RUGÍ Incorporation

The Philippines' First High-Fructose Corn Syrup 55 Manufacturing Plant

A Plant Design
Presented to the Faculty of
Chemical Engineering Department
College of Engineering

Batangas State University

The National Engineering University

In Partial Fulfillment
of the Requirement for the Degree
Bachelor of Science in Food Engineering

Manzanilla, Enamae L.
Marquez, Mark Kevin D.
Temple, Nicole Andrea Mae
Villarba, Minette D.

April 2023
 Republic of the Philippines
BATANGAS STATE UNIVERSITY
College of Engineering, Architecture and Fine Arts
Alangilan, Batangas City

APPROVAL SHEET

This Plant Design entitled “RUGÍ Inc. The Philippines' First High-Fructose Corn

Syrup 55 Manufacturing Plant” prepared and submitted by Enamae L. Manzanilla, Mark

Kevin D. Marquez, Nicole Andrea Mae Temple, and Minette D. Villarba in partial fulfillment of

the requirements for the Degree of Bachelor of Science in Food Engineering, has been

examined and accepted.

____________________________
Engr. NICO JOHN R. ABRATIQUE
Adviser

Approved by panel on the Oral examination with a grade of __________.

PANEL OF EXAMINEES

___________________________
Engr. RHONALYN V. MAULION
Chairman

_____________________________ ______________________
Engr. DIANNE YSPHER H. HABAL Engr. RIZELLE LOPEZ
Panel Member Industry Expert

___________________________
Engr. REJIE C. MAGNAYE
Course Instructor

Accepted and approved in partial fulfillment of the requirements for the Degree of
Bachelor of Science in Food Engineering.

________________ ________________________
Date DR. REYNATO A. GAMBOA
Dean, CEAFA
 ACKNOWLEDGEMENT

We would like to take this opportunity to express our sincerest appreciation and deepest
gratitude to the people who have been with and supported us throughout this research.
First and foremost, praises and thanks to Almighty God, for the guidance, intelligence,
strength, and determination He bestowed upon us all through our research and to complete it
successfully.
To our families, especially our dearest parents. Their encouragement, concern, and
financial support aided us in overcoming obstacles and remaining focused on our research.
And, most importantly, for believing in us and our ability to succeed.
In addition, we would like to express our thanks to Engr. Nico John R. Abratique, our
mentor, for expressing and sharing his thoughts and knowledge. His assistance,
encouragement, and advice have all aided us in completing this project, and we owe him our
deepest appreciation.
Besides, so much appreciation is given to our course instructor, Engr. Rejie C.
Magnaye. To our chairperson, Engr. Rhonalyn V. Maulion and members of the panel Engr.
Dianne Yspher H. Habal and Engr. Rizelle Lopez for their constructive criticism, which aided
in the development of this paper.
And to the people who have contributed to the development of this study. To our friends
and seniors, who supported us and became an inspiration to finish this study.
 DEDICATION

“Ask, and it will be given to you; seek, and you will find; knock, and it will be opened to you. For
everyone who asks receives, and the one who seeks finds, and to the one who knocks it will be
opened.”
Matthew 7:7-8

We dedicate this
To our adviser, who has always been incredibly encouraging and supportive
To our friends who have been there for us from the beginning and have
supported us.
To our families that trusted in our ability to succeed.

This work is for you.

 MISSION
Rugi Inc. aims to convert corn into High-fructose Corn Syrup 55 through a
semi-automated process to produce and distribute the highest quality and cost-efficient products
that will emphasize and recognize customer value and satisfaction while upholding food product
safety and quality assurance.

VISION
To be the first and most highly recognized manufacturing plant that produces top-quality
High Fructose Corn Syrup 55 in the Philippines by minimizing waste generation, providing
cost-efficient products, and satisfying customer demand.
 TABLE OF CONTENTS

TITLE PAGE i
APPROVAL SHEET ii
EXECUTIVE SUMMARY iii
ACKNOWLEDGEMENT v
DEDICATION vi
MISSION AND VISION vii
TABLE OF CONTENTS viii
LIST OF TABLES ix
LIST OF FIGURES x
LIST OF PLATES xi
LIST OF SPECIFICATION SHEETS xii
CHAPTER I – INTRODUCTION 1
Introduction 1
Objective of the design 2
Background of the Study 3
Limitations of the Study 5
Production Level 5
Plant Location 5
Raw Material Availability 6
Water and energy availability 7
Land Adequacy 8
Transportation Facilities 8
Labor and Site Topography 9
Years of Projection, Capture Market and Marketability 9
Technical Limitations and Capability 10
Equipment Limitations 10
Environmental Limitations 10
Financial Limitations 11
 Significance of the Study 12
Definition of Terms 12
CHAPTER II- LITERATURE SURVEY 14
Raw Materials 14
Historical Background of Corn 14
Description of Corn 15
Parts of Corn 17
Classification of Corn 21
Production of Corn in the Philippines 25
Uses of Corn 25
Products: High Fructose Corn Syrup and Corn Oil 27
Historical Background of High Fructose Corn Syrup 28
Description of High Fructose Corn Syrup 29
Application of High Fructose Corn Syrup 31
Product: Corn Oil 32
Historical Background of Corn Oil 32
Description of Corn Oil 33
Application of Corn Oil 34
Manufacturing Process 35
Corn Milling 35
Wet Milling Process 35
Dry Milling Process 38
Comparison of Wet and Dry Milling Processes 39
Production of High Fructose Corn Syrup 40
High-Fructose Corn Syrup Manufacturing Process 43
Production of Corn Oil 50
Related Studies 52
Synthesis 57
CHAPTER III- MARKET STUDY 60
Industry Overview 60
 Corn syrup 60
Corn Oil 62
Target Market 64
Corn Syrup 64
Corn Oil 65
Competition 66
Pricing and Forecast 70
Swot Analysis 78
Product Distribution 80
Factors Affecting the Market 81
CHAPTER IV- PROJECT SCHEDULE 84
Front End Loading 1 84
Front End Loading 2 85
Front End Loading 3 87
Execution Phase of the Design 90
Pre-Operation Phase of the Design 91
Operation Phase of the Design 92
Gantt Chart of Project Schedule 94
CHAPTER V- PRODUCT SPECIFICATION AND PROCESS DESCRIPTION 95
Manufacturing Process 95
Product Specification 108
CHAPTER VI- PROCESS FLOW DIAGRAM AND MATERIAL BALANCE 110
Process Flow Diagram 110
Material Balance 111
Summary 125
Residence Time 126
CHAPTER VII- ENERGY BALANCE AND UTILITY REQUIREMENT 128
Energy Balance 129
Utility Requirement 132
Water 132
 Electricity 132
Steam 132
Air 133
CHAPTER VIII- HEALTH, SAFETY AND ENVIRONMENTAL ASPECTS 136
Hazard Index Based on Temperature Profile 136
Identification Procedure and Mitigation Technique for Undesirable
Accidents/Events 137
Provide Hazard Checklist 137
Administration Controls 138
Preventive Maintenance Systems 138
Emergency Preparation 138
Hazard and Operability (HAZOP) Study 140
Hazard Analysis Critical Control Points 146
Methods for Hazardous of Waste Management 151
Methods of Reducing Equipments Hazard 152
Potential Hazards in the Workplace and the way of controlling them 153
Inherent Safety 155
Delivery, Handling and Storage of Raw Materials 157
Storage Tank and Piping Leak Detection 157
Community Health and Safety 158
Hazard and Hazard Control 159
Methods for Hazardous Waste Management 159
Disposal of Hazard Waste 160
Personal Protective Equipment (PPE) 161
Energy Conservation 162
Environmental Aspects 163
Occupational Safety 164
Process Hazard Checklist 167
Preliminary Risk Analysis 167
Personal Protective Equipment 169
CHAPTER IX- EQUIPMENT LIST AND SPECIFICATION SHEET 171
Equipment Specification Sheet 171
Pump Specification 244
CHAPTER X- EQUIPMENT COST SUMMARY 250
Equipment Cost Summary 250
CHAPTER XI- EQUIPMENT LAYOUT 255
Equipment Layout 256
CHAPTER XII- PLANT SITE LOCATION AND PLANT LAYOUT 261
Plant Site Location 261
Raw Material Availability 261
Market Availability 261
Energy Availability 262
Water Supply 262
Land Adequacy 263
Transportation Facilities 264
Water Disposal 264
Labor Supply and Site Topography 264
Climate 265
Community Factors 265
Plant Layout 265
CHAPTER XIII- FINANCIAL ANALYSIS 279
Financial Assumption 279
Equipment Cost Estimation 281
Capital Investment 282
Production Cost 284
Amortization Schedule 285
Payback Period 286
Return on Investment (ROI) 287
Return on Owner’s Investment (ROOI) 288
Break Even Analysis 288
 Breakeven Selling Price 289
Net Profit Margin (Return on Sales 289
Gross Profit Margin 290
Operating Margin 290
Cash Flow 291
Income Statement 291
CHAPTER XIV- SUMMARY, CONCLUSIONS, AND RECOMMENDATIONS 292
Summary 292
Conclusion 292
Recommendation 292
BIBLIOGRAPHY
APPENDICES
A. Market Study
B. Material Balance
C. Chemical Energy Balance

D. Mechanical Energy Balance

E. Piping and Design Calculations

F. Utilities

G. Process Hazard Checklist

H. Equipment Specification Calculations

I. Financial Analysis

J. Documentation

K. Multiple Constraints

L. Curriculum Vitae
 LIST OF TABLES

Table Title Page

2.1 Physical Properties of Corn 17

2.2 Physico-chemical Properties of Corn Kernels 19

2.3 Chemical Properties of Yellow Flint Corn 22

2.4 Carbohydrates Content of Yellow Flint Corn 22

2.5 Carbohydrates Content of Yellow Flint Corn after Enzymatic 23

Hydrolysis

2.6 Physical Properties of Corn 24

2.7 Historical Production of Corn per Region in the Philippines 25

2.8 Physicochemical Properties of High Fructose Corn Syrup 32

2.9 Physicochemical Properties of Corn Oil 34

2.10 Comparison of Enzymatic Hydrolysis and Combination of 43

Acidic and Enzymatic Hydrolysis

2.11 Comparison of Enzymatic Degumming and Traditional Degumming 51

3.1 Basis of Pricing for High Fructose Corn Syrup 55 and Corn Oil 70

3.2 Basis of Pricing for High Fructose Corn Syrup 55 and Corn Oil in 70
2028

3.3 Historical Data and Projected Value of High Fructose Corn Syrup 55 72

3.4 Statistical Methods for High Fructose Corn Syrup 55 Market Share 73

3.5 Historical Data and Projected Value of Corn Oil 74

3.6 Statistical Methods for Corn Oil Market Share 75

5.1 Product Specification for Rugi Manufacturing Plant 109

6.1 Summary of Corn Wet Milling 111

6.2 Summary of High-Fructose Corn Syrup 55 Production 115

6.3 Summary of Corn Oil Production 120

6.4 Summary of Wastewater Treatment 122

6.5 Total Annual Production of High Fructose Corn Syrup 55 and Corn 125
Oil

6.6 Residence Time 126

7.1 Summary of Energy Requirement of Equipment 128

7.2 Summary of Energy Requirement of Storage Tanks 130

7.3 Summary of Energy Requirement of Pumps 133

7.4 Summary of the Overall Utility Requirements 135

8.1 Temperature Profile for Equipment 136

8.2 Hazard and Operability (HAZOP) Study Guide Word 140

8.3 Area 100 Hazard and Operability (HAZOP) Study 141

8.4 Area 200 Hazard and Operability (HAZOP) Study 143

8.5 Area 300 Hazard and Operability (HAZOP) Study 144

8.6 Area 400 Hazard and Operability (HAZOP) Study 145

8.7 Critical Control Points 147

8.8 Methods of Reducing Equipment Hazard 152

8.9 Equipment’s Potential Hazard and their Preventive Measures 153

8.10 Inherent Safety Approaches 156

8.11 Summary of Recommended PPE According to Hazard 162

8.12 Energy Conservation Techniques of Rugi Manufacturing Plant 163

8.13 Occupational Safety with Preventive Measures 166

8.14 Methods of Reducing Equipment Hazard 168

8.15 Methods of Reducing Equipment Hazard 170

9.1 AREA 100: Specification Sheet No. 1 171

9.2 AREA 100: Specification Sheet No. 2 172

9.3 AREA 100: Specification Sheet No. 3 173

9.4 AREA 100: Specification Sheet No. 4 174

9.5 AREA 100: Specification Sheet No. 5 175

9.6 AREA 100: Specification Sheet No. 6 176

9.7 AREA 100: Specification Sheet No. 7 177

9.8 AREA 100: Specification Sheet No. 8 178

9.9 AREA 100: Specification Sheet No. 9 179

9.10 AREA 100: Specification Sheet No. 10 180

9.11 AREA 100: Specification Sheet No. 11 181

9.12 AREA 100: Specification Sheet No. 12 182

9.13 AREA 100: Specification Sheet No. 13 183

9.14 AREA 200: Specification Sheet No. 14 184

9.15 AREA 200: Specification Sheet No. 15 185

9.16 AREA 200: Specification Sheet No. 16 186

9.17 AREA 200: Specification Sheet No. 17 187

9.18 AREA 200: Specification Sheet No. 18 188

9.19 AREA 200: Specification Sheet No. 19 189

9.20 AREA 200: Specification Sheet No. 20 190

9.21 AREA 200: Specification Sheet No. 21 191

9.22 AREA 200: Specification Sheet No. 22 192

9.23 AREA 200: Specification Sheet No. 23 193

9.24 AREA 200: Specification Sheet No. 24 194

9.25 AREA 200: Specification Sheet No. 25 195

9.26 AREA 200: Specification Sheet No. 26 196

9.27 AREA 200: Specification Sheet No. 27 197

9.28 AREA 200: Specification Sheet No. 28 198

9.29 AREA 200: Specification Sheet No. 29 199

9.30 AREA 300: Specification Sheet No. 30 200

9.31 AREA 300: Specification Sheet No. 31 201

9.32 AREA 300: Specification Sheet No. 32 202

9.33 AREA 300: Specification Sheet No. 33 203

9.34 AREA 300: Specification Sheet No. 34 204

9.35 AREA 300: Specification Sheet No. 35 205

9.36 AREA 300: Specification Sheet No. 36 206

9.37 AREA 400: Specification Sheet No. 37 207

9.38 AREA 400: Specification Sheet No. 38 208

9.39 AREA 400: Specification Sheet No. 39 209

9.40 AREA 400: Specification Sheet No. 40 210

9.41 AREA 400: Specification Sheet No. 41 211

9.42 AREA 400: Specification Sheet No. 42 212

9.43 AREA 400: Specification Sheet No. 43 213

9.44 AREA 400: Specification Sheet No. 44 214

9.45 Specification Sheet No. 45 215

9.46 Specification Sheet No. 46 216

9.47 Specification Sheet No. 47 217

9.48 Specification Sheet No. 48 218

9.49 Specification Sheet No. 49 219

9.50 Specification Sheet No. 50 220

9.51 Specification Sheet No. 51 221

9.52 Specification Sheet No. 52 222

9.53 Specification Sheet No. 53 223

9.54 Specification Sheet No. 54 224

9.55 Specification Sheet No. 55 225

9.56 Specification Sheet No. 56 226

9.57 Specification Sheet No. 57 227

9.58 Specification Sheet No. 58 228

9.59 Specification Sheet No. 59 229

9.60 Specification Sheet No. 60 230

9.61 Specification Sheet No. 61 231

9.62 Specification Sheet No. 62 232

9.63 Specification Sheet No. 63 233

9.64 Specification Sheet No. 64 234

9.65 Specification Sheet No. 65 235

9.66 Specification Sheet No. 66 236

9.67 Specification Sheet No. 67 237

9.68 Specification Sheet No. 68 238

9.69 Specification Sheet No. 69 239

9.70 Specification Sheet No. 70 240

9.71 Specification Sheet No. 71 241

9.72 Specification Sheet No. 72 242

9.73 Specification Sheet No. 73 243

9.74 Pump Specification Sheet 244

10.1 Equipment List and Cost 250

10.2 Pump Cost 252

10.3 Conveyor Cost 254

10.4 Summary of Equipment Cost 254

11.1 Area Description 255

13.1 Total Annual Consumption per Year 279

13.2 Total Annual Growth Projection 280

13.3 Selling Price of HFCS 55 and Corn Oil 281

13.4 Total Capital Investment of RUGI Inc. Manufacturing Plant 282

13.5 Total Production Cost of RUGI Inc. Manufacturing Plant 284

13.6 Amortization Schedule of RUGI Inc. Manufacturing Plant 285

13.7 Payback Period of RUGI Inc. Manufacturing Plant 286

13.8 Return on Investment (ROI) of RUGI Inc. Manufacturing Plant 287

13.9 Return on Owner’s Investment (ROOI) of RUGI Inc. Manufacturing 288

Plant

13.10 Return on Sales (ROS) of RUGI Inc. Manufacturing Plant 289

13.11 Gross Profit Margin of RUGI Inc. Manufacturing Plant 290

13.12 Operating Profit Margin of RUGI Inc. Manufacturing Plant 291

 EXECUTIVE SUMMARY
Title: The Philippines' First High-Fructose Corn Syrup 55 Manufacturing Plant
Authors: Enamae L. Manzanilla, Mark Kevin D. Marquez, Nicole Andrea Mae Temple,
Minette D. Villarba
Type of Document: Undergraduate Plant Design
Name and Address of the Institution: Batangas State University- Alangilan

