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- Origin, Maize
- Global scenario
Marketing of Maize
- Indian Scenario
- Employment Opportunities
CHAPTER-IV
methods of maize. The production and processing are two important activities in
the maize value chain. These two areas are presented in two different sections in
this chapter. Section A deals with the maize production at global, national, state
level and lastly in the study area. Section B deals with industrial processing of
maize by dry and wet milling operations and producing value added products. This
section also highlights the factor endowments for setting up of maize processing
units.
A. Maize production
Maize, a kharif crop, is perhaps the only coarse grain in India whose
production and yield has shown a steady growth in the past 5 years. It has
emerged as the third most important crop after wheat and rice.
maize accounts for 15 per cent of the world's proteins and 19 per cent of the
calories derived from food crops. It is the single largest source of calories and
protein for the poor in about 20 countries and a primary weaning food for the
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Origin
Maize (Zea. Mays) has been cultivated for thousand of years. During
archeological excavation in New Mexico, grains of maize and parts of maize ears
were found in caves and rocks shelter, which are thought to be about 4,500 years
old. Of even earlier origin, pollen grains of Zea tripsacum and euchlaena were
found at a depth of about 50 meters under Mexico City, (Weather wax and
Randolph) . At the time of discovery of New world, maize was already cultivated
in many parts of the American continent, especially in the more highly developed
regions of Mexico, Central America and South America where it formed the staple
diet of the indigenous population. Recently, it has been postulated that maize
came to India well before Columbus discovered America in 1942. For a long time
it was thought that maize was descended from a hybrid between teosinte
Global scenario
The total area under maize cultivation in the world is 139 million hectares
with a production of 598 million MT. (M.MT). USA is the world's largest
producer and exporter of maize with all output of 250 MMT from an area of 29
million hectares. Other major producers are China (125 MMT); European Union
(39 MMT); Brazil (37 MMT); Mexico (19 MMT); Argentina (14 MMT) and India
(11 MMT).
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Table - 4.1: Major maize producing countries
The above table-4.1 shows the major maize producing countries. USA is
the number one produces followed by China, Brazil and Mexico. India produces
only 11 million tones of maize where as USA produces 250 million tones. Among
all cereals, maize occupies the fifth largest in area, fourth largest in output, and
third largest in yield in the world. India is the tenth largest producer with a
production of 11.10 MMT from an area of 6.6 million hectares. The average yield
in India is 1.77 MMT- 2 MMT / a hectare, which is very low as against 7 MT/ha.
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4.1 Major Maize Producing Countries
250 n =
2004
150
1 I i I
USA China Brazil Mexico France India
Countries
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The below given table shows the area, output and yield of maize in India
year by year. The increase in the maize production in terms of area, output and
yield indicate that maize is becoming one of the prominent agro produces in India.
Maize is cultivated in almost all states in India. The leading maize producing
states in India are Kamataka, Bihar, Rajasthan, Madhya Pradesh, Uttar Pradesh,
Andhra Pradesh, Himachal Pradesh, and Maharashtra etc. The crop is grown in
three seasons - kharif, rabi and summer. More than 70 per cent is grown during
kharif season.
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4.2 Production of Maize in India
3
a.
3
o
Year
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Table - 4.3: Production performance of major maize growing states
India. Karnataka is one of the important maize growing states in the country. The
average yield and production of maize in the state is highest in the country
compared to other states. Other major maize growing states are Bihar, Uttar
grows varied types of agro and horticultural products. The major agro-products
grown in the state are paddy, jowar, maize, wheat, bajra, ragi and other cereals.
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Table-4.4: Principle agricultural crops in Karnataka
important crops are paddy, jowar, maize, bajra, ragi etc. In Karnataka maize is
grown in all the three seasons i.e., kharif, rabi and summer. The maize production
in the state for the last ten years is given in the below table.
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Table - 4.5: Area and production of maize in Karnataka
year. For the lost few years there is a slight decline in the production due to sever
drought in the state. In terms of production and yield, Karnataka stands first
among the maize producing states (Ranjith Kumar Singh, Vol. 17, 2004) . The
state is also witnessed the maximum increase in maize area. Except two coastal
districts, maize is grown in all other districts in the state. The district wise maize
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Table - 4.6: District-wise maize production in Karnataka during 2004-05
105
According to the table-4.5 maize is grown in almost all districts in state.
