Industrial Training Report on

Maltodextrin Plant

Created by
Siddhant Mane

At
Sahyadri Starch & Industries Pvt.Limited
Plot No. 6-7-8, Miraj M.I.D.C.,
Miraj-416410(Sangli)
Maharashtra (India)

Submitted to
Head of Department
Department of Engineering, Sciences & Humanities
Vishwakarma Institute of Technology, Bibwewadi, Pune-37

Under Guidance of
Dilip Chougule
(Asst. Production Manager of Maltodextrin Plant)
 Content Table
Introduction………………………………………...2
List of Test…………………………………………5
List of Figures……………………………………...6
Chapter 1: Introduction to Maltodextrin Plant……7
1.1 Starch Slurry Preparation…………………….7
1.2 Liquefaction…………………………….……8
1.3 Decolourisation……………………………..11
1.4 Filtration…………………………….............11
1.5 Evaporation…………………………………12
1.6 Spray Drying ……………………………….14
1.7 Air Pollution Control………………………..16
1.8 Powder Packing……………………………..17
Chapter 2: Conclusion……………………………18

1
 Introduction
India is an agricultural country. A vast majority of people
are involved directly or indirectly in agricultural process. This
has led to rise of many agro-tech and food processing
industries. Among these, starch industry is one of the major
industry. Sahyadri Starch Industries & Pvt. Limited uses
maize as its raw product. The supply of maize to this industry
comes from the states of Maharashtra, Karnataka, Andra
Pradesh and Bihar. Maize is a kharif crop but is taken twice a
year. It comes to the industry in the month of September till
November. Along with this, it also comes in the month of
April to June. Maize consists of 4 components. Germ (6-7%),
Gluten (8-10%), Starch (70-72%) and Fiber (10-12%) are the
components of maize. Due to such a variety of composition,
which could be extracted, it is profitable for the industry.
Sahyadri Starch manufacture Starch, Modified Starch,
Pharmagrade Starch, White Dextrin, Yellow Dextrin, Liquid
Glucose, Maltodextrin and High Malto Corn Syrup. Along
with these products, it also manufactures by-products, which
include Germ, Gluten, Fiber, Germ oil and Germ oil cake.

2
Company Profile
Study Area
Sahyadri Starch Industries & Pvt.
Limited is located in M.I.D.C Miraj,
Plot No. A/6-7-8, Sangli- 416410. It is
2 km away from Miraj, 6 km away
from Kupwad and 8.5 km from Sangli.
History of Company
Sahyadri Starch Industries & Pvt.
Ltd was established in the year 1982
by Late Honorable Mr. J.H.Majithia. The aim of company
was to provide Indian Market with Excellent quality starch
and its derivatives, generating jobs for youth and upgrading
lifestyle of surrounding people.
About Organization
Initially, Sahyadri Starch Industries & Pvt.Ltd started on
small scale industry by grinding 15 metric tonne per day.
With time, it achieved milestone of grinding 400 metric tonne
per day. The company has 150 permanent employee, 350
permanent employee and 300 contract based workers. The
company has various departments, which act as pillar for this
industry. Production Department, Store Department, Dispatch
Department, Administration Department, Boiler Department,
ETP (Effluent Treatment Plant), etc. Store Department keeps
the availability of all the spare parts, chemicals, packing
material required in industry. Dispatch Department deals with
the dispatching of the product formed in the industry to client
as per requirement. Administration Department deals with all
legal issue of industry. Boiler Department help in maintaining
the steam required in the industry. This high pressure boiler

3
has capacity of 35 tonnes/hr. The steam pressure of 45 kg/m3
is developed here. After using this steam, it is passed through
Steam Turbine for power generation purpose. 2.5 Mega Watt
energy is generated from this steam and then after reusing it
for the process. ETP treats the waste water generated in
industry. Everyday1000 m3 of waste water is generated every
day. The waste water is used in Digester to generate biogas
(CH4). This biogas is used for power generation. The treated
water is provided to nearby farmers for agricultural purpose.