Rugi Inc. is the first High Fructose Corn Syrup 55 manufacturing plant in the Philippines
which would provide another supply of sweeteners for the biggest soft-drink manufacturers in
the country. The plant aims to provide high-quality products for the target consumers while
upholding food safety and quality assurance. Rugi Inc will also offer corn oil which is readily
available and cost-efficient.
The manufacturing plant will utilize 150 metric tons of corn per batch from corn
cooperatives and industries in Isabela which is the top producer of corn in the country. During
the manufacturing process, the corn will undergo the following process to produce HFCS 55 and
corn oil: Corn Wet Milling, HFCS 55 Production through Enzymatic Hydrolysis, and Corn Oil
Production and Refining. Rugi Inc. will operate 24 hours a day, 330 days annually which will
produce 4,098.85 MT and 1,813.14 MT of HFCS 55 and corn oil, respectively. Continuous
operations requiring wide-ranging manpower and comprehensive techniques of process
engineering will be employed. As well as compliance with the implementing rules and
regulations will be observed to ensure strategic management of the products.
As per the plant location, Rugi Inc. is located at Minallo, Naguilian, Isabela with a land
area of 65,000 square meters. The area is sufficient enough to keep distance from the
residential area and provide space for future expansion and development. There is also
sufficient energy and water supply for the manufacturing plant for its operation which will be
outsourced from Cagayan Electric Cooperative (CAGELCO) and Isabela Water District
respectively.
The proposed manufacturing plant will have a percentage market share of 2.45% locally
and 0.01% globally for the HFCS 55, a major product. Meanwhile, for its by-product, corn oil has
0.02% and 2.20% local and global percentage market shares respectively.
Furthermore, the plant possesses a total capital investment of Php 1,372,123,474.32 and
will start its operation in the year 2028. Thirty (30) percent of the capital investment will be
loaned from the bank having an interest of 10% amortized for 10 years. The pricing of the raw
materials was based on the current market, and the selling price of the products was based on
the breakeven analysis of each product. Its financial studies have an estimated payback period
which is 4.30 years with a percentage of 23.28% Return on Investment (ROI).
Based on thorough consideration of the engineerinsocio–economicic, technical, and
financial aspects of the design, the project is achievable, beneficial, and profitable.
 LIST OF FIGURES

Figure Title Page

1.1 Minallo, Municipality of Naguilian, Province of Isabela 5

2.1 Corn 14

2.2 USDA Corn Quality Grades 16

2.3 Composition of a Corn Kernel 18

2.4 Layered Structure of Corn Cob 20

2.5 Corn Husk 21

2.6 Sugar 27

2.7 High Fructose Corn Syrup 30

2.8 Corn Oil 33

2.9 Wet Milling Process 37

2.10 Dry Milling Process 38

3.1 Global Historical Data and Projected Value of High Fructose Corn 75
Syrup

3.2 Local Historical Data and Projected Value of High Fructose Corn 76
Syrup

3.3 Global Historical Data and Projected Value of Corn Oil 76

3.4 Local Historical Data and Projected Value of Corn Oil 77

3.5 Swot Analysis 78

4.1 Gantt Chart of the Project Schedule 94

5.1 Summary Flow Diagram for the High-Fructose Corn Syrup and 95
Corn Oil Manufacturing Plant

5.2 Block Diagram for the Area 100 96

5.3 Block Diagram for the Area 200 99

5.4 Block Diagram for the Area 200 100

5.5 Block Diagram for the Area 300 104

5.6 Block Diagram for the Area 400 106

6.1 Schematic Diagram of the Manufacturing Processes of Rugi 110

Incorporation
 LIST OF PLATES

Plate Title Page

1 Qualitative Diagram Sheet 1

2 Quantitative Diagram Sheet 1

3 Piping & Instrumentation Diagram Sheet 1

4 Isometric View Area 100: Corn Wet Milling 256

4 Isometric View Area 200: High-Fructose Corn Syrup 55 Production 257

4 Isometric View Area 300: Corn Oil Production 258

4 Isometric View Area 400: Wastewater Treatment 259

5 Overall Production Area (Top View) 260

6 Isometric View Plant Layout 267

7 Front View Plant Layout 268

8 Top View Plant Layout 269

9 Isometric View Production Facility 270

10 Isometric View Administration Building 271

11 Isometric View Dormitories 272

12 Isometric View Fire Station 273

13 Isometric View Clinic 274

14 Isometric View Canteen 275

15 Isometric View QA Building 276

16 Isometric View Maintenance Building 277

17 Isometric View Warehouse 278

18 Overall Manufacturing Plant Floor Plan Sheet 1

 CHAPTER I
INTRODUCTION AND BACKGROUND
I. INTRODUCTION
Sugar is one of the important agricultural commodities in the country. The Philippines
consumes around 2.5 million tons of sugar each year, making it one of the largest consumers in
Asia, along with India, China, Indonesia, and Thailand. However, there has been a noted
shortage of supply of sugar in the domestic market in the Philippines after a poor harvest for the
2021-2022 crop year wherein the sugarcane production from April to June 2022 dropped to 3.19
million metric tons or by -53.8 percent, from 6.91 million metric tons output in the same quarter
of 2021. Furthermore, weather disturbances, high input costs, and the delayed implementation
of an order to import sugar also aggravate the problem and affect the biggest soft-drink
manufacturers in the country including Coca-Cola and Pepsi Philippines. This led to an increase
in sugar demand which resulted in a price increase of the commodity.
In an attempt to solve the sugar shortage in the country, the Sugar Regulatory
Administration (SRA) found another source or supplier and allowed the importation of 300,000
metric tons (MT) of sugar to help alleviate the shortage of this sweetener being used in
households and by manufacturers of soft drinks and other products. This indicates that another
local sustainable source of sugar has the potential to solve the sugar crisis in the country.
Aside from sugarcane, there are different sources of sugars found in fruits and
vegetables in varying amounts such as sucrose, glucose, and fructose. For instance, bananas,
sweet peas, and peaches contain primarily sucrose, whereas glucose and fructose are the main
sugars in corn. In fact, sweeteners derived from corn slowly grew as applications and
functionality were developed in food and industrial products (Helstad, 2018). With this,
sweeteners from corn can be an alternative source of sugar in the country as corn is the second
most important crop in the Philippines.
In 2021, the production volume of corn in the Philippines amounted to over eight million
metric tons. In connection with this, Philippine corn production can provide enough supply to
yield different types of corn sweeteners available in the market including natural and artificial
sweeteners. Natural sugars are the sugars in whole foods such as glucose and fructose which
are found in fruits and vegetables. Although, they have received much interest due to increasing
health concerns over the consumption of sugar (Nguyen et al., 2019). Corn syrup is one
example of natural sugar. According to Featherstone (2015), it is a purified and concentrated
mixture of saccharides obtained by hydrolysis of corn starch. When the type of starch used is
not specified, the more general name, glucose syrup, is applied to the product. Furthermore,
they are commonly identified by a measurement called the “dextrose equivalent” or DE. It is a
measure of the amount of reducing sugars present as determined by Fehling's test or titration
(Helstad, 2019).
On the other hand, corn oil is a by-product of corn meal- and starch-making companies
(Ghazani, Marangoni, 2016). Corn oil is high in omega-6 acids essentially, free of omega-3
acids, and contains less saturated fat than soybean and cottonseed oil. The P/S ratio of over 4.5
is highly desirable in nutritional considerations. The major food uses include deep fat frying, as a
component of margarine and spreads, and for shelf-stable fried and baked snack foods. Corn oil
is rich in tocopherols and ferulic acid derivatives, both of which prolong fry life.
With this, the researchers will design a High Fructose Corn Syrup 55, and Corn Oil
Manufacturing Plant to address the increasing demand for soft drinks sweeteners in the
Philippines. This manufacturing plant will provide another source of HFCS 55, the sweetener
used by soft drinks manufacturing companies. And, the researchers will utilize corn as the main
raw material used to produce the products which is one of the top crops produced in the country.

II. OBJECTIVES OF THE DESIGN

General Objectives. The general objective of the study is to design a High-fructose Corn Syrup
55 and corn oil manufacturing plant in the Philippines from corn.
Specific Objectives. The study includes the following specific objective in connection with the
general objective.
1. To assess the feasibility of a semi automated manufacturing plant in producing
sweetener and corn oil products.
2. To design cost-efficient processing equipment for the production of HFCS 55 and Corn
Oil.
3. To evaluate financial limitations of the manufacturing plant and profitability of the
products.
4. To comply with environmental requirements that minimize waste generation and provide
an action plan for possible harmful contamination.

2
III. BACKGROUND OF THE STUDY
Sugars, like all other carbohydrates, are made up of carbon, hydrogen, and oxygen
molecules. Carbohydrates, together with proteins and lipids, play an essential role in
maintaining good health. The main agricultural source of sugar is sugarcane. In line with this,
the sugarcane industry contributes approximately P70 Billion to the Philippine economy
annually. Historically, the Philippines exported more than half of its sugar production to the
United States, but exports have declined significantly as domestic demand has increased. The
Philippine allocation for Fiscal Year 2021 is 138,154 metric tons of commercial weight. The
United States is currently the sole export market of Philippine raw sugar, which is used by some
sugar refineries on the west coast. (Mojica-Sevilla, F. 2021). In 2020, there are a total of 29
operating sugarcane raw mills in the country which have the capacity to produce about 185,000
of cane per day. However, due to inflation in agricultural chemicals, the sugarcane industry
declines its annual quota. These hikes in the prices of chemicals lead to an increase in
commercial sugar production. In fact, the supermarket retail price now ranges from P49.50-P71
per kilogram against last year's P41.07-P56.85 per kilogram. Meanwhile, wet markets presently
sell sugar at P70-P80 per kilogram.
The price increase and shortage of commercial sugar largely affect the soaring demand
of leading food and beverage companies in the country. This resulted in Coca-cola's production
being cut down by 30 to 40 percent because the company lacks premium refined sugar for
high-quality production. The company also stated that there is a 400,000 MT gap in the local
sugar supply based on a 2022 projected demand (Cariaso, 2022). In line with this, a wide range
of sweetener substitutes for the beverage industry is available.
Aside from artificial sweeteners, natural sweeteners can also be used in the food and
beverage industries. High fructose corn syrup provides different applications in food and
beverage industries as a natural sweetener for different food products. Corn syrup is made by
hydrolyzing cornstarch, either by heating it with diluted acid or by adding enzymes to the
cornstarch. It is widely used in the creation of jams and jellies, baked goods, and a variety of
other meals such as dairy products, confectioneries, and beverages. Corn syrup consumption is
predicted to increase dramatically in the food and beverage industry due to increased demand
for sweeteners in various processed goods. Corn syrup does not crystallize under specific
conditions and has a higher solubility. Furthermore, it is less expensive than sugar and serves
as a preservative, extending the shelf life of food and beverages (Allied Market Research,
2022). Thus, corn syrup is considered one of the main products obtained from corn.

3
 On the other hand, the majority of corn oil used in industry comes from the kernel's
germ, hence the term "corn germ oil". Corn has the highest oil content of the commercial
cereals because its germ is larger than those of other grains. Despite having lipids in its kernel
at a level of 3-5%, corn is not classified as an oilseed. Large-scale industrial dry and wet mills,
however, produce copious amounts of germ, which is typically diverted to the oil crushing and
animal feeding sectors. The germ accounts for 9–11% of the total kernel weight and comprises
roughly 80% of the lipids present in the whole kernel. Endosperm accounts for 15%, whereas
bran makes up the remaining 2% ((Barrera-Arellano et al., 2019). Two main steps make up the
industrialization of corn oil: the extraction of crude oil (which also produces corn oil cake as a
byproduct) and the refining of crude oil. Depending on the economic factors involved with the
raw material source, consumer hubs, or industrial final destination, these processes may be
performed in a single facility or in separate units (Singh et al., 2011; Shende and Sidhu, 2014).
Generally, corn is the main raw material for the Rugí Inc. Manufacturing plant. The
Philippines cultivate both rice and corn as food staples and the corn growing season and
harvest time vary from region to region. Corn production in the Philippines is highly dependent
on local climate and terrain. More than 8 million metric tons of corn were harvested in the
Philippines in 2021, down from 8.12 million metric tons the year before. The parts of corn kernel
necessary for the manufacturing plant's production are endosperm and germ. The corn
endosperm contains a high amount of starch while the germ contains a high concentration of
corn oil. The production will start with a corn milling process that will produce starch and corn oil.
The produced corn starch from corn milling will undergo hydrolysis to synthesize corn syrup.
The design of the Rugí manufacturing plant's processing of the main products uses modern
technology for the improvement of yield and quality. In the corn syrup production line, the
decolorization and demineralization were separated for a more purified quality of the syrup
rather than the traditional process that combines the two processes in one piece of equipment.
Summing up these pieces of information, the Philippines is currently experiencing a
sugar shortage due to several factors affecting the crops and sugar industry. Thus, Rugí
Incorporation would design a manufacturing plant to produce high-fructose corn syrup 55 and
corn oil, taking advantage of the abundant maize supply in the country.

4
IV. LIMITATIONS OF THE STUDY
1. Production Level
The corn used in this factory will be employed in making high fructose corn syrup
55 which is a sweetener and as well as corn oil as its by-product. A batch output of 24
MT of HFCS 55 and 6 MT of corn oil can be expected. It has the capacity to manufacture
4,098.85 MT of HFCS 55 and 1,813.14 MT of corn oil annually. The manufacturing
plant’s process is a semi-automated system that needs the assistance of operators
during the process.
Additionally, the facility will run nonstop for 330 consecutive business days per
year. Annually, the factory will temporarily cease operations in order to perform
preventative maintenance and repairs on the numerous pieces of machinery that make it
function. It is important to consider the long-term effects of a plant's site when making
decisions, as poor initial location planning can lead to persistent issues for the plant's
operations down the road. As a result, it has an impact on productivity, efficiency,
effectiveness, and profitability.

2. Plant Location

Figure 1.1 Minallo, Municipality of Naguilian, Province of Isabela

Source: Google Earth

5
 In the selection of plant location, the prospects were evaluated based on the
convenience and accessibility of the location, raw materials, and bodies of water. Based
on these criteria, Municipality of Naguilian, Province of Isabela in Cagayan Valley is the
appropriate location for the Rugí Inc. Manufacturing Plant. According to the Department
of Agriculture (2021), Isabela Province is the top producer of corn in the country. With
1,049,954 MT, Isabela province had the most impact on national corn output. With this,
the minimum production cost for the main raw material will be acquired. A 3.45-kilometer
paved route in Naguilian, Isabela would facilitate the swifter movement of agricultural
products and improve the driving conditions for farmers and other vehicles. Furthermore,
the chosen plant location is near the Cagayan River where the treated wastewater will
be discharged. Isabela province is known as a typhoon prone area in CAGAYAN Valley,
however the chosen plant location shows a history of the least typhoon disasters among
other municipalities in Isabela Province.

3. Raw Material Availability

The corn industry in the Philippines produced a total volume of around eight (8)
million metric tons in 2019. The province of Isabela is considered to be one of the main
producers of corn in the country with a production level of 1.1 million metric tons. In the
PSA data of 2018, Cagayan Valley comprises 43% of the total production of corn in the
country. Accordingly, Isabela Province shares 63% of the yellow corn produced in the
region (A. Salazar, Elca, Lapiña, and F. Salazar, 2021). In 2019, 6.65 million metric tons
of yellow corn were used for the manufacturing of animal feed. Corn is considered a
bumper crop which means it produces an unusual number of crops depending on the
climate and land. Therefore, local manufacturing plants of feed are encouraged to
purchase more corn from local producers (Reus, 2020). In line with this, other possible
sources of corn are the provinces of Nueva Vizcaya 218,446 MT and 73,423 MT in
Quirino. These provinces are located in the Cagayan region which gives easy access for
purchasing corn. The Rugí Manufacturing plant will source corn kernels from local
farmers and corn millers.
Moreover, according to PSA (2021), data from Supply Utilization Accounts of
Selected Agricultural Commodities states that 65% of total corn production is used for
feeds and waste regeneration, 5% is used for food processing industries, 8.3% is used
for non-food processing industries, and 0.16% is used as seeds. Therefore, Rugi

6
 Incorporation would utilize the available raw corn from the total 21.5% unprocessed and
market available corn.

4. Water and Energy Availability

Accessibility and sustainability of energy and water supply play a vital role in the
location of the manufacturing plant.
The Cagayan Electric Cooperative (CAGELCO) is the main source of energy that
will be acquired for this project. CAGELCO is a huge electric company in the CAGAYAN
VALLEY that supplies electricity to 33 industrial companies in 2019. The company
currently uses different types of fuel supply for their industry consumers such as coal,
geothermal and hydroelectric. The company has offered a contracted capacity of 20
Megawatts (MW) for the past 15 years. CAGELCO continuously improved the energy
source system, sourcing out additional long-term competitive selection processes. The
cooperative also aims compliance with renewable energy sources. Furthermore, the
manufacturing plant can also source its energy from other provinces such as Isabela
Electric Cooperative (ISELCO), Quirino Electric Cooperative (QUIRELCO), and Nueva
Vizcaya Electric Cooperative (NUVELCO).
Another source of electricity for the proposed plant is the use of generators. This
will use diesel generators at their core to power the plant with natural gas. This backup
power is provided by generators, which also contribute to the security of the plant and
employees. For the contingency of energy supply, renewable resources such as solar
panels will be installed in the plant.
Accordingly, the water supply of the plant will be from Isabela Water District. The
water system facility is located at Barangay Menzi in Isabela province. It can operate an
average water production of 10,000 CMD providing services for about 71% of the city's
entire population. Currently, the ISAWAD produces water supply from nine water
sources, two deep wells, four groundwater sources, and three surface water sources.
The district manages three water treatment plant facilities and nine reservoirs totaling
2,500 cubic meters of water storage with four pumping systems and six gravity-fed
systems. The district currently keeps up a total of roughly 20.34 km. 87.91 km of
transmission pipelines, ranging from 50mm to 300mm of AC, CI, GI, uPVC, and HDPE
pipes in a variety of sizes and types. Ilagan Water District is the other source of water of
Rugí Inc. Manufacturing Plant. Its pumping station has a 7.5 HP pump motor with a rated

7
 capacity of 5 LPS. The depth of the pipelines is 80 m below the ground which was
constructed in 2012. The territory of the district falls entirely within the administrative
borders of the province of Ilagan.

5. Land Adequacy
Municipality of Naguilian, Province of Isabela has a total land area of
approximately 1,166 km2. A significant percentage of the land area – 24.99% is not being
fully utilized leaving them idle and under utilized. The manufacturing plant location is
headed beside the Cagayan river with a total land area of 65,000 m2. The plant location,
Naguilian, has a sufficient land area for the establishment of the plant. The coordinates
for Naguilian on the island of Luzon are roughly 17.1478 and 121.8937. These
coordinates are approximately 50.6 meters (166.0 feet) above mean sea level (Isabela
Profile – PhilAtlas, 2013). The site is near Cagayan river which is readily available for
industrial and commercial use. The land is generally accessible for transportation. It is
suitable for the establishment of the processing, storage, and transportation of the
incorporation. There is also a spare space that is suitable for future expansions and
development of the site. The total area for the manufacturing plant establishment is
21,000 m2.

6. Transportation Facilities
The manufacturing plant is located in the corn capital of the Philippines which is
the CAGAYAN Valley. The accessibility of raw materials around the area will shorten the
travel time and gas consumption of trucks and other transportation engines. Specialized
trucks shall be used to transport raw materials and products from the nearby
manufacturing site to the consumers and vice versa. The newly widened road stretches
from Naguilian, Iguig to Barangay Babayuan, Amulung will be the roads to be taken by
specialized trucks. Hence, for fast shipping to distant cities and provinces in the
Philippines, air transportation is the most suitable. Cagayan North International Airport
will hold the shipping of the products. In case of unavailability or scarcity of raw
materials within the province, shipping of materials shall be done through other
transportation vehicles.