Bagalkot, Bijapur, Bellary, Dharwad, Davangere Gadag, Haveri etc. Maize has
diversified uses as food, feed and industrial raw materials. It has emerged as one
of the leading crops in the state. In India it is an important staple food for millions
of poor. In recent years, significant changes have occurred in the Indian maize
than 50 per cent of the maize produced in the country is used as animal feed, and
evidences suggest that the demand for maize as feed will increase faster with
important maize growing states have sizeable area under the crop. The maize
yield per hectare is much higher in these states than other states in the country. On
the other hand, states like Uttar Pradesh, Bihar, Rajasthan, Madhya Pradesh and
Punjab, which were the heartland of maize production before the green revolution,
could not reap the benefit of technological developments in the maize sector.
the time series for the years reveals that there is a constant increase in the area,
quantity of production and yield of maize. There was a decline in the production
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as well as its area for the last three years in the state i.e., from 2000-01, 2001-02,
and 2002-03. The decline was due to drought hit in the maize growing district of
the state.
Kamataka districts like Belgaum, Bijapur, Bagalkot, Dharwad, Bellary Gadag etc.
This study has considered six important maize growing districts in the state.
The maize grown in these districts is nearly 40 per cent of the total maize
produced in the state. The districts select for the study purpose include- Belgaum,
Bijapur, Bagalkot, Bellary, Gadag and Dharwad. The cluster of these district share
the commonality in several aspects, such as, agriculture, climate, food habit of the
people, agricultural production etc. Maize is the number one crop in these districts
grown in all the three seasons - rabi, kharif and summer. The table given below
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Table-4.7: Maize production in the study area during 2004-05
Kharif Rabi Summer
District
Area Prod. Yield Area Prod. Yield Area Prod. Yield
Bagalkot 30630 92831 3190 10520 24026 2404 23 40 1850
Belgaum 70686 233142 3472 29654 57335 2035 300 352 1850
Bijapur 5751 21373 3912 4216 9629 2404 ~ ~ ~
Dharwad 18381 64977 3721 74 152 2159 12 21 1850
Bellary 30252 95976 3340 1217 2472 2139 ~ ~ ~
Gadag 17956 64872 3803 17 35 2159 ~ ~ ~
Total 173656 573171 ~ 45698 93649 ~ 235 413 ~
Karnataka 445586 1535627 3628 48899 100187 2157 269 473 1850
Percentage 39 37.3 3573 94 93.5 ~ 87 87 ~
followed by rabi. During summer it is grown in very less quantity. In recent years
there is a slight decline in the production of maize in the state due to the draught in
the state. Lack of incentives for growers, such as remunerative price and
processing to utilize the surplus maize in the state are the reasons for distress sale
the price gluts. Processing units create better market for the maize by producing
more value added commercial products. Since, Karnataka is the leading maize
growing state in the country, few small and large-scale maize processing units in
the three different seasons. Availability of Maize in all the seasons ensures the
maize supply almost round the year. Maize processing industry is basically
108
resources based industry. Therefore, establishing maize processing units near the
availability of maize will have several benefits. It reduces the transportation cost
of raw materials, ensure regular supply and create good number of employment
processing creates in the region would solve many social and economic problems.
Maize milling unit would give birth to several supporting industries like
encourage the farmers to grow better quality and quantity Maize for good prices.
problems such as -
2. Negligible processing
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The above problems can be considerably reduced by the combined efforts
technology.
The major share of the maize produced in the developed countries is either
feed, brewery and animal feed. There is no precise data available on the
estimated on the basis of the natural average. It indicates that only 30 per cent of
the maize is utilized for human and animal consumption in the state. The
outside the state. There is only one large-scale maize-processing unit in Kamataka.
Pradesh and one unit each in Punjab, Chattisgarh and Tamil Nadu. The
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Marketing of maize
The demand for maize has been growing very rapidly in both domestic as
indicates that domestic demand for maize is growing much faster. The growth is
mainly due to increased utilization of maize as feed and industrial raw material.
which is the regulated market, facilitates the sale of agricultural output by linking
growers and dealers. But, large quantities of agro-produces are sold in open
market. There are three channels used by maize growers in the state to sell the
surplus maize.
Traders offer low price to the growers and cheat farmers in weighment.