4
List of Test
Baume Hydrometer
Starch-Iodine Test
pH Paper test

Test involved in final product

Moisture Test
Bulk Test
Density Test
Dextrose Equivalent Test
Ash Content
Micro Test

5
List of Figures
Starch Slurry Tank……………………………………….…8
Holding Column……………………………………………9
Incubator………………………………………………..…..9
Filter Aid…...………………………………………………10
Filter Press………………………………………………….10
Pure and Impure Maltodextrin Sample……………………..11
Process flow diagram of Triple Effect Evaporation Unit…..12
Triple Effect Evaporation Unit……………………………..13
Process flow diagram of Spray Dryer………………………14
Spray Dryer…………………………………………………15
Scrubber tank……………………………………………….16
Powder Packing Unit……………………………………….17

6
 Chapter 1: Introduction to Maltodextrin Plant
Maltodextrin is a polysaccharide obtained by partial
hydrolysis of starch slurry obtained from Starch Plant. It is used
for pharmaceutical and food grade purpose. Maltodextrin plant
runs continuously for 24 hours in 3 shift. Each shift lasts for 8
hours. In each shift, there is a Supervisor along with permanent
workers and contract labors.
Chemical Formula C6nH(10n+2)O(5n+1), 2<n<20
Appearance Creamy to white
Solubility Free soluble in water, slightly
soluble to insoluble in
anhydrous alcohol
Table 1. Properties of Maltodextrin
Industrial Process involved in production of Maltodextrin
are:-
1. Starch Slurry Preparation
2. Liquefaction
3. Decolourisation
4. Filtration
5. Evaporation
6. Spray Drying
7. Powder-Packing
1.1 Starch Slurry Preparation
The raw material of Maltodextrin is Starch Slurry
obtained from Starch Plant. The Baume of this slurry is
around 21-20 and pH is about 4.5 to 5. According to
requirement, Baume is adjusted. This is done in Starch
Slurry Tank with the help of Agitator.

7
 Fig 1. Slurry Tank

1.2 Liquefaction
After adjusting Baume, Soda is added to maintain pH
4.8-5.5. Calcium Chloride (CaCl2) is added to it. It acts as
preservative. A prescribed dose of Alpha-Amylase enzyme
is added to slurry. It is then passed through Jet Cooker with
a flow rate of 4 to 4.5 m3/hr at temperature of 104oC to
110oC. Slurry is now, passed through Hydrolyser coil. In
the hydrolyzer coil, enzymatic conversion takes place and
starch gets hydrolyzed and liquefied. After moving through
Hydrolyser coil, it is flashed into flash vessel. In flash
vessel, phase is separated. Vapor is let out and liquid is
moved down to holding column by action of gravity. There
are 4 Holding column with capacity of 3 m3 each. The
residence time maintained is around 2 to 2.5 hours. Here,
liquid is subjected to Starch-Iodine Test for checking any
presence of starch in it. Then, Holding column overflow is
taken to Incubator. Incubator is a large cylindrical vessel
with a capacity of 20000 litre. Dextrose Equivalent (DE) of

8
 juice will be checked.
Once DE is matching to
party’s specification,
enzymatic reaction is
deactivated by decreasing
pH up to 3 with the help
of hydrochloric acid
(HCl).

Fig 2. Holding Column

Fig 3. Incubator

9
 1.3 Decolourisation
This juice is
then, passed in
Process Tank (1/2).
Process Tank is a
Stainless Steel
container of capacity
5000 litre. In this
tank, filter aid and
carbon is added. pH
of juice is maintained
from 4 to 4.5 by
Fig 4. Filter Aid using Soda. Filter aid
is added to enhance
the filtration. Activated Carbon is used as bleaching
reagent. This helps in decolourisation.

Fig 5. Filter Press

10
 1.4 Filtration
In Maltodextrin juice filtration, plate and frame type
filters are provided. Juice is passed through 10 micron
polypropylene cloth. It is important to ensure that no filter
outlet is containing carbon particle, a manual inspection is
done of all the outlet filters. If any filter outlet is releasing
carbon-loaded juice, it is again circulated in the filter press.
The filtered juice is again passed through safety filter to make
sure no suspended particles are moving forward. This juice is,
then, feed to Multi Effect Evaporator.