8
7. Labor Site and Topography
According to the Philippine Statistics Office (2020), the population of Cagayan
Valley as of May 2020 was 3.68 million people which accounts for 3.38% of the
Philippine population. The population of the region is composed of skilled and unskilled
workers with different expertise that can be prospective workers for manufacturing
plants. Furthermore, the labor force and employment rate of the region are 64.8% and
97.7%, respectively. Thus, the region can provide enough labor supply to achieve the
manpower requirement for the manufacturing plant. And, the salary of the workers will be
based on the minimum wage rates of the province.
Generally, the climate in Cagayan Valley is warm, humid, and sunny. The
average temperature in the region is 79°F to 89°F and is rarely below 76°F or above
92°F. This temperature is suitable for the growth of corn as its temperature requirement
for growth is 75°F to 86 which will also be beneficial for the manufacturing plant.
Landslide and flooding are the two most common natural disasters in Cagayan Valley.
Moreover, Cagayan Valley is prone to severe earthquakes because of the region's three
active fault lines.

8. Years of Projection, Captured Market, and Marketability

The Rugi Manufacturing Plant will begin its operation in the year 2028 of January,
guaranteeing the availability and stability of the raw material for the next 25 years. This
manufacturing company is the first in the Philippines to use corn as a natural sweetener
for industry use instead of domestic. As the demand for sugar is high and the benefits of
alternative sweeteners are recognized in the market, the connections to the consumers
to use natural sweeteners will be established to ensure the industry's long-term stability.
Furthermore, corn oil is the best alternative to most cooking oil.
The target markets of the Rugi Manufacturing Company are the Beverage and
Baking industries and have export potential. And, the marketability of the product will
increase through seminars, webinars, and social media to introduce the products to
different types of consumers.

9
9. Technical Limitation and Capability
The primary focus of the study will be on the design of a manufacturing plant for
the production of corn oil, high fructose corn syrup derived from corn’s germ and
endocarp as raw materials. For the production of corn oil, corn kernels have been
steeped in which they produce soft corn kernels that will undergo evaporation to produce
steep water and soft corn kernels. The softened corn kernels will go through
degermination where the germ will be separated. The separated germ will be washed
and dried for the corn oil extraction. Corn syrup, on the other hand, is produced from
enzymatic hydrolysis to convert starch into its desired saccharide derivative.
Consequently, the manufacturing plant will also be fully automated to make it
easier to use and maintain, enhance product quality, ensure production is consistent,
and facilitate operations. Moreover, the equipment, processes, and products must be
thoroughly investigated and analyzed for further improvement of the operation.

10. Equipment Limitation

The proposed equipment for the manufacturing plant is categorized by function
and cost that will be procured from both local and foreign suppliers. To process corn into
corn oil, numerous pieces of equipment are required, including steeping tank,
dewatering gravity screen, attrition mill, hydrocyclone , dewatering screen, drier,
horizontal rotary cooker, and expeller press. Moreover, the corn syrup process includes
equipment such as a mixing tank, jet cooker, filter, saccharification tank, decolorization
tank, isomerization, chromatography, mixing tank, and decolorization tank. These
equipment are fabricated which are mostly purchased internationally.
Furthermore, maintenance and assistance with equipment installation are
required to prevent possible issues. This also includes periodic maintenance service and
assistance with equipment installation to ensure product quality.

11. Environmental Limitation

The Rugí Manufacturing Plant will follow ISO 45001: 2018 or the Occupational
Safety and Health Standard management system to produce corn oil and high-fructose
corn syrup. Furthermore, it will also comply with ISO 14001: 2015 and ISO 14004: 2016
for the environmental management system. The guidance of this International Standard
can assist an organization in improving its environmental performance and integrating

10
 environmental management system elements into its core business processes. It will
also prevent serious environmental hazards and potential threats to plant operations in
the environment.
Accordingly, the manufacturing plant will follow and comply with the implementing
rules and regulations of environmental conservation in the Philippines. It will comply with
the Republic Act No. 9003 or the Ecological Waste Management Act of 2000 to adopt a
systematic, comprehensive, and ecological solid waste management program to ensure
proper waste storage, treatment, and disposal. Moreover, the plant will also comply with
RA No. 8749 or the Philippine Clean Air Act of 1999 to minimize air pollution and ensure
that the National Air Quality Guidelines are followed. Finally, RA No. 9275, or the
Philippine Clean Water Act of 2004 to lessen the impact of water pollution.
With this, the proposed manufacturing plant is designed with its own wastewater
treatment facility. This will ensure that the water inflow from Isabela Water District and
effluent will be treated before and after use in the production process.

12. Financial Limitation

In building the manufacturing plant, the starting capital cost will be based on a
70:30 ratio in which 70% of the capital cost will be coming from the investors or
stockholders, and the remaining 30% will be loaned from the commercial bank. The
capital cost will cover the expenses of building the manufacturing plant, raw materials,
and equipment procurement. Furthermore, the raw materials, daily production process,
and labor costs will determine the cost of the products. And, the manufacturer will also
ensure that the products are cost-effective and in line with the current market pricing.

11
V. SIGNIFICANCE OF THE STUDY

The following will benefit from the development of corn oil and high-fructose corn syrup:
Corn producers, as a result of the fact that the company would directly acquire the raw
materials from the agricultural corn industry, the proposed manufacturing plant will support them
in increasing their income from corn farming.
Food industry, the proposed plant will promote much healthier sweeteners, in bakeries
and restaurants, that they can use as natural sweeteners in their baked goods and corn oil for
cooking food.
Filipinos, this plant will not only provide employment and job prospects to the residents
of the area immediately surrounding the plant, but also to people living throughout the entirety of
the country.
In the Philippine economy, the development plant is able to satisfy the growing demands
for sweeteners in the local market, reducing the reliance on foreign imports and helping the
economic boost.

VI. DEFINITION OF TERMS

Corn Steep Liquor. Corn steep liquor, a byproduct of corn wet milling, is a rich source of
organic nitrogen and a key component of several growth mediums, particularly
biosurfactant-producing media (Danyelle, 2013).
Endocarp. The endocarp is the inner layer of the pericarp and completely encases the
seeds (Carrillo-López & Yahia, 2019).
Enzymatic Conversion. Enzymatic conversions are biological and biochemical
processes in organisms such as animals, plants, or microorganisms. The conversion
mechanisms in plants are significantly more complex and difficult to imitate than those found in
bacteria (Aresta et al, 2014).
Germ. Corn germ is a Co-product of the corn wet milling process which is dried. After
grinding the corn kernels into a coarse powder, you get the germs, which are where the corn oil
is found (Jungbunzlauer, 2022).
Hydrochloric Acid. Hydrochloric acid is used in the production of chlorides, refining ore
for tin and tantalum, pickling and cleaning metal products, electroplating, removing scale from
boilers, neutralizing basic systems, as a laboratory reagent, as a catalyst and solvent in organic

12
syntheses, in the manufacture of fertilizers and dyes, and photography (Environmental
Protection Agency, 2016).
Osmophilic Yeasts. Osmophilic yeasts degrade high-sugar foods including jams,
molasses, corn syrup, flavored syrups and toppings, honey, and concentrated fruit juices
(Murray Brown Labs, 2022).

13
 CHAPTER II
LITERATURE REVIEW

I. RAW MATERIALS: CORN

A. Historical Background of Corn

According to Pruitt, J.D. (2016), maize or corn is an important crop, historically as
well as today. From its initial domestication in the Balsas River Valley of Mexico to its
role in the world economy, maize has had a storied past. Many historical societies have
been built on maize production. European explorers came to the new world looking for
treasure, but in maize, they found something that would become much more important.
Today, it is the most important crop in terms of volume produced in the world.
Pruitt also added that the unique characteristics of maize have made it a valued
crop throughout history. As ancient agriculturalists harnessed its genetic variation to
adapt new varieties of maize to new environments they were laying the groundwork for
the agricultural revolutions in maize of the 20th Century. Northern Flints provided
environmental adaptability that allowed farmers to move corn production north and west
and Southern Dent corn 26 provided increased yield. These two types came together to
form the genetic backbone of modern corn hybrids.

Figure 2.1 Corn

Source: Britannica, 2022

Maize yields have increased dramatically over the last 100 years and are
expected to rise even further in the next 100. Early in the twentieth century, double cross
hybrids were developed, launching yields on an unstoppable upward trajectory.
Transgenic corn production has accelerated due to the transgenic era. New genetic
variation sources have been introduced into maize germplasm, increasing its adaptability
and yields.
Moreover, corn is the second most productive crop in the Philippines, after rice,
reaching 7,770 k metric tons on 2.61 million hectares in 2014 after a nearly steady
increase in productivity since 2003 (Philippine Statistics Authority, 2015). A similar rise in
productivity was also seen in the province of Bukidnon, which in 2014 was the second
most productive province in the Philippines, behind Isabela. Isabela and Bukidnon were
responsible for more than 10 and 15% of the country's total production, respectively
(Transon, 2017).

Description of Corn
Corn (Zea mays) is a major cereal crop plant in the Poaceae family. Corn is also
known by various synonyms such as zea, corn, silk corn, maize, and so on. Makka and
Barajovar are the Hindi names for it. Corn is the mother grain of Americans and is
thought to be the first cultivar of the new world. Corn has a short life cycle and
necessitates warm weather, proper apprehension, and management. Corn is not only an
important human nutrient, but it is also a key component of animal feed and raw material
in the production of many industrial products. 100 g of dried corn contains 0.12 mg of
vitamin C, 10 mg of calcium, 2.3 mg of iron, 90 g carotene, 66.2 g carbohydrate, 0.10 mg
of riboflavin, 1.78 mg of amino acids, 342 mg of calories, 2.7 g of fiber, 3.6 g of fat, 11.1
g of protein, 114 mg of sulfur and the rest makes the dry matter (Karthik et al., 2017).
Corn has numerous health benefits. It is primarily composed of insoluble fiber,
making it a low-glycemic index food. This means it is a food that is slowly digested and
does not cause an unhealthy blood sugar spike (Caitlin Terpstra, 2021).
It also contains a lot of B vitamins and minerals like zinc, magnesium, copper,
iron, and manganese. Because corn is a starchy vegetable, diabetics should remember
that a half cup of corn, or a small ear of corn, contains 15 grams of carbohydrates and
counts as one carbohydrate food choice.
Furthermore, about 90% of the U.S. corn crop for 2021/2022 was rated U.S. No.
1, the USDA's highest grade for corn. Corn grown in the United States will be classified
into six grades, with U.S. No. 1 being the highest and U.S. Sample grade being the
lowest. The grain is graded using a minimum test weight/bushel and maximum limits for

15
damaged kernels, broken corn, and foreign particles. The crop must have a minimum
test weight of 56 pounds/bushel, fewer than 0.1% heat-damaged kernels, less than 3%
damaged kernels overall, and less than 2% broken corn and foreign material to get the
U.S. No. 1 grade. Corn graded U.S. Sample doesn't fulfill U.S. No. 5 criteria (46-pound
test weight/bushel, 3% heat-damaged kernels, 15% damaged kernels, 7% broken corn
and foreign material). It is also labeled U.S. Sample grade if it contains 0.1% or more
stones, two or more pieces of glass, three or more crotalaria seeds, two or more castor
beans, four or more particles of an unknown foreign substance or a commonly
recognized harmful or toxic substance, eight or more cockleburs or similar seeds singly
or in combination, or animal filth in excess of 0.2% per 1,000 grams. Musty, sour, or
economically objectionable foreign odors give corn a U.S. Sample grade (Feed & Grain,
2022).

Figure 2.2 USDA Corn Quality Grades

Source: Pickrell, 2021

According to the study conducted by Girijal et al., (2017), the physical properties
of corn are presented in Table 2.1. The average length of sweet corn was found to be
237.5 ± 17.0 mm. The mean diameter of sweet corn was measured to be 55.62 ± 3.42
mm. The unit weight of the sweet corn was recorded as 361.26 ± 34.24 g. The mean
bulk density of sweet corn was found to be 1150.55 ± 0.298 kg/m3. The ear-to-kernel
ratio of sweet corn was computed to be 2.3:1.

16
 Table 2.1 Physical Properties of Corn

Parameter Value

Length (mm) 237.5 ± 1.70

Diameter (mm) 55.62 ± 3.42

Unit weight (g) 361.26 ± 34.24

Bulk Density (kg/𝑚 )

3 1150.55 ± 0.298

Ear-to-Kernel Ratio 2.3:1

Source: Girijal et al., (2017)

1. Parts of Corn
Regardless of the variety of the type of corn, they all share the same basic
anatomy. The corn plant is made up of roots, a stalk, a husk, silk, a leaf, a tassel, cobs,
and kernels. Additionally, yellow dent corn is 62% starch. The maize kernel also contains
protein and fiber (19%), water (15%), and oil (4%). It may also contain traces of other
ingredients, but these are minor in comparison to the primary components. Starch is
made up of two different polymeric molecules: amylose and amylopectin. Amylopectin
accounts for 50% of the yellow dent corn kernel (80% of the starch) while amylose
accounts for 12% of the kernel (20% of the starch).

Corn Kernel
The corn kernel is the fruit or caryopsis borne in the plant's female inflorescence,
which contains the embryo and stored tissues designed to generate the new seedling
and generation plant upon germination. Kernels are made up of three basic anatomical
parts: pericarp, germ, and endosperm, and they contain a lot of starch, protein, oil, and
other nutritionally significant components (Lara et al., 2019).
Figure 2.3 depicts the composition of a corn kernel. It shows yellow dent corn,
which is often used in the manufacturing of ethanol. The endosperm is largely made up
of starch, which serves as the corn's energy storage, and protein, which aids in
germination. The starch is the component utilized to make fuel. The pericarp is the outer
layer that protects and maintains the nutrients within the kernel. The pericarp is resistant

17
to water and water vapor, as well as insects and microorganisms. Meanwhile, the germ
is the living organism within the kernel. It contains genetic information, enzymes,
vitamins, and minerals that aid in the development of the kernels into a maize plant.
Corn oil accounts for around 25% of the germ and is a key component of the kernel.
Water and nutrients flow through the tip cap, which is where the kernel is linked to the
cob. The pericarp does not cover this section of the kernel (Alternative Fuels from
Biomass Sources, 2018).

The following are parts of the corn kernel that will be utilized in the study:

Figure 2.3 Composition of a Corn Kernel

Source: Alternative Fuels from Biomass Sources (2018)

a. Germ
Corn germ is the initial by-product, containing 40–50% oil. In the wet milling
process, the corn germ fraction makes up around 5% of the bulk of the kernel. As a
by-product of the wet milling industry, corn germ is where the majority of commercial
maize oil is produced. The development of the wet milling procedure in the late 1800s
aimed to maximize the extraction of corn starch from maize kernels. The 70% starch in
maize kernels is effectively removed by wet milling, which also yields three main
by-products, sometimes referred to as co-products because of the sizable profits they
provide for the corn wet mill (Robert A. Moreau et al., 2014).

18
 b. Endosperm
Maize endosperm is a huge storage organ that accounts for 80-90% of the
mature kernel dry weight. The enzymes that they code for have been used to
characterize at least 11 key genes in corn. At least two genes encode the enzyme
adenosine diphosphate glucose pyrophosphorylase (AGP), which influences the rate of
starch production. With a similar function of controlling the rate of starch production, this
enzyme is also present in other plants, such as potatoes (Corn Journal, 2017).

Table 2.2 Physico-chemical Properties of Corn Kernels

Corn Composition Mass Mass per Component

Moisture 10%

Starch 81.1%

Fat 4%

Ash 1.3%

Protein 10.1%
Source: Fonseca et al., 2013

Corn Cob
Corn cobs are dense and relatively uniform, have a high heat value, generally
low N and S concentrations, and can be gathered during the corn grain harvest. The
harvesting of cobs is unlikely to affect soil residue, soil carbon, or the nutrient needs of
succeeding crops. It seems that corn cobs are a highly sustainable but rather
low-yielding feedstock (Pennington, 2020).

19
 Figure 2.4 Layered Structure of Corn Cob
Source: Zou, Y., et al. (2018)

a. Glume
The maize kernels on the cob of pod corn, also known as tunicate maize, are
covered by long membrane husks called glumes rather than being 'naked.' The maize
kernels in this variety are encased in delicate glumes that, when dried, resemble a
papery leaf sheath. In addition to having long glumes around them, the male flowers,
which grow in a panicle at the very tip of the stem axis, can sometimes yield kernels that
are unique to the cob (Pod Corn Develops Leaves in the Inflorescences, n.d.).
b. Pith
The pith of the corn cob has an oblong cross-section, with an exterior woody ring
and glume that are both round. Pith accounts for about 15% of the total mass, while fiber
makes up 20%. Parenchyma and a few vascular bundles can be found dispersed
throughout the pith. Aside from being light and airy, it also possesses a high absorption
rate and weak mechanical strength (Chen, 2015).
c. Woody Ring
Mechanical strength comes mostly from the woody ring, which has a
microstructure of hollow tubular structures made of cellulose and bound together by
lignin (Zou et al., 2021).

20
Corn Husk
The green leaves that cover corn ears are called corn husks. The maize kernels,
the plant’s edible part, are shielded by these leaves (Lauren, 2017). Corn husk is the
outer shell of the sweetcorn plant. When the cobs have developed and are ready to
harvest, the green peel is often discarded. However, skilled artisans are making good
use of this material by drying and browning the husks in the sun (Bomzer, 2022). In
addition, corn husks are widely used to enclose items that will be steamed or baked,
adding a subtle corn flavor. Corn husks can be used to garnish a dish, but they are not
edible and should be removed afterward.

Figure 2.5 Corn Husk

Source: Bomzer, R. (2022)

2. Classification of Corn
a. Yellow Corn
The flint corn is a variety of maize that stands out from the others by appearing
tougher and shinier. It contains much more natural sugar than white flint. It has a more
rounded, smaller form. Specifically, yellow flint serves as a base material for alcoholic
beverages like beer. Distillers' dried grain with soluble (DDGS), a byproduct of the
ethanol production process, is exported as a feed ingredient. High fructose corn syrup, a
less expensive and sweeter alternative to cane sugar, can also be made from it as the
raw material. Yellow corn embryos can also be used to extract cooking oil. The use of
maize as a raw material in food, feeds, industrial, and medical goods has led to yellow

21
 corn's breeding and yield being significantly improved over other varieties (Salazar et al.
2021).
The chemical properties of corn are presented in Table 2.2. The mean moisture
content of yellow flint corn on a wet basis was found to be 76.14 ± 0.01d1%. The mean
value of protein content of yellow flint corn was found to be 7.16 ± 0.01d1%. The mean
value of fiber content of yellow flint corn was estimated to be 21.18 ± 0.03d1% and the
mean value of ash content was 1.92 ± 0.02d1%. The carbohydrate content of sweet corn
was determined to be 50.80 ± 0.02d1%.

