it premium oil for the consumer. The current of major uses of corn oil are in fry and sealed applications as also in margarine preparation. Corn oil can supply about 15% of the US recommended daily allowance of vitamin E for an adult consumer i.e. one table spoon (120 calories per day).

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STRUCTURE OF STARCH:Starch is the reserve substance in plant cells. It is a polymer of D-gleropyranose units linked together with a-1, 4 glycosidic linkages. Starch consists of a mixture of amylase and anylopectin. 1) AMYLASE: It consists of long unbranched chain in which 200-500 glucose units are bound with a-1, 4 linkages. These chains vary in molecular weight from a few to about 1,500,000. Amylose gives intense blue colour with iodine. 2) AMYLOPECTIN: Amylopectin has over glucose units and its molecular weight is about 200,000 to 1,000,000. It has a branched structure. The average length of the branch is from 24-30 glucose residues depending upon the species. The backbone glycosidic linkage is a-1, 4 but the branching has a-1,6 glycosidic linkage. It gives red violet colour with iodine. Starch on hydrolysis yields lower molecular weight polysaccharides, and finally glucose or maltos. Partial hydrolysis results in substances called dextrins. At first erythrodextrins are forms which give red colour, with iodine. Further hydrolysis results in the formation of achroodextrins which do not give the red colour with iodine. Finally, reducing sugars appear. The enzymes which bring about hydrolysis of starch are called amylase. thousand

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PROPERTIES OF STARCH:In India, starch is manufactured from maize, tapioca, potato and rice and to some extent Starch granules, varying from 0.5 to 175 m in diameter are located in the root, tuber, stem pith, leaf seed, fruit and pollens of plants. 1. The partial crystalline nature of granules which imparts insolubility in water makes isolation & handling of native starches and relatively simple starches. 2. Granules of any one starch will usually gelatinize over about 10 temperature

range. In effect, crystalline areas melt, molecules hydrate and irreversible granules swelling occurs. The melting (gelatinization) range can be accounted for in terms of having crystalline range that varies in size and degree of molecular order or crystalline perfection. 3. Addition of salts and sugars generally gelatinization temperature depending on the substances and its level of addition, bases, iodine and thiocynates are known to lower gelatinization temperature. 4. Turbidity precipitation and gel formation in starch preparations are all signs of retrogradation. The process whwewby starch is transformed from being in a dissolved or hydrated state to one of solubility. 5. The major other factor in both retogradation and gelatinization is the molecular composition of the starch namely amylase to amylopectin. 6. Unwanted process foams have been traced to changes in surface tension brought about soluble derived from contaminating proteins.

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MODIFICATION OF STARCH:Maize starch is sold as plain maize starch & modified starches. Bharat starch industries is pioneer & leader in Indian market for modified starches. The modified starches are being sold to food, textiles, pharmacy, industries in addition to wide applications in ice-cream, sindoor, mattresses, soaps etc. maize starch is more uniform in quality than the other sources & has become the genetic name for method:1. Enzymatic 2. Acidic

Brief explanation of enzymatic and acidic modified starch and their uses: 1. Enzymatically modified starch: Enzymatic conversion of starch is used for making improved glucose containing syrups. The first enzymatic starch hydrolysis had been observed in 1833 by Payen and Persoz when an unknown material in a precipitated malt extract was found to convert starch to sugar. The mysterious material was called diastase from the French word meaning separation. Diastase eventually become a generin word for all amylase. Specific enzymes were later discovered, they were named by adding ase to the substrate used by the particular enzyme. Amylase (an enzyme) was derived from amyl (starch) ase. Some important fungal amylases which here used for commercial uses are described below:Aspergillus Orymae: Enzyme used for the removal of starch in the production of pectin. Aspergillus Oryzae: mold bran is used in the production of alcohol. Aspergillus Enzyme: preparations are responsible for lowering dextrose yield during saccharification by the formation of reversion product, primarily to maximize glucose production for manufacture of crystalline glucose and for the production of sweeter, less viscous glucose-containing syrups. It also helps in selective production of more maltos of more glucose, depending on the enzymes chosen. Use of enzymatically modified starch in some industries: The -amylase had also been suggested for use in baking as an antisaling agent & for reducing viscosity in chocolate syrup.

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In starch industry by allowing the economic production of much purer starch hydrolysates containing predominantly glucose, enzymatic conversion also set the stage or the expansion of starch based sweeteners into territories once the exclusive domain of sucrose.

In textile industry for removing starch from women-fibers (designing) to permit uniform bleaching & dying. In brewing industry for liquefaction of corn, rice and wheat.

2. Acid Modified Starch: The commercial manufacturer of acid-modified starches is usually done by treating approximately 40% starch in a slurry of dilute HCL or H2SO4 acid at 25-55C for the length of time required to obtained the thinned starch i.e. sought corn and way maize and waxy maize is the rich source of starch. Condition for acid modification of starch: The condition for treatment are varied depending upon the ratio of cold to hot paste viscosity and get characteristics are sought. If sample of starch is treated with higher concentration of acid will exhibit the greater gel strength and vice-versa. To modify a starch consistently, it is necessary to use the same starch concentration, the same acid concentration and some temperature conditions. Starch exists as major source of carbohydrate storage in all plants containing chlorophyll, starch is a polymer of anhydrous glucose units. The starches that are obtained from grains and from rots and tubes are of principal industrial importance jowar. Industrial usage of starch will be greater than normal methods of economic projection would indicate. The birth of enzyme engineering made possible low cost conversion of starch to Dglucose and on to an equilibrium mixture of D-glucose and D-fructose equivalent in sweetness to invert sugar from cane or beet. A second event that makes projections for starch use difficult but still suggests an upward demand is the increase price of energy. This places new usage requirements on low costs starch to serve as a source of alcohol, components for plastics, special adsorbents, paper extenders, oil well drilling mud, and as an additive of tertiary oil recovery systems.

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A third large area of starch usage, as a basic food to supply nutritional requirements of the growing world population. Traditionally, carbohydrates supply 80% of the calories consumed by human population with 2-3rd of these calories coming from starch. Each of these considerations indicates a firm for starch as a future industrial raw material.

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