The maize purchased from farmers in the state is supplied to maize processing
units i.e., food, feed and industrial purposes. Starch units in adjoining states like
Maharashtra, Madhya Pradesh and Gujarat purchasing maize from the state.
The market prices of Indian maize fluctuate between Rs.350 per quintal to
Rs.750 per quintal in different states and in different seasons. The price is
normally high for rabi season maize than kharif season maize. The price
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fluctuation is due to seasonality of production, it creates a demand and supply gap
during off-season. In order to reduce the demand supply gap, the government
Price fluctuation for maize is not very wide in Karnataka in particular and
in the country in general. Farmers are in the opinion that the price of maize at
times falls below the cost of production. In recent years, there is vjo significant
farmers in the state. Government of Karnataka also came forward to protect the
According to above table-4.7, for a period of seven years the market price
of maize has not considerably increased. According to the growers, at times, maize
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B. An overview of maize processing
India in Plaines as well as in the hilly regions, especially in the areas with hot
In India the local urban population use the maize in the form of food
ingredient. For chapatti making, it is used as a major cereal in the traditional area.
The use of processed maize foods for breakfast and snacks is very little. In
addition, green ears are consumed in roasted form. In bakery production, maize
has played an important role in the human diet in the urban areas. Use of bread,
buns, rusks, biscuits etc., it popular. It is also used in baby protein supplementing
foods. Opaque-2 variety, protein supplement from maize, can make much cheaper
All the major sweeteners are commercially made from maize starch. Maize
starch is a polymer of anhydrous glucose units (dextrose) and is the raw material
for sweeteners. To make them starch chains, they are depolymerized with acids or
maize syrups and HFCS are sold as liquids. Many industries in Haryana, Gujarat,
Punjab, Madhya Pradesh and Uttar Pradesh have come up to derive starch from
maize.
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Importance of maize as a food and industrial product can be seen from its
1. Modified Starches: Maize starch and its derivatives are essential e.g.,
"binder" for high precision casting moulds, and compounds oil well mud,
to cool and lubricate rotary drilling bits. Starch has 280 varieties on regular
sale e.g.. Polyvinyl alcohol, polyvinyl accato and acrylic adhesives both
organic and synthetic products in the compiled field of sizing, finishing and
adhesive products.
extent for destine (e.g. in foundry and oil well drilling operations.
3. Maize Oil: Maize oil is very fine cooking medium when fully refined with
polymerizing organic (starch) and synthetic polymers are already in use for
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Maize (zea. Mays) is classified into dent, flint, waxy, sweet and popcorn
categories. Dent com also known as field com, containing both hard and soft
starch becomes indented at maturity. Flint com having hard, homy rounded or
short and flat kemels, with the soft and starch endosperm is enclosed by hard outer
layer. Both of these varieties are used for industrial purposes. Popcom has small
pointed and rounded kemels with very hard endosperm which an exposure to dry
heat poped or evened by the expulsion of the contained moisture and forming a
white starchy mass many times the size of the original kemel. Sweet com is
Maize kemel consists of three main parts namely hull or bran coat, with
high fibre content, embryo or germ rich in oil and starchy endosperm. The
proposition of the three kemel parts are approximately as follows (per cent of
whole kemel) bran 4.4 - 6.2 (avg. 5.3); germ and scutellum 10.2 - 14.1 (avg.
11.9); and endosperm, 97.7 - 83.5 (avg. 81.9); tip cap, which is usually removed
115
Potential products from maize
Maize is the main raw material for the starch and starch-derived products.
The maize starch industry in terms of volume and value of the final products is
most important sectors in the world. About 57 per cent of the maize produced in
India is used in poultry and cattle feed. Thirty three per cent is used as food; only
9 per cent is used in manufacturing starch and allied products, and one per cent as
seed. In the US and European countries maize is mainly used to produce starch
According to table-4.9, maize is the major raw material for starch production
116
According to table-4.10, USA is the top producer of starch followed by
Asia and Europe. Industry manufactures over 5 billion pounds (2.3 billion Kgs) of
starch in United States per year. More than 50per cent of the starch is sold to
industries and remaining is converted into dextrin and starch group. The data
given below shows the starch production of USA, Europe and India.