Table 2.3 Chemical Properties of Yellow Flint Corn

Parameter Value

Moisture,% 7.62 ± 0.01d1

Protein, % 7.16 ± 0.01d1

Fiber,% 21.18 ± 0.03d1

Ash, % 1.92 ± 0.02d1

Carbohydrates 50.80 ± 0.02d1

Source: Prasanthi et al., (2017)

And, there are four types of carbohydrates when the yellow corn undergoes to milling
and converts it into starch. According to Nedwin et al. (2014), those carbohydrates are the
glucose, maltose, and oligosaccharides which are composed of 0.30%, 2%, and 97.70%
respectively.
Table 2.4 Carbohydrates Content of Yellow Flint Corn

Carbohydrates Value

Glucose, % 0.30

Maltose, % 2

Oligosaccharides, % 97.70
Source: Nedwin et al., (2014)

22
 In producing HFCS 55, glucose is the main carbohydrate required. To increase the
amount of glucose, enzymatic hydrolysis is one of the methods to used. Based on the study of
Petride (2020), after saccharification of the starch, the amount of glucose increased because
the oligosaccharides is converted into glucose. With this, the resulting carbohydrates
components of the starch includes glucose and oligosaccharide which values are 99.7% and
0.03%, respectively.

Table 2.5 Carbohydrates Content of Yellow Flint Corn after Enzymatic Hydrolysis

Carbohydrates Value

Glucose, % 99.7

Oligosaccharides, % 0.03
Source: Petride (2020)

b. White Corn
In the country, white flint is utilized for food. After removing the outer coat and
embryo, the remaining hard starchy component is milled into the proper size grits. White
flint corn is primarily consumed in mountainous parts of Visayas and Mindanao in the
Philippines. According to PSA (2015), per capita consumption of corn per year was only
14 kg in 2006, rising to 22 kg in 2014. This is just around 20% of what rice (114 kg) was
in 2014 (Salazar et al. 2021).
According to the study conducted by Amantea et al., (2012), the physical
properties of corn are presented in Table 2.3. The specific heat capacity of dry corn was
found to be 1122 J kg-1 K, latent heat of vaporization of corn kernel (J kg-1) was 3638548
- 4000720 M - 3529.08 T. The corn kernel area per unit volume was computed to be 784
3
m2m-3, dry corn kernel density was 620kg/𝑚 , the corn bed porosity was found to be
0.44, and the corn kernel heat transfer coefficient was computed to be 31.5 W m-2 K.

23
 Table 2.6 Physical Properties of Corn

Parameter Value

Specific heat capacity of dry corn (J kg-1 K-1) 1122

Latent heat of vaporization of corn kernel (J kg-1) 3638548 - 4000720 M - 3529.08 T

Corn Kernel area per unit volume (m2m-3) 784

Dry corn kernel density (kg/𝑚 )

3 620

Corn bed porosity 0.44

Corn kernel heat transfer coefficient (W m-2 K-1) 31.5

Source: Amantea et al., (2012)

24
 B. Production of Corn in The Philippines
Table 2.7 Historical Production of Corn per Region in the Philippines
REGION YEAR
(METRIC TONS) 2017 2018 2019 2020 2021
CAR 242,850.00 207,439.20 232,350.58 244,550.47 216,066.47
Region I-ILOCOS 556,462.00 560,885.00 574,852.00 563,388.00 571,259.15
Region 1,837,480.34 1,625,325.36 1,866,918.34 1,861,855.63 1,891,169.70
II-CAGAYAN
VALLEY
Region 258,746.00 271,944.50 284,714.54 274,274.82 323,002.68
III-CENTRAL
LUZON
Region IV 92,762.15 91,418.06 69,786.67 75,761.11 67,145.22
A-CALABARZON
Region IV 121,098.00 130,146.41 106,939.80 121,201.15 115,297.47
B-MIMAROPA
Region V-BICOL 287,005.00 279,731.94 248,242.62 282,000.57 292,748.28
Region 301,286.00 310,838.81 313,974.95 320,379.86 351,433.67
VI-WESTERN
VISAYAS
Region 1464,70.00 127,602.00 105,584.25 127,595.33 107,314.00
VII-CENTRAL
VISAYAS
Region 73,481.00 74,197.26 74,220.40 73,122.83 63,190.57
VIII-EASTERN
VISAYAS
Region 234,455.00 258,909.87 184,636.71 168,854.81 195,571.69
IX-ZAMBOANGA
PENINSULA
Region 1,287,303.00 1,289,538.00 1,312,925.80 1,338,165.21 1,455,030.45
X-NORTHERN
MINDANAO
Region XI-DAVAO 256,735.00 274,674.71 244,810.36 261,923.15 266,894.04
Region 1,257,177.00 1,231,074.00 1,108,187.29 1,108,972.45 1,105,238.85
XII-SOCCSKSARG
EN
CARAGA 119,980.00 135,626.55 135,727.21 157,639.11 141,648.84
ARMM 841,618.00 902,566.96 1,114,973.03 1,138,861.40 1,137,310.72
Source: Philippine Statistics Authority (2021)

USES OF CORN
Corn is one of the most productive and dominant crops in the world. It is widely grown for
human and livestock food, as a biofuel, and as a raw material in industry. Corn comprises
greater than 96% of U.S. feed grain consumption and production. Consequently, animal feed
accounts for roughly 40 percent of the country's corn consumption. This is due to the fact that
corn is a rich source of carbohydrates, and when combined with the protein found in soybeans,
it can serve as an excellent animal feed. In the United States, vehicles are required to utilize a

25
mixture of gasoline and biofuels such as ethanol, 94% of which is derived from the starch in
corn grain, per federal regulations. Therefore, a significant amount of U.S. corn is used to
produce ethanol.
In addition, the ethanol distillation process generates a co-product known as dried
distillers grain, which serves as low-cost, protein-rich animal feed. Each week, the ethanol
industry in the United States produces around 90,000 tons of distillers grains. Animal feed and
ethanol production account for around 73% of maize consumption in the United States. Other
applications of corn include the manufacture of sweeteners, starch, cereal, and alcoholic
beverages such as whiskey (Bhutada, 2021). Many components of the corn plant are used in
industry, and certain maize varieties are grown primarily for industrial use. Wet milling, in which
the grain is steeped in a dilute sulfurous acid solution; dry milling, in which the corn is subjected
to a water spray or steam; and fermentation, in which starches are converted to sugars and
yeast is used to convert the sugars to alcohol.
Moreover, cornstarch (which is made from wet-milled corn) can be converted into corn
syrup, a common sweetener that is less expensive than sucrose. Corn syrup is available in two
varieties: light and dark. Light corn syrup has been clarified and decolorized and is used in
baked goods, jams & jellies, and a variety of other foods. It is highly regarded as a component in
sweets since it does not crystallize when heated. Dark corn syrup is sweeter than light corn
syrup and is prepared by blending corn syrup, molasses, and caramel coloring. Dark corn syrup
is used in the same manner as light corn syrup, as well as as a table syrup. Corn syrup can be
processed further to produce high-fructose corn syrup, which is widely used in processed goods
such as soft drinks and candy (Malcolm, n.d.).

26
 II. PRODUCTS: HIGH FRUCTOSE CORN SYRUP AND CORN OIL

SUGAR
Sugar is a natural ingredient that has always been in every person’s diet. It is also one of
the world’s oldest documented commodities (Helen Bond, 2014). According to Manju Malhi of
Making Sense of Sugar, when the Persian Emperor Darius invaded India in 510 BC, he
discovered cane sugar. While the finished product was exported, the secret of cane sugar was
kept closely guarded. When the Arabs invaded Persia in 642 AD, they discovered sugar cane
growing and learned how to make it. As their conquests continued, they established sugar
production in other lands, including North Africa and Spain.
Furthermore, as Dr. James Russell stated, the first sugar was recorded in England in
1069, and European sugar was refined for the first time in the 15th century AD in Venice.
Columbus sailed to the Americas in 1493, bringing sugar cane plants to the Caribbean. Sugar
beet was discovered as a source of sugar in 1747, but it was kept a secret until the Napoleonic
Wars at the beginning of the nineteenth century.

Figure 2.6 Sugar

Source: Rabideau, 2019
Sugar is an important crop in the Philippines, and while it is grown throughout the
country, it is most abundant in the Visayas, particularly on Negros Island. Sugarcane production
was $815 million in 2020, making it the fifth most valuable commodity after rice, bananas, corn,
and coconuts. Sugar is mostly consumed locally, with a small amount exported to the United
States as part of the sugar tariff-rate quota. Historically, the Philippines exported more than half
of its sugar production to the United States, but exports have declined significantly as domestic

27
demand has increased. The Philippine allocation for Fiscal Year 2021 is 138,154 metric tons of
commercial weight. The United States is currently the sole export market for Philippine raw
sugar, which is used by several west coast sugar refineries (USDA, 2021).
Natural sweeteners are those that are derived from fruits, vegetables, nuts, seeds, and
roots without the use of chemicals. Raw honey, maple syrup, and molasses are a few examples.
Bees make raw honey from floral nectar, and it contains antioxidants, like Vitamin C. Maple
syrup, on the other hand, is made from the sap of maple trees and has less calories and a
higher mineral concentration than honey. Blackstrap molasses has high levels of calcium,
magnesium, potassium, and iron. Natural sugar-containing foods, such as fruits, are more
nutritious than pure table sugar because they contain vitamins and fiber that aid digestion, and
they may have a lower glycemic load. These are healthier alternatives with less calories than
table sugar, but they can still cause rise in blood sugar and weight gain if consumed in high
quantities (Uy, 2020).

HIGH FRUCTOSE CORN SYRUP

A. Historical Background
Richard O. Marshall and Earl R. Kooi invented HFCS in 1957 after discovering the
enzyme glucose isomerase. The enzyme altered the composition of glucose in corn
syrup, converting it to fructose. From approximately 1975 to 1985, it was quickly added
to numerous processed foods and soft drinks in the United States. Coca-Cola and Pepsi
still use sugar in other countries but converted to HFCS in the United States owing to
rising sugar costs. HFCS is found in virtually every packaged food and soft drink. In the
American market, HFCS has replaced higher-priced sugar in a range of applications,
including the beverage business (41%), processed food makers (22%), cereal and
pastry producers (14%), multiple-use food manufacturers (12%), dairy sector (9%), and
confectionery industry (1%) (Beau, 2020).
According to Reshanov (2012), the process of producing high fructose corn syrup
begins with the manufacturing of syrup from cornstarch. This initial stage corn syrup is
mainly glucose and is available in supermarkets. This syrup is then isomerized (atoms
are moved about) in order to convert some of the glucose into fructose. The method was
first introduced in 1957, but it did not take off immediately. There are three varieties of
high fructose corn syrup available, each named after its fructose content: HFCS-42 (42%

28
 fructose), HFCS-55 (55% fructose), and HFCS-90 (90% fructose). The first was
HFCS-42, which is still used in processed foods and some beverages today.
The fructose component of HFCS-90 is retained by passing HFCS-42 through an
ion exchange column. The resulting primarily-fructose product is not utilized as a
sweetener, but rather is combined with HFCS-42 to produce HFCS-55. The
intermediately sugary HFCS-55, developed in the late 1970s, is the most widely used
sweetener in soft drinks in the United States. This fine-tuning of HFCS production
occurred at a time in US history when sugar was getting more expensive (owing in part
to trade restrictions) and corn was becoming cheaper. Farm subsidies that encouraged
farmers to produce as much maize as possible resulted in an excess supply and, as a
result, falling prices. Switching to corn-based products could save manufacturers money.
Coca-Cola first used HFCS in its beverages in 1980, and by the mid-1980s, most other
soft drink companies had followed suit (Reshanov, 2012).

B. Description
According to the Corn Refiners Association, (2022), all maize sweeteners are
natural and have significant advantages, such as stability and crystallization control.
However, each form of sweetener offers varied attributes to food manufacturers, such as
varying amounts of sweetness, a variety of caloric values, and other significant
properties. Corn sweeteners serve major roles in consumer and industrial products due
to their wide range of helpful qualities. Different sweeteners, for example, increase the
pliability of leather during the tanning process and prevent shoe polish from caking.
Speciality maize sweeteners are used to bind industrial components and to produce
value-added specialty biochemicals such as amino acids, sugar alcohols, organic acids,
antibiotics, and enzymes. The most common corn sweetener is high fructose corn syrup.

29
 Figure 2.7 High Fructose Corn Syrup
Source: Villines, Z. (2019)

Corn syrup is a liquid sweetener derived from corn starch that is used in a wide
range of culinary applications, including the production of confectionery, jams, jellies,
frostings, and baked products such as cookies, pies, and cakes. Corn syrup is made up
of pure glucose, a simple sugar, as opposed to table sugar, which is made up of
sucrose, a disaccharide composed of glucose and fructose (Alfaro, 2022).
According to the Center for Food Safety and Applied Nutrition (2018), corn syrup
is the result of breaking down corn starch into individual glucose molecules. Fructose is
a simple sugar that is found in fruits and berries and is used to manufacture high
fructose corn syrup (HFCS). To make HFCS, enzymes are added to corn syrup to
convert some of the glucose to fructose. When compared to the glucose content of corn
syrup, HFCS is "rich" in fructose. The amount of fructose in various forms of HFCS
varies.
However, corn syrup and high fructose corn syrup are different from each other.
Both products are made from corn starch, but corn syrup is 100 percent glucose,
whereas high-fructose corn syrup (HFCS) contains some glucose that has been
enzymatically transformed into fructose. Because it is a less expensive ingredient to
produce than sucrose or traditional sugar, high-fructose corn syrup is utilized in many
commercially manufactured foods and soft drinks (Fernandez, 2022). Furthermore, corn
syrups are sweeteners that contain less than 66 dextrose equivalent (DE) while high
fructose corn syrup is usually greater than 95 DE (Helstad, 2019).

30
 Based on the Code of Federal Regulations, the two most prevalent types of
HFCS comprise either 42% or 55% fructose; they are known as HFCS 42 and HFCS 55,
respectively, in the food sector. Glucose and water make up the rest of the HFCS. A lot
of processed meals, cereals, baked products, and drinks include high-fructose corn
syrup, or HFCS 42. Soda drinks are the most common application for HFCS 55. One of
corn syrup's primary functions is in the food industry. The U.S. Food and Drug
Administration (FDA) regulates its manufacture and distribution, enforcing stringent
quality controls. The Maize Refiners Association, an organization of the industry's
leading corn refiners, has developed rigorous analytical processes for evaluating the
quality of corn products like corn syrup. Corn syrup's sweetness, solubility, viscosity,
acidity, and dextrose/fructose/solids content are all noteworthy qualities. Manufacturers
also routinely take samples of final corn syrup for analysis, in addition to monitoring raw
materials and production processes.
Sweeteners like high-fructose corn syrup are frequently used in carbonated and
fruit-flavored beverages. The prevalence of obesity and its associated health issues has
risen in tandem with the widespread usage of high-fructose corn syrup. It's been
questioned whether or not there's any link. High-fructose corn syrup shares many of the
same chemical properties as regular sugar. However, it's debatable whether or not the
human body treats high-fructose corn syrup any differently than regular table sugar
(Zeratsky, 2018).

C. Application
In 2011, the United States produced around 11 million metric tons of dry-weight
corn syrup. High-fructose corn syrups accounted for almost 70% of total output (HFCSs).
Maize syrup production and consumption have expanded in recent decades as the soft
drink industry prefers to employ sweeteners rather than crystallized cane or beet sugar.
Maize sweeteners are chosen over sucrose because they dissolve quickly in water, are
easier to mix into soft drinks, and provide a fruit taste to beverages and meals. At equal
concentrations, HFCSs with 90% fructose provide 1.7 times more sweetness than
sucrose. HFCS is used as a table sugar alternative, particularly in soft drinks. The
fundamental benefit of utilizing HFCS is that it dissolves well in water, is easily flavored,
and imparts a sweet fruit flavor to beverages and meals (Saldivar, 2016).

31
 Table 2.8 Physicochemical Properties of High Fructose Corn Syrup

Parameters Value

Molecular Formula C6H14O7

Molecular Weight 198.17

Appearance Clear to light straw liquid

Form Liquid

Odor No detectable foreign odors

Ash % Trace

Moisture % 22.5-23.5

Dry Substance % 76.5-77.5

pH 3.3-4.3
Source: T. M. A. Mahmoud (2014)

CORN OIL
A. Historical Background
Corn oil is a light yellow oil extracted from corn kernels. In 1889, the first commercial
manufacture of corn oil began. Corn oil that has been refined is tasteless and odorless.
Moreover, it is used for cooking and the production of hydrogenated oil. According to Gustav
Heess (n.d.), the grain species maize originated between Mexico and Peru, although its original
wild form cannot be known due to the fact that cultivated maize was rapidly selected from wild
maize species. In caves in southern Mexico, domesticated versions of wild maize were
discovered and dated to between 5,000 and 3,000 B.C. In Indian mythology and religion, corn
also plays a part. When the Spanish introduced corn to Europe about the year 1500, they took
the word "mahiz" from the natives of the Caribbean islands. Corn was regarded as a specialty,
although it was not grown in Europe until the 17th century. Through Italy, the Balkans, and
Russia, it arrived in India and China. Since World War II, the plant, which is actually tropical and
subtropical, has been globally cultivated. However, it is valued as cattle feed, a source of protein
(polenta, tortillas, corn, popcorn), and starch (pudding, starch flour, fine pastries and as a
thickener for soups and sauces as well as cornflakes).

32
 B. Description
Corn oil is an edible oil extracted from the kernels of corn (maize) that is valued for its
mild flavor and light color. The oil comprises approximately half of the germ (embryo) of the corn
kernel, which is separated from the rest of the kernel during milling to generate meal, animal
feed, hominy, breakfast foods, and other edible solids. The corn germ is dried in a kiln, and the
oil is extracted using either a hydraulic or a screw press; the pressed cake is then washed with
a solvent, often hexane, and the dissolved oil is recovered by evaporating the solvent. After
solvent extraction, the remaining oil cake is crushed into animal feed known as hominy feed
(Britannica, 2021).