Fig 6. Sample with no carbon particle (L) & sample with carbon particle (R)

11
 Fig 7. Process flow diagram of Triple Effect Evaporator

1.5 Evaporation
In Multi Effect Evaporator, solid content of juice is
increased from 32 solids to 52 solids. This Multi Effect
Evaporator functions in vacuum. It has 3 calenders and a
surface condenser. Steam is applied in first effect. Vapors
generated in first will be used in second effect as a heating
media and vapor generated in second effect will be used as
heating media for third effect. All the vapors will be
condensed to surface condenser. Surface condenser is a shell
and tube heat exchange in which cooling water is passed
through tubes and vapors is on shell side. Multi Effect
Evaporator are used to achieve steam economy. The
concentrated juice is transferred to process tank for further
processing.

12
Fig 8. Triple Effect
Evaporation Unit

13
 Fig 9. Process flow diagram of Spray Drying

1.6 Spray Dryer

After the concentrated juice is shifted to process tank,
pH is adjusted as per the requirement of client. This juice is
feed to Spray Dryer. Spray Dryer consist of cylindrical
chamber with conical bottom through which hot air is passed
at a temperature of 180oC to 190oC through air heater. At air
heater, steam pressure is maintained upto16 kg/cm2. In the
spray dryer chamber, air will be supplied by FD fan through
air filters and air heater. In spray drying operation, juice is
sprayed in chamber by rotor pump through automizer.
Automizer is having speed about 10000 rpm. At the
temperature of 180oC to 190oC of chamber, these droplets are
converted into powder. In order to avoid jamming of drying
chamber and rotary valve, vacuum of -5 to -10 MWC is
maintained in chamber. Powder formed is inspected through
View glass in Pneumatic Conveying Line. As per party’s

14
 specification pH,
bulk, density, and
moisture is to be
maintained. These
parameter of powder
can be maintained
through feed’s solid
content and air
outlet temperature.
In case of power-
cut, first close steam
valve and open
chamber doors.
After power-cut,
start entire system
from initial and first
free the automizer
by working dryer on
water. Check the oil
content of automizer
for every 1 hour.
Maintain oil-cup
level throughout the
process. To check
current of
automizer/ supplier
fan/ exhaust fan use
MCC.
Fig 11. Spray Dryer

15
 1.6 Air
Pollution
Control
(Scrubber
Tank)
In order to
avoid particle
(air) pollution,
Scrubber tank is
implanted. In
these scrubber
tank, wet
scrubbing is
used. In Scrubber
Tank, dry air
exhaust with
stack goes from
bottom of
scrubber and
water is sprayed
from top to
bottom. Due to
this, dust is
trapped and
dissolved in
water and fresh
air is let out
through chimney.

Fig 12. Scrubber Tank

16
 1.8 Powder Packing
Unit
After the juice
is converted to
powder, it is
conveyed to
bagging unit
through Pneumatic
Conveying Line. At
the bottom of
bagging cyclon
rotor valve,
vibroshifter is
provided to trap
oversize material. In
the shifter, 24 mesh
screen is provided
through which
maltodextrin
Fig 13. Powder Packing Unit
powder will be
passed into HDP
bag with inside liner. These bags have capacity of 25 kg. The
weight of each bag is noted. Packing is done in room with
AHU condition. The temperature of this room is around 25oC
to 26oC and humidity is maintained around 30-50 g/m3. Once
packing is done, it is shifted to go-down for transportation.

17
 Chapter 2: Conclusion
Maltodextrin Plant is one sub-unit of Sahyadri Starch &
Industries Pvt. Ltd. This plant deals with converting starch obtained
from maize to maltodextrin using plenty of mechanical & chemical
operation. This plant requires a lot of care towards the parameter of
product. At most care is taken of removing impurity gained during the
process via means of filtration, safety filtration and scrubber tank.
Maintaining the physical parameter of the product is done via primary
instrument/experiment like Baume Hydrometer, pH paper and Starch-
Iodine Test. The chemical property like Dextrose Equivalent (DE) is
checked by giving sample to laboratory.
Maltodextrin is flexible in its chemical and physical properties.
Due to this, it has to be dealt with responsibility or else it would cause
a loss to the company.

Name: Dhanesh Deshpande (DGM, Sahayadri Starch & Industries

Pvt. Ltd, Miraj)
Signature:

18