Though, India is one of the largest producers of maize in the world, value
advanced countries large part of the starch produced is converted into both high
value added nutrient sweeteners such as glucose, syrup, dextrose and fructose
syrup.
starch followed by food, paper, Pharma, adhesive confectionary etc. The starch
and starch derived products demand in India is presently met by local production
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as well as by importing from other countries. Therefore starch industry in India is
having a wide scope due to the growing demand for starch products. There is a
good demand for starch and starch-derived products in national and international
markets. The maize is an important raw material for starch and allied products in
Product TPA
Dry starch powder 1,55,000
Glucose syrup 1,10,000
Dextrose monohydrate 55,000
Sorbital 50,000
Source: Agricultural Economics Research Review, 2004.
The table-4.13 shows the starch and starch derives products manufactured
in India by maize. The surplus demand for the above products is presently met by
future.
Maize milling
Maize is one of the staple foods for poor families. Traditionally, the grain
is converted into flour in mills for making bakery products. Immature cobs are
roasted and eaten all over country. Maize is an important raw material for animal
and poultry feed and cornflakes manufacturing units. But the quantity of maize
utilized by these units is limited as the easting units are of small-scale in nature.
118
They make only a few products having limited demand. Hence, alternative large-
scale units, which can process a large quantity of maize to produce different value,
and wet milling. Dry milling produces grits, com flour, and minimum amount of
The dry milling units have a crushing capacity of 10 MT/day with a project cost of
Rs.20 lakh. Such units can be set up in any where in the state depending upon the
Dry milling
The maize kernels are screened, tempered with hot water/steam to loosen
the germ and bran. Then it is de-germinated to remove the germ. The husk is
produce grits, meal and flour. The germs separated is dried and passed through an
119
The table-4.14 shows the products obtained form maize processing from
dry milling operation. These dry milling units are small scale units can be
established with less investment. CFTRI has developed a mini mill for dry milling
of maize. The grits is the main product of dry milling process, which is used as
porridge by boiling domestically. The processing units use grits for manufacture of
products like ready-to-eat snacks (com flakes), wallpaper paste and manufacture
Cleaning => Conditioning => De-germinating => Drying & Cooling =>
Grading & Grinding => Sifting & Classifying => Purifying => Drying =>
Packaging
Wet milling
method in the world over. The by-products of starch manufacture, like com oil,
com steep liquor, gluten etc. are the important value added products. The grain is
unloaded from the tmcks directly in receiving area or stored in silos. The material
for debris such as sand, stones and any other foreign particles. The clean material
is then sent to steeping section. It is received in a tank where it is washed with hot
water first and subsequently steeped in water containing sulfur dioxide at 0.2 per
cent for 70 hrs at 52C. Steeping softens the kernels and also removes some
120
soluble. Sulphur dioxide act as preservative. The steep water produced in this
process is then concentrated and fortified with vitamins, minerals to produce com
steep liquor. It is then subjected to primary and secondary grinding, wherein the
The degermed maize is passed through a fibre washing section where the
fibre (husk) is separated by pressure washing. Now the mixture consists of gluten
and starch. The gluten is separated from starch by centrifiigal separation. The
usually has moisture content of 42 per cent. The starch slurry thus obtained is
and modified starches such as dextrose, dextrose mono hydrate etc. The wet starch
is then dried by hot air by passing through a drier. The dry starch has moisture
which a portion of the moisture is removed followed by drying in a hot air drier.
The dried gluten thus obtained has moisture content of 12 per cent. The gluten is
mainly used for poultry feed. The average recovery of various products and co-
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Starch - 60-62 per cent
Wet milling process involves the splitting of the grain into four main
components, namely germ, bran (or fibre), gluten and starch in sequence. Maize
starch is extensively used as a sizing material in the textile and paper industries. In
the food industry, it is used in the preparation of pies, puddings, salad dressings
and confections. Maize starch is used for the production of dextrose and com
syrup.