Figure 2.8 Corn Oil

Source: Gustav Heess (n.d.)

Corn oil is a great source of essential fatty acids, which typically account for more than
60% of its overall composition, with linoleic acid (C18:2) accounting for the majority and
α-linolenic acid (C18:3) contributing for less than 1.5%. As a result, it cannot be considered a
dietary source of omega-3 fatty acids. Oleic acid is the second most abundant fatty acid. There
are some recently discovered high-oil corns that contain comparable levels of linoleic and oleic
acids; thus, breeding for high-oleic corns is a possibility. Corn oil was widely employed in
research on the association between dietary fat and blood cholesterol levels in the mid-1950s
because it was the only highly polyunsaturated and non hydrogenated oil readily available to
researchers and patients. Corn oil has become the foundation for cholesterol lowering due to its
excellent stability, pleasant taste, and wide range of applications (Serna-Saldivar, 2019).

33
 Table 2.9 Physicochemical Properties of Corn Oil
Parameters Value
Physical Description Liquid
Percent Composition Glycerides of fatty acids: 95-99%; unsaponifiable
fraction: 1-3%; phospholipids: 0-2%
Boiling Point 230 to 238° C
Melting point Solidifies at −18 to −10 °C
Density 0.916-0.921 at 25°C
Vapor Pressure 3.18 x 10-11
Viscosity η = 70 mPa·s at 20°C
Flammability Flash point: 254°C
Octonol/Water (Kow) coefficient 1.86
Storage stability On prolonged exposure to air it thickens and
becomes rancid
Solubility Slightly soluble in alcohol
Source: Baker, B., & Grant, J. (n.d.)

The oil contains the following fatty acid glycerides: myristic 0.1-1.7%, palmitic 8-12%,
stearic 2.5-4.5%, hexadecenoic 0.2-1.6%, oleic 19-49%, and linoleic 34-62% (Merck, 2015).
When compared to other commercial vegetable oils, the unsaponifiable portion ranges between
1-3%. The unsaponifiable part of crude kernel oil contains phytosterols such as γ-tocopherol,
which accounts for 0.58-1.05% of crude kernel oil, followed by α-tocopherol at 0.07-0.25%. The
rest consists primarily of isomeric sitosterols and waxes such as myricyl and ceryl alcohols.
Ferulic acid is an antioxidant found in maize oil that forms an ester with ß-sitosterol. Up to 2%
phospholipids in the form of lecithin and inositol esters can be found in crude corn oil (Baker, B.,
& Grant, J. (n.d.).

C. Application
Corn oil is a refined vegetable oil that is commonly used in cooking, particularly deep
frying. It has numerous different applications and is often employed in industry or as a cosmetic
ingredient. To produce corn oil, corn must go through a thorough refining process. Corn oil is
useful in both cooking and non-cooking purposes. It is used as an industrial cleaner and
lubricant, as well as in the production of fuel for gasoline and diesel engines. It's also found in a
variety of cosmetics, liquid soaps, and shampoos. It is still best known as a frying oil. It has a
very high smoke point (the temperature at which oil begins to burn) of around 450°F (232°C),
making it suitable for deep-frying foods to perfect without burning them (Shoemaker, 2019).

34
III. MANUFACTURING PROCESS
A. CORN MILLING
According to Hockmeyer Equipment Cooperative, milling is the use of mechanical
energy to break down particles through various mechanical forces including grinding
media, pegs, rods, pebbles, and screens. When the material is pumped through the mill,
the mill’s components act on the solids in the mixture to tear them apart or crush them,
further reducing them in size. The industrial milling process helps to maximize the yield
of the mix’s ingredients and can improve the resulting product’s functionality as well.
One of the applications of this process is in corn milling, which can be used in the
production process for ethanol extraction from starch or grits, meal, flour, and other
co-products. There are two distinct processes for processing such as corn wet-milling
and dry-milling (O’brien et al., n.d) which will be discussed below to assess what are the
most suitable methods to employ for the Rugí manufacturing plant.

1. Wet Milling Process

The wet milling process is mainly used for the extraction of starch from maize but
recently, its use has been extended to the separation of different fractions of grains in
cereals and pseudocereals. According to Cruz-Requena (2019), wet-milling methods use
water for fiber extraction but differ in the reagents and conditions employed. There are
different wet-milling methods, such as conventional, alkali, enzymatic, and modified wet
milling. Steeping, germ recovery, fiber recovery, protein recovery, and starch washing are
the five stages of maize wet milling. Each of these parts has its own set of equipment
and goals, but they are all linked by the flow of process water (Rausch, 2016).

Wet milling methods according to Cruz-Requena (2019):

a. Alkali wet milling
According to Du et al. (2018), an alkali corn wet-milling process was developed to
evaluate the process as a method to produce high-purity cornstarch and coproducts with
added value. This method consists of soaking the raw material in NaOH (pH 13) at 85°C.
Then, raw material is de-branded, cracked, and steeped in NaOH at 45°C, then ground
to a powder, which is next mixed with NaOH, ground, and sieved. Finally, the residue is
collected (Eckhoff et al., n.d).

35
 b. The enzymatic wet milling
Enzymatic milling is a modified wet-milling process that uses proteases to
significantly reduce the total processing time during corn wet milling and eliminates the
need for sulfur dioxide as a processing agent (Singh, n.d). The most common enzymes
used are proteases, which solubilize and hydrolyze the gluten matrix (protein);
α-amylase, which gelatinizes, hydrolyzes, and depolymerizes starch; and
amyloglucosidase, which disintegrates starch fragments to glucose. The NSP can be
recovered by precipitation with ethanol (Ramírez et al., 2012).

c. Modified wet milling

This technique involves the use of water and produces products with high purity.
This method, used for food applications, grinds the raw material into small particles to
increase the surface area. Then, the protein is extracted at an alkaline pH and followed
by acid precipitation. This method separates insoluble fiber using the differences in
swelling properties of the fraction. At room temperature, fiber has a higher swelling
capability than starch. Such differences in swelling capability give rise to different particle
sizes (Rodríguez-Herrera et. al., 2019). The insoluble fraction is dispersed in water and
screened through sieves with pore diameters in a range from 30 to 300 μm. The
supernatant is mainly a dispersion of starch granules, and the residue is fiber (Maphosa
& Jideani, 2016).
Moreover, the conventional wet-milling process involves the soaking of raw
materials in a sulfuric acid solution. Then the co-products and starch are physically
separated. Traditional wet-milling processes take up to 36 h to be completed.
Wronkowska and Haros (2014) used wet milling for starch extraction and found that this
method did not change the properties of starch compared to raw material. And this
method has been widely used in the starch and glucose industry as it produces 99%
purity of the starch.

Process of Wet Milling:

36
 Figure 2.9 Wet Milling Process
Source: Rausch (2016)
Steeping
Steeping is crucial to corn wet milling and will be covered in greater depth than
the other topics. If steeping is done properly, good starch recovery may be achievable if
downstream processing is done correctly. If corn is not steeped properly, no amount of
downstream processing can compensate. Steeping is a separate process that involves a
series of chemical and biological reactions, mechanical pressures, leaching, and kernel
hydration (Rausch, 2016).

Germ Recovery
After steeping, the initial goal is to recover the swollen germ. The germ is an
oil-soaked sponge, it is removed as early as possible in the process to optimize oil
recovery, and avoid the oil from interfering with subsequent separation phases,
particularly starch recovery. When used correctly, mechanical shear can separate the
germ from the other components while causing little damage to the germ itself (Rausch,
2016).

Fiber Recovery
The fiber recovery functions in allowing starch and protein that have already been
released from the fiber to travel directly to the mill stream thickener (MST) in the protein
recovery stage of the process. The screen-retained material is put through a double-disk
refiner mill to extract any leftover starch from the weakened protein matrix (Rausch,
2016).

Protein Recovery

37
 Protein separation is based on the density differential between the starch and the
protein. Starch has the highest density of the residual maize kernel components and the
lowest density of any cell wall or fiber that goes through the pressure-fed screens
(Rausch, 2016).

Starch Washing
Starch washing is the final step in the wet milling process and the only time
freshwater is introduced into the system. Starch washing is done counter currently with
10-14 steps of hydro cyclones. Each stage of the starch-washing system comprises
enough hydrocyclones to manage the starch slurry flow rate at that point (Rausch,
2016).

2. Dry Milling Process

Dry milling is the simplest method of producing maize products for human
consumption. According to Rausch (2016), the maize dry milling process attempts to
fractionate the maize kernel into the germ, pericarp, and endosperm components. There
are three different dry milling processes of corn.

Figure 2.10 Dry Milling Process

Source: Rausch (2016)

a. Stone Grinding
The oldest dry milling technique is also known as whole-kernel dry milling or
full-fat dry milling (Eckhoff, 2016). Whole kernel dry milling does not seek to fractionate
the maize kernel, but rather to grind it into uniformly sized particles, typically flour or
meal. The term "stone ground" refers to the process of grinding maize into flour or meal
using two stone grind plates. Other particle size reduction devices, such as hammer

38
 mills, pin mills, and disk mills, can be used to produce this meal or flour. The
distinguishing feature of this dry milling type is that nothing is separated during the
process, and the finished product is used for human nutrition. Because the germ has not
been separated from the other components, the products are commonly referred to as
"full fat" flour or "full fat" meal.

b. Hammer Milling
A hammer mill is used to grind maize to the desired particle size prior to jet
cooking, liquefaction, saccharification, and fermentation. To avoid confusion, this process
is now known as "Dry Grind Ethanol." The dry grind process results in coproducts that
are entirely different from other processes, primarily the production of fuel ethanol and
distillers' dried grains with solubles (Rausch, 2016).

c. Degerminated Dry Milling

This process attempts to remove the germ and coarse fiber (or pericarp) from the
collection of grits, meals, and flour that is left. Degerming improves the shelf life of
endosperm products by removing the bulk of the oil in the maize kernel (∼75%).

Comparison of Wet and Dry Milling Processes

Wet milling is a process that disperses particles suspended in a liquid slurry through
shearing or crushing (Sharma, 2021). After milling, these particles are ready for use or can be
dried and separated for incorporation into other products. Wet milling is more complicated than
dry milling because of the addition of a liquid, but it also has the ability to reduce a product into
finer particles. Furthermore, AMG Incorporated, a consulting engineering firm, stated that the
wet milling process is capital-intensive with higher operating costs because the ability to
produce a variety of products can be valuable in dealing with volatile markets. As it allows for
the creation of a wider range of byproducts such as corn steep liquor and dried starch which are
marketed to the food, paper, and textile industries (Aziz, 2018).
Dry milling, on the other hand, uses no liquid element and is most commonly used for
particle size reduction of dry materials such as powders and granules, as well as
de-agglomerating and de-lumping bulk materials (Deshengrui Machineries, 2020). It is less
versatile and less capital-intensive as it focuses primarily on grain ethanol production. Moreover,
in recent years, dry milling processes have been introduced following the hammer milling

39
operation in an effort to generate income from higher-value co-products (AMG Inc., n.d). As a
matter of fact, various processing operations have been introduced to remove non-fermentable
components of the corn kernel with varying degrees of success. These dry milling efforts always
result in co-products with less purity than those produced by the corn wet milling process.
Consequently, the ethanol yield from a dry grind wet milling process is negatively impacted as
the result of fermentable starch exiting the process with the co-products.

B. PRODUCTION OF HIGH FRUCTOSE CORN SYRUP

Corn syrup is a generic name for a whole spectrum of nutritive sweeteners prepared
from corn starch. According to Mills (2022), corn syrup products may be manufactured with a
wide range of sweetness depending on the degree of starch hydrolysis and dextrose
isomerization to fructose. He also added that high fructose corn syrup with a sweetness of about
130 is made by complete hydrolysis of corn starch to dextrose and maximum enzymatic
conversion of dextrose to fructose. Low sweetness corn syrup products would be manufactured
using only partial hydrolysis of corn starch to dextrose and no conversion of dextrose to
fructose. In this study, the Rugí will produce High Fructose Corn Syrup. Below are the different
processes to produce HFCS to evaluate the most suitable process for the manufacturing plant.

Hydrolysis
a. Enzymatic Hydrolysis
HFCS can be obtained by two different methodologies of hydrolysis: enzymatic
hydrolysis and acidic hydrolysis followed by enzymatic hydrolysis. Enzymatic hydrolysis
is considered the most promising method for the saccharification of biomass, in which
polysaccharides are hydrolyzed into monosaccharides that can be subsequently
converted to biofuels by microorganisms (Wang et al., 2021). Compared to traditional
acid hydrolysis, enzymatic hydrolysis needs less energy and milder operational
conditions (approximately under the temperature of 40–50°C and pH of 4–5).
In this method, the conversion of HFCS from starch is carried out using several
steps: liquefaction, saccharification, and isomerization (Abadalla et al., 2014). Below is
the process description of this method.

i. Liquefaction

40
 Liquefaction is the hydrolysis of the starch to oligosaccharides: glucose polymers
of up to ten glucose residues. In this step, the starch was gelatinized by thermal
treatment and treated with alpha-amylase to produce a maltose and glucose mixture
from the solution. Liquefaction lowers the viscosity of the solution. This means the more
specialized reactions occurring in the next step can be more easily controlled.

(C6H10O5) n +n H2O → nC6H12O6 Starch oligosaccharides (D-glucose)

ii. Saccharification
The saccharification step was carried out with glucoamylase producing pure
glucose syrups from the mixture obtained in the previous liquefaction step.

iii. Isomerization
The isomerization converts glucose into a glucose and fructose mixture. This is
done by suspending the enzyme glucose isomerase in a gel column and running the
glucose through the enzyme. Once the glucose is run through the gel column a mixture
containing approximately 42% fructose and 52% glucose, known as HFCS-42, is
produced.
iv. Carbon Treatment
Carbon decolorization, with granular or powdered carbon, is an effective and
common method used to remove organic impurities. Due to the corn refiner’s scale of
operation, granular carbon is most commonly used. The typical granular carbon
decolorization unit is a pulsed-bed column through which the syrup is pumped at a
temperature of 70–80°C (Helstad, 2019). The porous carbon granule has a large surface
area, effective at trapping and removing color bodies.
v. Demineralization
Demineralization systems are used to remove color bodies and impurities from
sweeteners. It typically follows carbon treatment and consists of alternating beds of
anion and cation removal units (Helstad, 2109). In addition to removing salts, these
resins are very effective at removing proteins and other color bodies and precursors. As
a result, ion-exchanged syrups tend to have better color and color stability than the
equivalent nonion-exchanged products.
vi. Evaporation

41
 Evaporating of finished syrups takes place in multiple-effect falling-film, vapor
recompression, or mechanical recompression evaporators. The syrup is evenly
distributed to a series of tubes. During the process of flowing down the walls of the tubes
under vacuum, a portion of the water vaporizes, and the remaining liquid discharges at
the bottom of the tube. By using multiple effects, where each stage boils at lower
pressure and temperature, it is possible to reduce unwanted color development in the
syrup to levels below that which can be achieved by using a single-effect process
(Helstad, 2019).

vii. Mixing of HFCS 42 and HFCS 90

HFCS 55, is considered to have the same taste as sucrose. By mixing the
enriched 90% fructose with the 42% fructose product, a blended product containing 55%
fructose and 40% dextrose is produced (Chen, 2015). Both 42% and 55% HFCS are
widely used in many food applications to replace sugar. However, the beverage industry
is the largest consumer of both 55% and 42% HFCS, these products are manufactured
to meet the guidelines established by the International Society of Soft Drink
Technologists (ISBT) (Helstad, 2019).
b. Combination of Acidic and Enzymatic Hydrolysis
Acid hydrolysis can be used for the preparation of monosaccharides.
Hydrochloric acid, sulfuric acid, trifluoroacetic acid, formic acid, and nitric acid are
commonly used in acid hydrolysis (Chen, 2015). Compared with other methods, acid
hydrolysis results in a higher sugar yield and good reproducibility. In this method, the
starch will undergo acid hydrolysis and isomerization to produce HFCS.
i. Acid Hydrolysis
In this step, the corn starch will be treated with dilute hydrochloric acid, and then
the mixture will be heated at temperatures of 130-170°C under pressure, and acidic
conditions (pH 4.5-5). The amount of HCL needed is 35% of the amount of starch
entered. The obtained syrup will be purified and concentrated under a vacuum to raise
the solid concentration.
ii. Isomerization
The glucose isomerase is an enzyme that converts glucose to high fructose corn
syrup 90 and the enzyme comes in solid form, because of the high cost of glucose

42
 isomerase, the enzyme must be reused HFCS-90 blending with glucose syrup to
produce HFCS-55 (55%fructose).

Table 2.10 Comparison of Enzymatic Hydrolysis and Combination of

Acidic and Enzymatic Hydrolysis

Methods Advantages Disadvantages

1. Ability to work under mild 1. High operating cost.

conditions. 2. Have a high purification
2. Increasing reaction rate and standardization.
3. Operates without
contamination by
microorganisms
Enzymatic Hydrolysis 4. Requires simple
equipment
5. Easily controlled and can
be easily stopped when the
desired degree of
conversion is reached.

1. Higher sugar yield 1. Inducing the formation of

2. Good reproducibility coloring and flavoring
substances as well as
other contaminants such
as furfural, levulinic acid,
Combination of Acidic and and formic acid (which of
Enzymatic Hydrolysis all give in high refining
costs).
2. Lack of process control.
3. Unsafe process.

High-Fructose Corn Syrup Manufacturing Process

1. Gelatinization
In this phase, starch will not precipitate even if the liquid is not stirred; this process is
known as gelatinization. Also, starch milk refers to a clear and viscous liquid. In general, the
starch slurry can be thoroughly gelatinized at 85 °C for 5 minutes. Therefore, at the point of
enzyme injection, it is assumed that the starch slurry is completely gelatinized.

43
 a. Mixing tank
To make starch milk, combine the starch and water to make a dense slurry, then
add enzymes and regulate the PH and temperature. The starch will not precipitate at
these conditions since the material used in high fructose corn syrup facilities has been
prepared for glucose production.

b. Tank Agitators
Tank agitators are pieces of equipment that allow you to mix different
components in an industrial process. Its purpose could be maintenance,
homogenization, dispersion, dissolution, or heat exchange. With their rotational
movement, they mix low or high-density solids and liquids that require homogenization.

2. Liquefaction
After the mixing tank has completed the biological reaction, the starch milk will be
pumped into the liquefaction process using a pump, corn powder or starch will be sprayed at
high temperature at regular intervals, and the corn powder or starch will be transferred to
glucose slurry. Adjust the PH level to 4.4-4.5 after the process to prepare saccharification.

a. Jet Cooker
The Jet Cooker is a crucial piece of equipment for generating glucose from starch
via an enzyme or acid process. It is commonly used for starch liquefaction in the
production of glucose and fructose. The jet cooker is ideal not only for medium- and
high-temperature enzymes, but also for direct processing techniques used on potatoes,
maize, rice, etc. It is also a type of steam injection that is utilized largely in starch
cooking, wet mill processing of starch, ethanol production, or fructose and alcohol
production. High-pressure steam is injected into the starch or grains as it is pumped
through an orifice.

b. Liquefaction tank & ejector

In a high fructose corn syrup facility, the liquefaction tank consists of a laminar
tank, a maintenance tank, and a neutralizing tank. The liquefaction process converts
starch milk into liquid dextrin. The ejector is used to pump the liquid.

44
 3. Saccharification
Glucoamylase (amyloglucosidase) derived from Aspergillus sp. is added and is often
employed at a pH between 4 and 5 at a temperature of around 60°C. The maximum conversion
rate achievable with these enzymes is approximately 96% in 60–90 hours. Transport the liquid
to the saccharifying tank, adjust the temperature to 60°C and the PH to between 4.2 and 4.8,
then add some saccharifying enzyme and let it sit for 36 to 50 hours.

a. Saccharification tank
After liquefaction, the pH is lowered to 4.2-4.5, and as soon as the solution
temperature reaches 60 °C, glucoamylase is added. Typically, the reaction time for
saccharification is between 24 and 48 hours, depending on the rate of enzyme activity.
Glucoamylase releases single glucose units from the ends of dextrin molecules; syrups
of 95% glucose or higher are generated by the saccharification tank, necessary for
fructose syrup production in high fructose corn syrup manufacturers.

4. Isomerization
Enzymatic isomerization of glucose syrups (DE 95–98; 40–50%, DS) in column reactors
with immobilized enzymes creates high-fructose corn syrups (HFCSs). The pH of reactors is
between 7.5 and 8.0, and the temperature is between 55 and 60°C. For the manufacturing of
high fructose corn syrup, this isomerism is required to convert glucose to fructose. The
employed isomerase is a type of immobilized enzyme. By converting isomerism from a soluble
state to an immobilized form, its stability will be considerably increased, and it can be utilized
repeatedly in the production of high fructose corn syrup. This immobilized enzyme used in food
processing renders food free of enzymes after production, eliminating the requirement for heat
treatment to deactivate enzymes, hence improving food quality and providing economic
benefits.

a. Isomerism system
This process is used to convert glucose into fructose. The isomerism system can
cause the pure glucose solution to be isomerized by a reactor containing immobilized
isomerase in order to produce fructose syrup comprising 42% fructose.

45
 5. Decolorization
Carbon decolorization, utilizing granular or powdered carbon, is an efficient and
widespread technique for removing these chemicals. A typical granular carbon decolorization
unit consists of a pulsed-bed column through which the syrup is driven at a temperature
between 70 to 80°C. Using powdered carbon, syrups can also be decolored using a batch
technique. In this technique, powdered carbon is introduced to the starch hydrolysate in a batch
reactor and allowed to react. After appropriate contact time, the purified hydrolyzate is pumped
through a filter to remove the carbon and is then transferred for additional refining.

a. Pulse Bed System

This equipment constantly decolorizes carbonated beverages as they ascend via
activated carbon-filled columns. The collector at the top of the carbon column discharges
decolorized clear liquor. On a daily basis, the bottom of the column is removed from
used activated carbon, which has lost all of its decolorizing properties. An equal amount
of regenerated carbon is fed to the column from the top at the same time.

b. Carbon Columns
Carbon columns reduce color, taste, odor, and turbidity in liquid sugar, sugar
cane refining prior to beet sugar crystallization, and sweeteners.

6. Filtration
The filter press will then be utilized to separate the syrup from the activated carbon. The
cleaning solution will enter the slot, while the activated carbon will remain within the filter. To
remove impurities such as residual proteins and fats, the raw sugar syrup must be refined. This
is accomplished by passing the solution through a rotating vacuum filter coated with
diatomaceous earth, followed by decolorization with activated carbon. The product is
subsequently concentrated to the appropriate solids level (usually between 75 and 85% solids).

a. Plate And Frame Filter Press

In fact, the filter machine will be employed in the decolorization process at the
high fructose corn syrup manufacturing facility. It is an important piece of equipment for
purifying syrup. The decolorization procedure uses the principle of activated carbon
adsorption to remove the color from a liquid.

46
 b. Rotary Vacuum Filter
A rotary vacuum filter known as a "drum filter" provides further filtration after the
mud centrifuge. The rotary filter is covered with a cloth and coated with a 10- to a 15-cm
layer of diatomaceous earth, precoat, or another suitable filtering media. While the drum
is rotating, the vacuum draws the hydrolysate through the precoat layer. The outer layer
of the precoat gradually becomes clogged as it entraps starch's leftover insoluble
substance. As the drum rotates, a knife continuously removes this thin coating of
material in order to maintain the precoat's flow.

7. Demineralization
To eliminate color bodies and impurities from sweeteners, demineralization
equipment is used. This may be used in conjunction with or in place of a carbon system.
Typically, demineralization follows carbon treatment and consists of beds of alternating
anion and cation removal units. In addition to removing salts, these resins are highly
effective at removing proteins as well as other color bodies and precursors.
Consequently, ion-exchanged syrups have better color and color stability compared to
non-ion-exchanged syrups of comparable composition.

a. Demineralization system
To eliminate anionic and cationic impurities, a demineralization method is utilized.
Automatic control instruments control the Exchange Column. Moreover, in the
sweeteners sector, ion exchange resins used for deashing and mixed bed polishing are
macroporous polystyrene beads that have been functionalized or "charged" to absorb
undesirable ions in the syrup stream. When the syrup is pumped through the resin bed,
the cation column captures the positive ions and the anion column captures the negative
ions.

8. Evaporation
The evaporation of finished syrups occurs in the multiple-effect falling film, vapor
recompression, or mechanical recompression evaporators. A series of tubes receive an equal
amount of syrup. A portion of the water vaporizes as it flows down the sides of the tubes under
vacuum, and the remaining liquid exits at the bottom of the tube. By employing multiple effects,

47
in which each stage boils at a lower pressure and temperature, it is feasible to limit undesirable
color development in the syrup to a level lower than that which can be accomplished with a
single-effect procedure.

a. Falling Film Evaporator

Falling film evaporators can function with relatively low-temperature differences

between the steam and syrup, and their product contact periods are typically under a few
seconds. Due to these characteristics, the falling film evaporator is ideally suited for
heat-sensitive substances. It is currently the most popular form of the evaporator.

b. Plate Evaporator

During the process of plate evaporation, the syrup is pumped between thin plates
with a heating material on the mating surfaces. The subsequent evaporation of syrup
produces a core of high-velocity vapor. This expansion in volume results in the formation
of a high-velocity, thin film on the heat exchange surface, which facilitates effective heat
transfer.

9. Chromatography
A mixture containing 55% fructose, often known as HFCS-55, has the same taste
as sucrose. Liquid chromatography is used to convert a portion of HFCS-42 to HFCS-90
in order to produce HFCS-55. By distinguishing between their distinct structures, liquid
chromatography separates glucose and fructose molecules. After the process of
evaporation, the clean syrup is pumped into an ion exchange column, where the resin
will attract all cations, anions, and other small electrons, resulting in an extremely pure
glucose syrup. This phase in the manufacture of high fructose corn syrup aims to
eliminate impurities and ions to ensure the syrup's purity.

a. Ion exchange column

Ion exchange can remove Ca2+, Mg2+, etc., while the negative ions, pure syrup,
and resin require regeneration by acid and alkali washing after several days of
operation. After the liquid syrup has been processed by the ion exchange column, we
can obtain a product that can be consumed by humans.
b. Chromatography Columns

48
 For large-scale purifying procedures, chromatography is the preferred method. It
allows the separation of the two components using a resin and differences in their
affinities. To attain optimum efficiency on an industrial scale, it is consistently applied.
A continuous chromatographic separation technique separates the isoglucose
syrup into a fructose-rich (90% purity) extract and a glucose-rich (raffinate) fraction. The
raffinate is recycled to the isomerization process, while the extract is mixed with iso
glucose syrup to obtain the desired level of 55% fructose.

10. Mixing
By blending the enriched 90% fructose with the 42% fructose, a product with 55%
fructose and 40% dextrose is produced.

a. Agitators

Agitators utilized in the industrial manufacturing of food and beverages have the
same concept and operating principle. Attached to the central axis shaft, which rotates or
at least agitates liquids, are impellers. In addition, it is difficult for Agitators to combine
dense material. This type of machinery is not advised for extremely viscous substances.
Agitators can perform a variety of tasks, including blending miscible liquids, dissolving
gas in a liquid, connecting or dispersing liquids that cannot combine, suspending
particles in liquids, and transferring heat in agitated liquid.

b. Paddle Mixers

Paddle Mixers are designed to provide effective mixing for a variety of industrial
applications. Its dual-shaft paddle-type agitator is suited for solid-to-solid and
liquid-to-solid mixing of heavy or light materials, respectively. The mixer's specific design
and arrangement of mixing paddles on both shafts create a fluidized zone. With a low
filling ratio, a freely movable mass is produced. In a relatively short period of time,
powders and granules will be optimally dispersed in fluidized zones.

49
C. PRODUCTION OF CORN OIL

Typically, there are two distinct phases in the industrialization of corn oil: the initial
extraction of crude oil, which also produces a corn oil cake coproduct, and the following refining
of the crude oil. Depending on the raw material source, consumer hubs, and final industrial
destination, these processes may be performed in a single facility or in separate locations
(Singh et al., 2011; Shende and Sidhu, 2014).

Degumming
The corn oil and soft water will be mixed with a ratio of 98.8:1. Then, 0.20% w/v
of phosphoric acid will be added to the mixture which will react with free fatty acids in
order to form gums. And, the mixture will be preheated to 100°C and 0.0987 atm for 1.20
hours.
The gums formed are removed in the centrifugation with a loss of 3.88% of the
total mass input.

a. Enzymatic Degumming
The process of enzymatic degumming has only been around for about 20
years. More and more people are turning to the enzymatic degumming process
because it has the potential to increase oil output (Gupta, 2017).

b. Traditional Degumming
Traditional degumming processes like water degumming, acid
degumming, and alkaline degumming have either high oil losses or high residue
phospholipids (Jiang, 2019).

50
 Table 2.11 Comparison of Enzymatic Degumming and Traditional Degumming
Methods Advantages Disadvantages
6. Diglyceride production 3. Because of the high
has significantly price of enzymes,
boosted (DAG). commercial enzymatic
7. The loss of neutral oil in degumming is
the gums has been challenging to
reduced. implement.
Enzymatic Degumming 8. Minimized oil waste 4. enzyme purification
during processing. challenges
9. Reducing the amount of 5. Need for cutting-edge
oil in the dish. machinery.
10. Brings nearly all gums
to a state where they
can absorb water

3. Low-cost material 4. High oil losses.

treatment. 5. High residue
phospholipids.

Traditional Degumming

Neutralization
The degummed oil will be transferred to a second centrifuge. Then, 1.40% w/v of
sodium hydroxide will be added to neutralize the free fatty acids. Next, it will undergo
washing with water at 100°C and 0.0987 atm to produce neutral oil and soapstocks. The
soapstocks will be removed during the centrifugation for 1.11 hours with a loss of 3.66%
of the total mass input.

Bleaching
The washed oil will enter the clarification reactor. Then, 2% w/v bleaching clay
will be added and operate at 95°C with a pressure of 0.05 to 0.2 atm. The reactor will
operate for 1.20 hrs and it contains a cold filter which will aid the clay removal from
bleached oil. Equipment loss is 1.59%.

Dewaxing
The bleached oil will enter the crystallizer through a pipe and 0.50% w/v dicalite
will be added. The operating temperature and pressure during the process is 105°C and
0.07 atm respectively, and will operate for 1.20 hours. The waxes formed will be
separated and the dewaxed oil will proceed to the next refining process. Equipment loss
is 3%.

51
 Deodorization
The dewaxed oil will enter the deaerator to remove the air with an operating
temperature of 110°C and operating pressure of operating pressure of 0.07 atm. Then, it
will proceed to the deodorization tower and 4% of steam will be introduced and
subjected to heating at 220°C and 0.005 atm for 1.20 hours to remove the volatile
odorants from deodorized oil. Equipment loss during deodorization is 3.87%.

Filtration
The deodorized oil will undergo a vacuum filtration system using a polyester felt
filter material, a synthetic felt stronger than filter paper. The filtration will take 1.20 hrs
and the equipment loss is 0.80%. The resulting refined corn oil will have a purity of
98.80% and is comparable to the commercially produced corn oil - of which 98.80% is
the triglycerides content, 0.05% free fatty acids and 1.15% unsaponifiables.

VII. RELATED STUDIES

A. Foreign Literature
TITLE: MAIZE: WET MILLING
REFERENCE: K.D. Rausch, 2016

This study thoroughly explained the wet milling technology including all of its five
sections: steeping, germ recovery, fiber recovery, protein recovery, and starch washing.
Steeping is one of the most important areas of the wet milling process as it will prepare the
kernels for milling, separation, and other processes. The quality of the steeping depends on the
three steeping stages which are lactic acid-dominated, sulfur dioxide diffusion, and sulfur
dioxide reaction. Generally, the steeping process of kernels is soaking them in an aqueous
solution that contains varying amounts of sulfur dioxide and lactic acid for a period of 24–48 h at
50–55 °C. When it is not done properly, all the products are affected including starch and germ
which is the main product of corn wet milling and can be utilized as corn oil, respectively. And,
no amount of downstream processing can correct this process.

52
TITLE: FRUCTOSE CONTENT AND COMPOSITION OF COMMERCIAL HFCS-SWEETENED
CARBONATED BEVERAGES
REFERENCE: J. White, L.J. Hobbs, & S. Fernandez, 2014

A high-pressure liquid chromatographic method for the measurement of sugars in

carbonated beverages sweetened with HFCS-55 was developed and validated. The approach
was used to measure the percentage of fructose in three categories of carbonated beverages.
Acceptable linearity (R2 > 0.99), accuracy (94–104% recovery), and precision (RSD<2%) were
exhibited to demonstrate the method's validity. Fructose represented 55.58% of total sugars
(95% confidence interval: 55.51–55.65%) based on 160 total measurements by 2 independent
laboratories of 80 randomly selected carbonated beverages sweetened with HFCS-55. The
variation between laboratories' fructose values was statistically significant but small (0.1%).
Differences in fructose based on product category or age were not statistically significant. Within
product categories, the total sugar content of carbonated beverages correlated closely
(0.01–0.54%; 95% confidence interval). Using validated analytical methodology for
HFCS-sweetened carbonated beverages, this study confirmed the hypothesis that fructose as a
percentage of total sugars is in close agreement with published specifications in industry
technical data sheets, published literature values, and governmental requirements and
standards.

TITLE: STUDY OF FACILITY DESIGN FOR CONVERSION OF GLUCOSE TO HIGH

FRUCTOSE CORN SYRUP
REFERENCE: A. Ullah et. al, 2019

The use of HFCS increased from the mid-1970s to the mid-1990s, as most food
formulators were drawn to its low cost. The design for the manufacturing of HFCS requires an
extensive variety of skills. Furthermore, this research aims to design equipment for the
production of HFCS with the minimum possible production costs. In this research, pumps,
reactors, mixers, evaporators, condensers, and heat exchangers utilized in the production of
high fructose corn syrup (HFCS) were designed. Each piece of equipment has been thoroughly
designed, including calculations of all essential parameters.

53
TITLE: STATISTICAL STUDY FOR CONVERSION OF GLUCOSE TO HIGH FRUCTOSE
CORN SYRUP
REFERENCE: A. Ullah et. al, 2019

The purpose of this study is to introduce the statistical analysis for the manufacturing of
High-Fructose Corn Syrup from glucose. This study details the production of High-Fructose
Corn Syrup along with a flow diagram of the process. In this research, the material and energy
balances of the equipment used throughout the entire operation were also calculated. The
starch is converted to 42% HFCS through four primary phases of processing. A fifth stage can
be added to the fructose product refining process in which additional refining of the 42% HFCS
solution is employed to produce high-quality 55% and 90% fructose syrups.

TITLE: CORN OIL: CORN REFINERY - PROCESS MODELING AND TECHNO-ECONOMIC

ASSESSMENT (TEA) USING SUPERPRO DESIGNER
REFERENCE: D. Petrides, 2020

In an effort to capture the projected stream flow rates, process equipment, and
manufacturing costs, a conceptual process for maize wet milling integrated with glucose and
fructose syrups was modeled and economically analyzed using SuperPro Designer. Flowsheet
sections in SuperPro are merely related collections of unit procedures (processing steps). The
contents of each flowchart section in this example are detailed in greater detail. In addition, this
SuperPro Designer example examines an integrated corn refinery, beginning with corn wet
milling and culminating in the manufacture of glucose and fructose syrups, corn germ, corn
gluten feed, and natural starch. The outcomes include material and energy balances, equipment
sizing, and estimations of capital and operational costs..

TITLE: FOODS FROM MAIZE

REFERENCE: S.O. Serna-Saldivar, 2016

Most of the maize is first industrially processed by wet milling, dry milling, or
nixtamalization. In the production of high fructose corn syrup, corn wet milling is employed as a
pre-treatment process of the raw material as they produce pure germ. HFCS is manufactured
starting from a 90 DE glucose syrup, which is produced from the hydrolysis of starch. And,

54
further treated with immobilized glucose isomerase. Furthermore, there are three major types of
HFCSs: 42, 55, and 90. However, only HFCS is considered to have the same taste as sucrose.
It is manufactured by mixing 42 and 90 HFCSs. HFCSs are used as substitutes for table sugar,
especially in soft drinks. The main advantage of using HFCS is that they readily dissolve in
water, are easily flavored, and impart a sweet fruit flavor to beverages and foods.