Starch is the predominant carbohydrate of the maize kernel (66.8 - 74.2 per
cent on dry basis). Starch occurs in the endosperm as granules of varying sizes
encased in a protein matrix. In the outer homy endosperm, the granule are small
and the protein matrix relatively thick; in the inner floury endosperm, the granules
are large and the protein matrix thin and weak. Lipids - Maize oil is obtained by
About 84 per cent of the total fat of the kernel is found in the germ and 14
per cent in the endosperm, Cmde maize oil has a dark reddish amber colour with a
taste and odour characteristic of the original grain. For use as food, maize is
122
ground to flour or whole-meal atta and baked into roti or chapatti; it is in this form
that maize is consumed in most parts of northern and western India. Whole-meal
maize atta, unlike wheat atta, does not form dough with elastic properties when
By using appropriate amounts of boiling water, dough for making flat cakes
may be obtained. Chapatis can be easily made from a blend of maize and wheat
flours. Excellent dough with good elastic properties can be made from maize flour
made from dehuUed grain. Treating maize seed with lime or ash does the
dehulling. Maize is also processed into semolina or suji and it substitutes for wheat
suji in various food preparations. The grain may be parched, ground to flour and
The global production of starch from all sources was 48.5MMT in the year
2000. US with largest starch industry contribute 51 per cent followed by EU (17
per cent) and the rest by others. During the same period 39.4MMT of starch was
derived from maize, whereas potato and wheat contributed 2.6 and 4.1MMT,
respectively.
The world demand for starch products is growing at an annual rate of 4 per
cent. The demand for starch syrups is higher than dry starches in developed
123
steady growing demand, the total world output of dry starches and syrups were
US and Thailand. The largest starch consumers are US, EU, China and India. The
world per capita demand for starch is 8.4 kg/annum, whereas India's per capita
Indian scenario
are about 17 wet milling units with a crushing capacity of about 3400 MT of
maize/day. The state-wise number of wet milling units and the installed capacity is
124
Table - 4.15: Wet-milling units in India
SI. Name of the State No. of Installed capacity
No. Units (MT of maize/day)
1 Gujarat 6 1,350
2 Maharashtra 5 1,050
3 Madhya Pradesh 3 450
4 Karnataka 1 300
5 Punjab I 100
6 Chattisgarh 1 150
Total 17 3,400
Source: Director of Maize Research, Annual Report
Gujarat is the largest producer of starch, having six units with a total crushing
capacity of 1350MT of maize per day, followed by Maharashtra with 5 units and
capacity of 1050 MTand Madhya Pradesh with 3 units and capacity of 450MT
maize.
day. There are plants with as high crushing capacity as 400 MT/day. However,
there is no plant in the country with crushing capacity of less than 100 MT/ day.
The selection of technology is very important as regards to the viability of the unit
is concerned. A unit in Buland Sahar, Uttar Pradesh has been reported to be closed
125
Figure-4.1: Starch manufacturing unit in India
1600
1400 -B
1200 S
1000 8
800 ^
600 -r
400 - t
200 I
0 u
K^^ <,'* ^^ -^ . ^ J^
^-^^ ^ ^
^^j'\<^''\y^^ <^^ J
v ^
State
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 (70per cent). Germ is used to extract germ oil, which is
low cholesterol containing edible oil. Animal feed manufacturers uses fibre,
mainly the husk. It has demand in wet form itself for animal feed. Com Steep
Liquor is one of the substitutes for culture media for manufacturing of antibiotics
126
In India, Mumbai, Delhi, Ahmedabad and Kolkata are the major markets
in Mumbai. Hence, Ahmedabad and Mumbai are the major trading centres for
cornstarch in India.
traders as well. Most of them have their marketing offices in metros and big cities
for direct sale. They also sell through trading agencies as well. These traders
restrict marketing of the products of one or a few companies and prefer to procure
maize processor to have processing facilities for starch and its derivatives like
different types of starch and the processor should be able to meet their demand to
compete in the market. Starch and Gluten have good export potential as well. India
exports these products to Sri Lanka, South East Asian countries, Bangladesh and
South Africa.
127
Factor endowments for setting-up a maize processing plant
Raw material
and uninterrupted supply of raw material to the unit. On an average, a unit with a
crushing capacity of 100 MT/ day will require about 30000 MT of maize per year
(assuming 300 days of operation of the plant). Hence, the availability of raw
processing unit. Keeping in view the cropping pattern, consumption of the maize
by local population and market surplus, it should not be a problem for a unit of
above capacity to procure the raw material. The plant will be able to procure major
portion of its raw material requirement with in the radius of 200 km. The state
produces mainly yellow dent corn, which is most suitable for wet milling for
manufacture of starch and other by-products. As the traders procure maize from
the farmers, the unit will be able to source the raw material from traders for
^^.^^ ~~^V\^^cr'
t
128
Land
large area to set up plant and machinery and effluent treatment plant. There should
be enough land for disposal of treated wastewater. A unit with crushing capacity
reasonable price, the unit may acquire up-to 15 acre of land to meet future
expansion requirements.