TITLE: DESIGN OF A HIGH FRUCTOSE CORN SYRUP PILOT PLANT

REFERENCE: T.M.A. Mahmoud, 2014

In this study, the production of HFCS from corn waste by acid hydrolysis followed by
glucose isomerase enzyme hydrolysis yields ethanol as a byproduct. The objective of this paper
is to design a novel plant for High-fructose corn syrup (HFCS) production from corn, calculate
the quantity of materials required in the plant, and determine the amount of energy required for
the pilot plant to operate and produce HFCS. The project requires 2861.1 tons/day of corn
waste, 1.14 tons/day of sulfuric acid (H2SO4), 44.06 tons/day of ethanol, 15.9*103 tons/day of
Glucose isomerase, and 1000 tons/day of HCl. The process that was used includes mixing corn
starch and α-amylase to produce maltose and glucose, separation of α-amylase out of the
mixture using a filter, adding glucoamylase to the maltose and glucose mixture to produce pure
glucose, separating glucoamylase from glucose using a filter, running glucose mixture through
the enzyme glucose isomerase to produce HFCS-42, mixing HFCS-42 and HFCS-90 to produce
HFCS-55, and using Carbon Adsorption to remove impurities. This research shows that sugars
make up the rest of high-fructose corn syrup (HFCS), which contains 24% water. The variety of
high-fructose corn syrup known as HFCS 55, which contains around 55% fructose and 42%
glucose, is the one that sees the most widespread application.

TITLE: CORN SWEETENERS

REFERENCE: S. Helstad, 2019

This study identified various varieties of corn sweeteners as well as an overview of their
manufacturing processes. This article provides an updated summary of how corn-derived
sweeteners are manufactured and utilized to make a wide range of food, beverage, and
industrial products. Corn sweetener uses gradually increased as uses and usefulness in food
and industrial items were created. Changes in technology eventually enabled refiners to develop

55
new and better-tasting goods. These goods were determined to be functional by the food
industry, assisting in the creation of good-tasting, shelf-stable products. With the invention of
high-fructose corn syrup (HFCS) and later ethanol for fuel, corn milling and sweetener-refining
capacity increased beginning in the mid-1970s. The production of sweeteners and maltodextrins
using acid, acid/enzyme, and enzyme/enzyme processes has steadily improved.

TITLE: CORN OIL: COMPOSITION, PROCESSING, AND UTILIZATION

REFERENCE: D. Barrera-Arellano, A. P. Badan-Ribeiro, & S. O. Serna-Saldivar, 2019

Corn has an average of 4% lipids, the most of which are connected with the germ
fraction. Adapted to temperate and subtropical climates, high-oil corn (HOC) genotypes
containing up to 8% oil have been produced. On an industrial scale, the oil is recovered from
germ coproducts containing 25%–50% oil, which are obtained using dry-milling or wet-milling
processes. The resulting crude oil is refined by the sequential processes of degumming,
neutralization, bleaching, winterization, and deodorization, and refined oils are either used
directly or treated via hydrogenation, fractionation, and interesterification. Corn oil has a slightly
yellowish color and a mild, unique aroma and flavor. It is a major source of minor bioactive
lipids, including phytosterols, tocopherols, tocotrienols, and carotenoids. Linoleic acid is required
for metabolic processes and is found in high concentrations in corn oil. The second most
abundant fatty acid is monounsaturated oleic acid, which, in some HOC, nearly equals linoleic
acid levels, allowing for the development of novel high-oleic cultivars. Corn oil has superior
oxidation stability and technical and nutritional properties compared to other vegetable oils. In
addition, this study discusses corn oil comprehensively, including its chemical composition,
physical properties, conventional and alternative extraction methods, refining procedures,
quality analysis, modification processes, nutritional features, and industrial applications.

TITLE: CORN OIL. AN EMERGING INDUSTRIAL PRODUCT

REFERENCE: D. Chaudhary et. al, 2012
Typically, mechanical expression and hexane extraction are employed to extract the oil
from the germ. After cleaning and steeping, the germ is separated from the kernel during the
starch extraction process. Several steps are involved in refining: (i) formation of sodium soaps
from free fatty acids, (ii) removal of the emulsion containing soaps and phospholipids by
centrifugation, (iii) removal of waxes by chilling, (iv) removal of pigments by contact with

56
bleaching clays, and (v) removal of odors by high-vacuum distillation at 225°C to 260°C. By
heating the emulsion in the presence of concentrated sulphuric acid, the fatty acid fraction is
extracted and sold for use in feed rations. The germ residue is collected and utilized as an
animal feed ingredient. The grain's starch component is further refined to produce a variety of
products. 50-60% of germ oil is recovered during the wet corn milling process. With the proper
oil extraction equipment, a variety of useful products, including corn oil and corn meal, can be
produced.

TITLE: CONTENT OF FATTY ACIDS IN CORN (ZEA MAYS L.) OIL FROM ECUADOR
REFERENCE: W. CARRILLO et. al, 2017

The objective of this study was to assess the fatty acid content of corn seed oil (Zea
mays) from Ecuador. Cold pressing was used to extract corn oil from corn oil seeds. Using gas
chromatography (GC) with a mass selective detector and the NIST 14.L database library, methyl
esters fatty acids were analyzed to determine the chemicals present in maize seed oil. Using
the GC mass spectrometer (GC-MS) analytical approach, methyl esters fatty acids in corn (Zea
mays) seeds were discovered. Palmitic acid, stearic acid, oleic acid, elaidic acid, linoleic acid,
arachidic acid, and linolenic acid were evaluated as methyl esters on a capillary column
DB-WAX 122-7062 with good separation. The GS-MS approach was used to determine the
structure of methyl ester fatty acids. 52.68% of corn oil's total fatty acid composition is linoleic
acid (omega 6) and 29.70% is oleic acid (omega 9) 12.57% palmitic acid was detected in the
sample. Omega 6 and 9 fatty acids are abundant in corn oil. Omega 6 contained 52.68 % value.
53.8 % of the lipids in corn oil are polyunsaturated, whereas 14.86 % are saturated.

VIII. SYNTHESIS
Bond (2014) claims that natural ingredients like sugar have always been a part of
everyone's diet. It is also one of the oldest commodities in the world. However, the Philippines
suffer from an insufficient supply of sugar. Recently, the top soft drinks manufacturing
companies in the country gave their joint statement that confirmed the reports of a refined sugar
shortage, amid surging commodity prices and a government row on imports (Pangilinan, 2022).
Corn syrup is nearly 100% glucose which is the result of breaking down corn starch into
individual glucose molecules. According to Zeratsky (2018), sweeteners like HFCS are
frequently used in carbonated and fruit-flavored beverages. However, the usage of corn syrup

57
has been linked with the prevalence of obesity and its associated health issues. Hence, the
Maize Refiners Association has continued to develop analytical processes to evaluate, improve
the quality of corn syrup, and to answer whether or not the human body treats corn syrup any
differently from table sugar. Moreover, corn oil is a by-product of corn meal- and starch-making
companies. According to Ghazani et al. (2016), fatty acid composition of corn oil comprises a
relatively high level of linoleic acid (58–62%). The major food uses include deep fat frying, as a
component of margarines and spreads, and for shelf-stable fried and baked snack foods. Corn
oil is rich in tocopherols and ferulic acid derivatives, both of which prolong fry life (List, 2016).
Corn is the chosen raw material to produce corn syrup because of its abundance in
supply. According to the Philippine Statistics Association (2019), the corn industry in the
Philippines produces a total volume of around eight (8) million metric tons. In the corn milling
process, wet milling was chosen. Among the wet milling methods, modified wet milling will be
utilized. According to Rodríguez-Herrera et. al., (2019), This technique involves the use of water
and produces products with high purity. This method, used for food applications, grinds the raw
material into small particles to increase the surface area. Then, the protein is extracted at an
alkaline pH and followed by acid precipitation. This method separates insoluble fiber using the
differences in swelling properties of the fraction. Thus, this will yield a higher concentration of
the desired products.
In the production of high fructose corn syrup, enzymatic hydrolysis of starch is chosen. It
starts with gelatinization, followed by liquefaction, saccharification, isomerization, purification,
and mixing. This is one of the processes used to synthesize the physical and chemical
properties of starch that are changed in an effort to enhance its useful properties. The process
will start with gelatinization so that the starch will be susceptible to enzymatic degradation
(Helstad, 2019). Followed by enzymatic hydrolysis including the process of liquefaction and
saccharification to produce pure glucose syrup (Abadalla et al., 2014). Thereafter, pure glucose
syrup will undergo isomerization which will result in a glucose and fructose mixture. The
resulting mixture will then undergo refining which includes carbon treatment, demineralization,
and evaporation to purify the mixture. Since the resulting mixture is HFCS 42, it will be
converted into HFCS 55 as it is considered to have the same taste as sucrose (Wang et al.,
2021).
On the other hand, corn oil is the by-product produced in the corn milling from germ
through mechanical extraction. The chosen refining process for crude corn oil produced is
chemical refining which includes degumming, neutralization, bleaching, winterization, and

58
deodorization (Zhao et al., 2022). Degumming process will remove phospholipids, gums, and
some trace metals that can cause dark color, off-flavors, and decrease the chemical stability of
corn oil (Vaisali et al., 2015). Next, is the neutralization process (or deacidification) which will
neutralize free fatty acids. This process will produce a by-product called soapstock which will be
removed by further centrifugation or water washing (Febrianto and Yang, 2012). Followed by
bleaching to remove pigments such as chlorophylls and carotenoids (Ayerdi and Larbi, 2016). It
is also responsible for the removal of lipid hydroperoxides, phospholipids, residual soaps, trace
amounts of metal ions, and other contaminants that can impede filtration and negatively affect
the color, flavor, and quality of oil (Ghazani and Marangoni, 2013; Vaisali et al., 2015). Then, the
winterization (dewaxing) process to remove waxes which otherwise can cause cloudiness in the
refined oil. Finally, deodorization process to remove undesirable odor-related compounds such
as aldehydes, ketones, hydroperoxides, epoxides, and other volatile components, producing
high-quality oil with bland flavor and odor (Ayerdi and Larbi, 2016; Febrianto and Yang, 2012).

59
 CHAPTER III
MARKET STUDY
This chapter provides a comprehensive market analysis of the high fructose corn syrup
and corn oil market with respect to its industry overview, global and local demand and supply,
target market, major players and competitors, pricing and forecast, strengths, weaknesses,
opportunities, and threats (SWOT) analysis, as well as its product distribution and the factors
affecting the market.

I. INDUSTRY OVERVIEW
A. PRODUCT
CORN SYRUP

Corn syrup is a food syrup manufactured from corn starch and, in certain countries, it's
called maize. Depending on the grade, it contains maltose and oligosaccharides. Corn syrup, or
glucose syrup to confectioners, is used to soften foods, provide volume, prevent sugar
crystallization, and enhance flavor. High-fructose corn syrup (HFCS) is made by converting a
large part of corn syrup's glucose into fructose with D-xylose isomerase. Cornstarch and dilute
hydrochloric acid were combined and heated under pressure to produce it. Commercially
prepared foods use corn syrup as a thickener, sweetener, and humectant. In addition, it is an
ingredient that absorbs moisture and keeps food fresh and is marketed as light and dark corn
syrup (ProfShare Market Research, 2021).

In the food and beverage industry, the demand for corn syrup is continuously increasing.
Due to the numerous benefits of corn syrup, food and beverage producers are rapidly using this
product. In addition, maize syrup is one of the most useful ingredients on the commercial
market. The sweetener adds texture to meals, helps keep their color, enhances the flavor of
diverse foods, and improves their quality. Furthermore, the cost of each of these additions is
less than that of any other caloric sweetener that can be used in food production. This means
that it can offer a variety of features that add value without having the same price instability as
its alternatives (Ocean, 2022).
GLOBAL MARKET

In the United States, corn syrup is used to sweeten processed foods and soft drinks.
Similarly, corn syrup can be utilized to produce sugar glass when combined with sugar, water,
and cream of tartar. The carbohydrate content of maize syrups affects their humectant or
hygroscopic qualities. Syrups with a lower DE are less hygroscopic than maltotriose and
maltotetraose, and these sugars are the most hygroscopic. In addition, based on a regional
analysis, corn syrup is split among numerous nations, including the United States, China,
Japan, Europe, India, and Southeast Asia. Corn syrup is most prevalent in Indore, Mumbai,
Delhi, Chennai, Hyderabad, and Ahmedabad in India. Consequently, the United States is the
leading producer and exporter of corn in the world (ProfShare Market Research, 2021).

The global corn syrup market is projected to reach $11.1 billion by 2028, increasing at a
4.0% CAGR during the forecast period. By application, the corn syrup market is classified into
food and beverages and pharmaceuticals. In 2021, food and beverages accounted for the
largest proportion of the corn syrup market. Increasing food and beverage production to meet
global demand is driving the food and beverage industry's expansion. Based on distribution
channels, the corn syrup market is B2B and B2C. In 2021, the B2B segment had a large part of
the corn syrup market. The segment's rapid growth is due to the expanding demand for corn
syrup in restaurants and other food facilities. Restaurants are rapidly adopting corn syrup as a
thickening and moisturizing agent. Meanwhile, the corn syrup market is analyzed throughout
North America, Europe, Asia-Pacific, and LAMEA. In 2021, North America had the greatest corn
syrup market share. The growth of the regional market is soaring since the US is a prominent
producer and consumer of corn syrup. This is due to the significant demand for prepared
beverages, baked products, confections, and processed meals across the US (Ocean, 2022).

LOCAL MARKET

Corn sweeteners are utilized in the production of soft drink formulations due to their
convenience in transportation. The increasing demand for corn sweeteners can be attributed to
a number of factors, including domestic sugar production quotas, international sugar import
tariffs, and domestic corn subsidies in the United States. The cost of sucrose is also higher than
the cost of corn sweetener, which is another reason why corn sweetener is used so often
(Ocean, 2022). Additionally, corn syrup is a substitute for sucrose in the food and beverage
industry. The major market for corn syrup is organic sweeteners. Currently, the majority of

61
businesses are producing organic sweeteners. This may be the reason to enhance corn syrup
market sales in the future (ProfShare Market Research, 2021).

B. BY-PRODUCT

CORN OIL
Oil made from maize germ is known as corn oil and is a type of vegetable oil. It comes in
both consumable and non-consumable varieties. Polyunsaturated fatty acids make up the bulk
of corn oil, while saturated fats make up a very small percentage. To that end, it's been heralded
as a more nutritious option than other commercially available edible oils. Increased consumer
health awareness and the prevalence of chronic diseases caused by poor lifestyle choices have
both played key roles in fueling the global market for corn oil. Corn oil's application in the
manufacturing of biofuel and other industrial items including soaps, paints, textiles, medicines,
poultry, insecticides, etc. has contributed to the market's expansion (Ltd, 2013).
Furthermore, corn has the highest oil content of the commercial cereals because its
germ is larger than those of the other cereals. The kernel of maize includes lipids, however it is
not considered an oilseed because the amount is so low (between 3% and 5%). Large-scale
industrial dry and wet milling operations, on the other hand, produce copious amounts of germ,
which are often sent to the oil crushing or animal feeding industries. Between 9 and 11 percent
of a kernel's total mass, the germ contains around 80 percent of the lipids present in the entire
kernel. The remaining percentage is split between the endosperm (15%) and bran (2%)
(Barrera-Arellano et al., 2019).
Additionally, the kernel root (1-2% cellulose), pericarp (5.5-6% cellulose), germ (10-14%
oil, proteins, and carbohydrates), and endosperm (82% starch, proteins, and lipids) make up a
corn kernel. Industrial corn production focuses on extracting starch from maize kernels
(60-75%), whereas the germ is a by-product. The kernel's germ comprises 80-84% of the oil,
followed by the aleurone and endosperm. GE can modify maize oil content. After screening,
kernels yield 20% more oil. High oil corn has more than 6% oil. Maize germ is essential for
generating oil. Corn germ oil contains 35.5%–56.0% linoleic acid. In addition to FFAs, sterols,
and phosphatides, maize germ has 1.5-2% FFAs. Since maize grain is converted into so many
useful items, there is essentially little waste. Corn germ oil is used in biodiesel and human
nutrition.

62
GLOBAL MARKET
It is estimated that by 2022, the global market for corn oil would be worth $7.2 billion.
The rising prevalence of chronic conditions caused by poor lifestyle choices, such as diabetes,
hypertension, and cardiovascular illness, bodes well for future expansion. Market growth is also
anticipated from increased demand for healthy and organic oils, as well as from increased
consumer knowledge of these products' health benefits. Moreover, maize oil is used as a
feedstock for biodiesel production and in a wide variety of other goods, including soaps,
medicines, paints, pesticides, etc., further increasing global demand for corn oil
(Techsciresearch, 2017).
Furthermore, In 2021, the international market for corn oil was worth US$5.25 billion.
The IMARC Group forecasts that by 2027, the market would have grown to be worth US$ 8.28
billion, with a CAGR of 7.97% between 2022 and 2027. Considering the unpredictability of the
COVID-19 pandemic, monitoring and assessing the direct and indirect effects of the outbreak on
a variety of end-use sectors on an ongoing basis. The report acknowledges that these findings
are a significant factor in the market (Corn Oil Market Size, Share, Growth, Trends and Forecast
2022-2027, n.d.).

LOCAL MARKET
The term "oils" refers to all different kinds of cooking oils, such as olive oil, sunflower oil,
palm oil, and corn oil, among others. The market for oils in the Philippines recorded a positive
compound annual growth rate (CAGR) of 4.45% from 2012 to 2017, with a sales value of PHP
79,979.16 Million in 2017—a 4.22% increase over 2016. The market's performance was at its
best in 2016, when it increased by 4.53% over the previous year, and it was at its worst in 2017,
when it increased by 4.22% over 2016. The market's strongest performance was achieved in
2016.

63
II. TARGET MARKET
Target marketing is a strategy that identifies target markets and demographics to
determine which consumers are most likely to be interested in specific products or services.
This type of marketing entails determining what attracts customers in the market for Rugí
Manufacturing Plant's products. Rugí Incorporation products include corn oil and high-fructose
corn syrup which will be sold to businesses and organizations that use these functional
ingredients. As a result, when a company designs, packages, and advertises its product,
identifying the target market is an important part of the decision-making process.
This study proves that the main products corn oil and corn syrup can be mainly utilized in
different industries.

A. CORN SYRUP
1. Food Industries
Corn syrup is used in food industries by bakers, confectioners, and
large-scale producers of baked goods, condiments such as jams and jellies, and
candy production. High-fructose corn syrup can be found in a wide range of
foods, including desserts, soft drinks, fruit juices, yogurts, bread, and cereals. In
some circumstances, the syrup is used as a humectant, which functions as a
preservative by keeping moisture and preventing some foods from drying out
(MasterClass, 2021).

2. Beverage Industries
High fructose corn syrup (HFCS) is a liquid sweetener made from a
modified type of corn syrup that can be used in place of sucrose in the beverage
industry. HFCS is more stable and works well in acidic beverages. Because it is
accessible in liquid form, it is easier to carry, handle, and mix than powdered
sucrose. Because fructose is sweeter than glucose, the syrup's total sweetness
rose, resulting in a more cost-effective use of sugar in food processing
(Persistence Market Research, 2021).