Water
The water requirement for the wet milling industry is relatively large with
an average use of 4 cum per MT of crushing per day. For a wet milling unit of 100
MT capacities, therefore about 4-lakh liter of water/ day is required. The site
where wet milling units are set up should have a good source of water, preferably
a pereimial river. As the unit also generate high amount of sewage water, which
require to be disposed off properly. In case the water is to be sourced from ground,
the water table should be high and the areas should fall in white category of
unrestricted use.
Power
The average power requirement is about 170-250 units per day per MT of
maize crushing. The milling unit requires uninterrupted power supply and hence a
129
Steam
manufacturing starch by wet milling in states like Maharashtra and Gujarat use
Technology
washing unit, which is imported through companies like Alfa Laval. The
fabricators at Ahmedabad and few other parts of the country can fabricate the
entire plant. There are a number of suppliers for setting up of the plant on turnkey
basis.
milling. The wet milling process is a complex process, which involves a series of
operations, by which the com is separated into three parts, the outer hull or bran,
the germ (the source of most of the com oil) and the endosperm (the source of
The critical operations, which have a direct bearing on the quality of the
Raw material selection and cleaning - Good quality yellow dent com
without various impurities will increase the quality of the final product.
by steeping.
130
Hydroclone washing - The simultaneous washing and concentration of
starch to the desired moisture and soHd level increases the quality and
Figure-4.3: Receiving
1
The corn is transported to the unit in trucks in gunny bags and offloaded in
receiving area or in silos. The receiving area should be designed in such a manner
that there is enough space for smooth movement of expected number of vehicles.
The grain is fed to the belt conveyor, which takes the maize grains to cleaning
section.
Cleaning
The grain contains various impurities like cobs, stones, metal parts, dust,
other foreign matter etc. These unwanted materials are removed in cleaning
section. The grain is passed over perforated metals sheets, air blowers, and
131
Steeping
The grain is fed into large steep tanks with hot water at 52 C and steeped
for 70 hr. Generally; the existing units in India use RCC steep tanks. However,
steep tanks can also be fabricated by stainless steel but it increases the capital cost.
The RCC tanks should be designed in such a manner that it withstands the
containing sulfur dioxide (SO2) at 0.2 per cent concentration in hot water is added
in the steeping tanks to prevent germination and bacteria. The steeping conditions
the grain for later steps by softening of the maize kernels and loosen the bonds
between germ, husk and endosperm. During the soaking process, nutrients are
absorbed into the water and this water is later evaporated to concentrate the
Grinding
stainless steel with adjustable RPM with or with out pneumatic settings. There are
steeped maize grains are ground coarsely to loosen the husk and germ. The second
stage grinding, known as fine grinding, help in detaching the germ from the grain.
The pasty mix obtained after fine grinding is pumped to water filled settling
the slurry containing soluble husk, gluten and starch are separated from germ. The
132
lighter density rubbery germ floats on the top and is skimmed off. The germ is
passed to germ drier which is finally sent to oil extraction unit. The germ contains
45 per cent oil and the rest is crude fibre and moisture. The starch manufacturers
generally prefer to sell germ rather than own oil extraction unit.
The slurry of husk, starch and gluten is ground for better recovery of starch.
The fibre washing is a 6-stage process, which is carried out by DSM box. The
husk is separated from the soluble starch and gluten slurry by a counter current
flow system. The husk is sent to either drying section or used as animal feed in
wet form. The husk is mainly carbohydrate, which also contains 8 per cent protein.
Thickening
to get the concentrated slurry. This machine is also called as milk stream
thickener.
Primary separation
Gluten thickening
of gluten. The gluten contains 65 per cent protein and is a good source of protein
133
Rotary vacuum filter
The thickened gluten slurry is further concentrated to get gluten cake with
40 per cent solids through a rotary vacuum filter. The cake is further dried by hot
air and / or sun to bring down the final moisture content to 12 per cent.
Hydroclone system
The starch slurry received from the primary separation is passed through a
multi stage hydroclone system, which concentrates the starch slurry to 42 per cent
solid level. Alfa Laval is the main company supplying this system in India for
starch units
Drying
The concentrated starch slurry is then dried by hot air application (175 C)
four major co-products for the feed industry namely the steep water, husk (hulls or
bran), germ and gluten. These co-products represent about 25-30 per cent of the
processed maize. The starch is raw material for various ancillary industries like
units.
134
The wet milling has developed into an industry that seeks optimum use and
maximum value from each constituent of the maize kernel. In addition to starch
and the various other products, and edible com oil, the industry has become an
industry.
should be set up as per the norms of State Pollution Control Board. It has been
Strengths
Com production in the country has been growing steadily over the past five
production of maize during the 10' Five Year Plan period and its inclusion
under the technology mission give impetus to maize production in the State.
Directorate of maize has set a target to raise the output of maize to 18MMT
by the end of the tenth plan period mainly through increase in yield to 23-
24 q / ha.
135
Starch manufacturing from maize generates about 1 MT of by-products for
every 2 MT of starch produced and these by-products are worth more per
Strong raw material base in the study area with total production of 6.0-7.0
Maize is becoming one of the cash crops for farmers, as a major part of it is
rain fed condition and so the farmers will continue to grow maize.
Agro processing is one of the thrust areas for the Government of Kamataka.
in North Kamataka.
The productivity of maize is high which can still be raised. Higher the
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Weaknesses
Seasonal availability of maize in Kamataka. Kharif crop is only the major
quantity of the local raw material may not be available in other seasons. To
run the plant during summer and rainy season maize grain has been
processing units.
Opportunities
Backward linkage with farmers (contract farming type arrangement) is
possible, as maize has become one of the cash crops in the state.
Demand for starch is high from varied users like food, pharmaceuticals,
Great export demand for corn gluten as a poultry feed in South East Asian
countries.
Substantial subsidies from the Govt, in the form of land, subsidized power,
water etc.
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Cornstarch is identified as one of the ingredients for manufacture of
future.
Threats
Maize cultivation is gambling with rainy season and mainly grown under
rain fed conditions.
Stiff competition from imports and other producers within the country.
SWOT Analysis
Strengths Weaknesses
- Growth in maize production. - Seasonal raw material.
- Adequate support from the - Poor farmer education.
government. - No organized market.
- Huge marketable surplus. - Processing technology.
- Maize processing generates more - High cost of production.
number of value added products.
- Maize starch is preferred over other
starch by the industrial customers.
Opportunities Threats
- Contract farming. - Maize cultivation is gambling with
- Substantial subsidy for maize monsoons.
processing. - Competition from imported starch.
- Application of maize product can be - Lack of coordination between
diversified in to different industries. growers and processors.
- International market.
The strengths and opportunities of maize processing in Kamataka outweigh
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Economic impact of maize processing
locally available rav^ material to produce value added products and create good
market for the same. The industry provides good employment opportunities in
rural areas. Further, it reduces the dependence on other country for import of
starch and other maize products. The farmers are benefited, as there will be a
ready market for their main kharif season crop. The processing units purchasing
maize from other states will get their raw material with in state at lower rates.
Employment opportunities
The wet milling unit creates both direct and indirect employment
opportunities. The manpower requirement of the unit is given in the below table
(4.16). The unit generates employment opportunities for around few hundred
skilled and unskilled workers directly. The chain goes on increasing down the line
by the maize processing unit. There fore, agro based industries in rural areas create
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good number of employment and income opportunities. Maize is used for both
industrial products and consumes more maize. There fore, large scale maize
References:
1. Collins. 1988. Production of Hybrid Seed Corn. p. 565. In G. F. Sprague and J. W. Dudle (ed.)
Corn and Com Improvement. 18. American Society ofAgronomy, Madison.
2. Weather and Randolp (1993). Maize breeding during the Development and Early Years of
Hybrid Maize, p. 13. In D. B. Walden (ed.) Maize Breeding and Genetics. John Wiley and Sons,
Nevv' York.
3. Delgado, CM. Rosegrant, H. Steinfield, S. Ehui and C. Courboise (1999). Livestock to 2020:
The Next Food Revolution, Food Agriculture and Environmental Discussion Paper, 28,
Washington, D.C., International Food Policy Research Institute (IFPRI).
4. Singh, R.P., Ranjith Kumar and N.P. Singh (2003). Transformation of The Indian Maize
Economy; Different Perspective in Maize Production in India; Golden Grain in Transition, Eds:
Ranjith Kumar and N.P. Singh (TB-ICN: 4/2003), New Delhi: Indian Agricultural Research
Institute, pp. 1-28.
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