3. Pharmaceutical Industries
Corn syrup is added to cough syrups and vitamin-based tonics in the
pharmacy industry. It is also utilized as a base, which is another beneficial
application in this business. It is also commonly used by pharmacists as a

64
 granulating agent and for tablet coating. Corn syrup has functional qualities such
as viscosity, high fermentability, humectant, colligative capabilities, and
sweetness (HL Agro, 2016).

B. CORN OIL
1. Food Industries
Corn oil has already replaced a substantial amount of saturated fat in a
variety of food products, and it is now the best option for reducing the amount of
trans fat in several of our favorite snack foods. Additionally, it has the potential to
be an efficient component in the elimination of trans fats in eating establishments
(Corn Oil, n.d.).

2. Pharmaceutical Industries
As both a disintegrant and a binder, it finds application in the
pharmaceutical industry. Tablets and capsules are able to "dissolve" into smaller
pieces with the help of a substance called a disintegrant, which allows the
medicine inside to become available for absorption (Corn Oil (Inactive
Ingredient), n.d.).

3. Cosmetics and Personal Care Industries

Corn oil contains linoleic and oleic acids, both of which are beneficial to
the maintenance of the hair and skin's health. As a result, the corn oil market is
being driven by the expansion of the cosmetics and personal care industry (Corn
Oil Market Size, Share, Industry Forecast 2029, 2013.).

65
III. COMPETITION

1. Global Competitors for Corn Oil

a. Archer Daniels Midland Company (ADM)
Archer Daniels Midland is a global food
processing and commodities trading company with over
400 crop procurement facilities and 270 food
processing plants. ADM's objective is to transform
natural goods such as cereal grains and oilseeds into a
diverse range of products such as food and beverage
additives and flavorings, vitamins, and nutritional products for pets and livestock.

b. Abu Dhabi Vegetable Oil Company (ADVOC)

ADVOC, founded in 1997, is Abu Dhabi's first
edible oil refinery and manufacturer of edible fats.
ADVOC operates one of the most modern fractionation
facilities in the GCC. ADVOC manufactures ingredient
oils and specialty fats for the food service and retail
industries in addition to edible oils and fats for
consumers. It manufactures bespoke specialized fats
for hotels, food processing firms, bakeries, catering companies, restaurants, and
cafeterias, among others, such as bakery fats, ice cream fats, chocolate fats, dairy fat
replacers, filling fats, and frying fats.

c. Elburg Global
Elburg Global is a full-service Dutch export
supplier of high-quality vegetable oils and fats. They
have created good relationships with consumers and
supported them through the years by being flexible, fast,
and accurate in their planning. They have expanded
their product offering over the years, and they now export to over 40 countries
worldwide.

66
2. Global Competitors for Corn Syrup
a. BNC Ingredients Corporation
BNC is a recognized importer, distributor, and
supplier of innovative, high-quality industrial equipment
and services to the food, personal care, animal
nutrition, and various other industries. This company
utilizes corn syrup to produce resins that they could
promote as material for packaging.

b. Archer Daniels Midland (ADM)

ADM works directly with farmers, supporting
them with personalized services and innovative
technologies. They partner with them to develop and
enhance sustainable practices and transform their
bounty into products for consumers around the globe.
This company advertises corn syrup as ‘Specialty
Syrup’. With their wide portfolio of specialty syrups, you can easily substitute sugar and
other traditional sweeteners without changing functionality, all while meeting consumer
demands.

c. Roquette America Inc.

Roquette is a global leader in plant-based
ingredients, a pioneer of plant proteins, and a leading
provider of pharmaceutical excipients. They offer
natural ingredients for food, nutrition, and health
industries. This American company sustainable
sourcing, by improving our operations and industrial
activities or by developing sustainable innovations that address consumer needs, we
have always placed sustainability at the center of how we work. Roquette’s formulation
of corn syrup is used for Pharmaceuticals and/or Nutraceuticals. It can also act as a
carrier or encapsulant to encapsulate flavors. According to Roquette Frères, some of its
applications are bakery, snacks, and savory.

67
3. Local Competitors for Corn Oil
a. Oleo-Fats Incorporated
Their corn oil is made in world-class facilities
from premium corn kernels. Oleo-Fats innovates and
constantly develops the corn oil production process
in order to generate products that match the
ever-changing demands of the local and worldwide
food industries, as well as your individual needs. In
fact, their products correspond to these requirements and exceed your expectations.

b. Flexs General Trading

Flexs General Trading is one of the
Philippines' most major manufacturers and suppliers
of corn oil. They have a supply network and export
Corn oil to the global market. They have all of the
essential documents to supply Corn oil in both the
domestic and foreign markets. They have all
relevant government certificates and permits for the
import and export trade, and they are an authorized trader and distributor of our Corn oil
in the Philippines.

4. Local Competitors for Corn Syrup

a. Roquette America Inc.
Roquette is a global leader in plant-based
ingredients and a provider of pharmaceutical
excipients. This company has its headquarters here
in the Philippines. Roquette Philippines, Inc. carries
the same policies and principles as American Inc.
They supply the same quantity and quality of Corn
Syrup but at a cheaper price since the consumers won’t have to pay for the shipment of
the products.

68
b. Zhu Delifood Incorporated
This company supplies Corn Syrup here in
the Philippines. They import corn syrup from
manufacturing companies like Merck and Archer
Daniels Midland. Zhu Delifood Incorporated
promotes their corn syrup formulation as the best
replacement for sugar especially in beverages
and baked goods.

c. JC Marketing PH
JC Marketing PH is a small business
in the Philippines. It mainly caters for cafe and
milk tea supplies that the locals need. They
also supply sugar alternatives, food colorings
and flavoring. This enterprise sells Corn Syrup
as one of their flavor enhancers.

d. Peotraco Food Inc.

Peotraco Food Inc. is a company in the Philippines
that caters confectioner's sugar industry. Peotraco has
evolved into a dynamic company that is constantly
reinventing itself. It has successfully introduced a number of
new product lines and integrated them into the confectionery
industry.

e. FERNA Corporation
Ferna Corporation is a company that offers food
and baking ingredients in the Philippines. The company
manufactures liquid corn syrup and liquid glucose. They
also sell powdered products used for baking.

69
 IV. PRICING AND FORECASTS
Pricing is the fundamental process of every manufacturing plant to gain profit and offer
products and services for the consumers at the right cost. With this, Rugí Inc. Manufacturing
Plant will propose the projected pricing of High-fructose Corn Syrup and Corn Oil. Meanwhile,
Table 3.1 and Table 3.2 presents the basis and projected price (by 2028) of High-Fructose Corn
Syrup 55 and Corn Oil.

Table 3.1 Basis of Pricing for High Fructose Corn Syrup 55 and Corn Oil

MARKET PRICE

Plant Capacity Capacity Market Price Total %

(kg/yr) (kg/batch) (Php/kg) (Php/batch)

High Fructose 4,098,854.92 45,542.83 260.00 11,841,135.80 92%

Corn Syrup

Corn Oil 1,813,140.40 6,043.80 177.89 1,075,131.582 8%

Total 12,916,267.382 100%

Source: JC Marketing

Table 3.2 Basis of Pricing for High Fructose Corn Syrup 55 and Corn Oil in 2028

MARKET PRICE
Market Price
Market Price Unit Selling
Market Price Projected
Products Projected Price Difference Good/Bad
(Php/kg) Price by
Price Non-VAT Non-VAT
2028

HFCS 55 260.00 331.83 296.28 204.65 91.63 Good

Corn Oil 177.89 227.04 202.71 140.02 62.69 Good
Source: JC Marketing

The remarks of (Good/Bad) for the pricing of the products are based on the difference of
prices between the market price and the RUGI Inc. unit selling price. The unit selling price of
both products are good since they have lower amounts than the projected non-vat prices of the
market products.

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PRODUCT: HIGH FRUCTOSE CORN SYRUP 55 AND CORN OIL
HIGH FRUCTOSE CORN SYRUP 55
Table 3.3 presents both historical global and local demand and supply of High-Fructose
Corn Syrup. This table discusses the computed projected values of High-Fructose Corn Syrup
between the year 2022-2047.

71
 Table 3.3 Historical Data and Projected Value of High Fructose Corn Syrup 55
Historical Demand and Supply of Corn Syrup
Demand (MT) Supply (MT)
Year
Global Local Global Local
2016 46,295,933.00 106,617.00 46,240,611.00 87,411.00
2017 48,255,373.00 104,835.00 47,562,243.00 80,317.00
2018 44,460,101.00 85,422.00 43,222,262.00 80,868.00
2019 42,456,001.00 100,881.00 42,064,691.00 88,204.00
2020 45,904,891.00 83,336.00 44,221,189.00 70,034.00
2021 49,076,622.00 164,658.00 43,516,297.00 141,035.00
Projected Values of Corn Syrup
Demand (MT) Supply (MT)
Year
Global Local Global Local
2022 52,399,293.90 202,240.20 44,633,201.20 187,370.70
2023 57,543,248.59 269,558.11 46,189,320.54 247,729.61
2024 63,938,564.09 351,982.89 48,311,629.03 321,145.35
2025 71,585,240.42 449,514.51 51,000,126.66 407,617.91
2026 80,483,277.57 562,153.00 54,254,813.43 507,147.29
2027 90,632,675.54 689,898.34 58,075,689.34 619,733.49
2028 102,033,434.34 832,750.54 62,462,754.40 745,376.51
2029 114,685,553.95 990,709.60 67,416,008.60 884,076.35
2030 128,589,034.39 1,163,775.51 72,935,451.94 1,035,833.01
2031 143,743,875.64 1,351,948.29 79,021,084.43 1,200,646.50
2032 160,150,077.72 1,555,227.91 85,672,906.06 1,378,516.81
2033 177,807,640.62 1,773,614.40 92,890,916.83 1,569,443.94
2034 196,716,564.34 2,007,107.74 100,675,116.74 1,773,427.89
2035 216,876,848.89 2,255,707.94 109,025,505.80 1,990,468.66
2036 238,288,494.25 2,519,415.00 117,942,084.00 2,220,566.25
2037 260,951,500.44 2,798,228.91 127,424,851.34 2,463,720.66
2038 284,865,867.44 3,092,149.69 137,473,807.83 2,719,931.90
2039 310,031,595.27 3,401,177.31 148,088,953.46 2,989,199.96
2040 336,448,683.92 3,725,311.80 159,270,288.23 3,271,524.84
2041 364,117,133.39 4,064,553.14 171,017,812.14 3,566,906.54
2042 393,036,943.69 4,418,901.34 183,331,525.20 3,875,345.06
2043 423,208,114.80 4,788,356.40 196,211,427.40 4,196,840.40
2044 454,630,646.74 5,172,918.31 209,657,518.74 4,531,392.56
2045 487,304,539.49 5,572,587.09 223,669,799.23 4,879,001.55
2046 521,229,793.07 5,987,362.71 238,248,268.86 5,239,667.36
2047 556,406,407.47 6,417,245.20 253,392,927.63 5,613,389.99

72
 Table 3.4 Statistical Methods for High Fructose Corn Syrup 55 Market Share
Methods
Demand Supply
Methods
Global Local Global Local
Arithmetic Straight
2,823,821.06 37,984.31 1,510,373.39 33,764.54
Line
Arithmetic Geometric 19,090,152.54 59,906.91 19,010,212.42 55,405.05
Statistical Straight
2,206,460.86 24,355.34 1,427,288.89 20,966.43
Line
Statistical Parabolic
1,559,685.55 15,433.02 1,240,358.38 13,206.03
Curve
Market Share
Type Global Local
GAP 30,249,251.36 87,374.04
TAP 2,148.99 2,148.99
%MS 0.01% 2.46%

CORN OIL
Table 3.5 presents both historical global and local demand and supply of Corn Oil. This
table discusses the computed projected values of Corn Oil between the year 2022-2047.

73
 Table 3.5 Historical Data and Projected Value of Corn Oil
Historical Demand and Supply of Corn Oil
Demand (MT) Supply (MT)
Year Global Local Global Local
2016 301,840,000.00 248,600.00 274,130,000.00 210,400.00
2017 304,710,000.00 249,800.00 280,160,000.00 205,800.00
2018 312,700,000.00 251,600.00 290,470,000.00 211,300.00
2019 319,020,000.00 253,500.00 305,220,000.00 236,300.00
2020 333,910,000.00 354,300.00 293,790,000.00 333,800.00
2021 340,570,000.00 470,610.00 318,640,000.00 437,400.00
Projected Values of Corn Oil
Demand (MT) Supply (MT)
Year Global Local Global Local
2022 337,307,000.00 609,205.00 321,244,000.00 578,400.00
2023 344,173,285.71 788,725.00 329,355,142.86 752,371.43
2024 351,273,500.00 1,002,943.21 337,542,714.29 958,807.14
2025 358,607,642.86 1,251,859.64 345,806,714.29 1,197,707.14
2026 366,175,714.29 1,535,474.29 354,147,142.86 1,469,071.43
2027 373,977,714.29 1,853,787.14 362,564,000.00 1,772,900.00
2028 382,013,642.86 2,206,798.21 371,057,285.71 2,109,192.86
2029 390,283,500.00 2,594,507.50 379,627,000.00 2,477,950.00
2030 398,787,285.71 3,016,915.00 388,273,142.86 2,879,171.43
2031 407,525,000.00 3,474,020.71 396,995,714.29 3,312,857.14
2032 416,496,642.86 3,965,824.64 405,794,714.29 3,779,007.14
2033 425,702,214.29 4,492,326.79 414,670,142.86 4,277,621.43
2034 435,141,714.29 5,053,527.14 423,622,000.00 4,808,700.00
2035 444,815,142.86 5,649,425.71 432,650,285.71 5,372,242.86
2036 454,722,500.00 6,280,022.50 441,755,000.00 5,968,250.00
2037 464,863,785.71 6,945,317.50 450,936,142.86 6,596,721.43
2038 475,239,000.00 7,645,310.71 460,193,714.29 7,257,657.14
2039 485,848,142.86 8,380,002.14 469,527,714.29 7,951,057.14
2040 496,691,214.29 9,149,391.79 478,938,142.86 8,676,921.43
2041 507,768,214.29 9,953,479.64 488,425,000.00 9,435,250.00
2042 519,079,142.86 10,792,265.71 497,988,285.71 10,226,042.86
2043 530,624,000.00 11,665,750.00 507,628,000.00 11,049,300.00
2044 542,402,785.71 12,573,932.50 517,344,142.86 11,905,021.43
2045 554,415,500.00 13,516,813.21 527,136,714.29 12,793,207.14
2046 566,662,142.86 14,494,392.14 537,005,714.29 13,713,857.14
2047 579,142,714.29 15,506,669.29 546,951,142.86 14,666,971.43

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 Table 3.6 Statistical Methods for Corn Oil Market Share
Methods
Demand Supply
Methods
Global Local Global Local
Arithmetic Straight
3,721,772.88 71,719.28 6,879,314.89 65,999.17
Line
Arithmetic
125,260,895.46 165,427.87 114,382,901.44 159,177.53
Geometric
Statistical Straight
2,717,046.25 45,755.32 6,135,923.57 41,341.37
Line
Statistical
1,755,827.61 14,856.43 6,127,675.59 8,346.39
Parabolic Curve
Market Share
Type Global Local
GAP 10,956,357.14 97,605.36
TAP 1,813.14 1,813.14
%MS 0.02% 1.86%

The following figures below present the historical and projected global and local demand
and supply of High Fructose Corn Syrup 55 and Corn Oil.

Figure 3.1 Global Historical Data and Projected Value of High Fructose Corn Syrup

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Figure 3.2 Local Historical Data and Projected Value of High Fructose Corn Syrup

Figure 3.3 Global Historical Data and Projected Value of Corn Oil

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Figure 3.4 Local Historical Data and Projected Value of Corn oil

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V. SWOT ANALYSIS
The corn oil and high fructose corn syrup manufacturing facility underwent a SWOT
analysis, a form of the strategic model, to evaluate its strengths, weaknesses, opportunities, and
threats.

Figure 3.5 SWOT ANALYSIS

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STRENGTH
1. New Source of the Products
Rugí Manufacturing Plant is the first large-scale producer of sweeteners from
corn in the Philippines. They offer products including high fructose corn syrup 55 which
is health-friendly. High fructose corn syrup is a functional ingredient commonly used in
drinks, soft drinks, fruit juice, cakes and pastries.
2. Novel Processes and Equipment
Rugí adopts novel processes and equipment for the production of corn oil and
high fructose corn syrup to ensure high-quality products were produced.

3. Reliable Waste Management Facility

The plant has a reliable waste management facility which will ensure that all the
effluent from the plant is in accordance with the standards and regulations.

WEAKNESSES
1. Marketing and Branding
Rugí Manufacturing Plant is an unfamiliar company or brand for consumers. The
company should work and thoroughly invest in marketing and branding so that the
consumers will recognize the products.

2. Geographical Location
The geographical location of the Philippines is a threat as it is prone to calamities
such as typhoons and volcanic eruptions. These phenomena will affect the supply of raw
materials and the production of products.

OPPORTUNITIES
1. Market Insights of Sweeteners
According to Future Market Insights research, the global sweetener market is
expected to grow at a CAGR of 3.8%. The sweetener market share value is projected to
increase from US$ 108.6 Billion in 2022 to US$ 157.7 Billion by 2032. Hence, Rugí’s
market is solid in the following years.

2. Research and Development

As the market insights of sweeteners are increasing, this is a good opportunity for
Rugí to widen the range of sweeteners they offer made from corn by developing their
by-products. It is also an opportunity to invest in research and development for
strengthening their products.

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THREATS
1. Climate Change
Climate change is inevitable, especially in the Philippines. It includes warming
temperatures and changes in precipitation in a specific place. The unpredictable weather
might affect the supply of corn and the efficiency of the production of the plant.

2. Geographical Location
The geographical location of the Philippines is a threat as it is prone to calamities
such as typhoons and volcanic eruptions. These phenomena will affect the supply of raw
materials and the production of products.

3. Wide Variety of Sweeteners

There are different varieties of sweeteners rising and available in the market.
Rugí might find it hard to compete as high fructose corn syrup is not the primary option
of sweeteners for consumers.

4. Global and Local Competitors

Competitive rivalry is one of the key threats affecting the company. The
sweeteners are highly competitive and consist of numerous small, large and
multinational companies. Sweetener products compete primarily on the basis of uses,
price, quality, product variety, distribution, advertising, packaging, convenience,
marketing, and promotional activity, as well as the ability to anticipate and respond to
consumer trends. Sweetener markets are growing and Rugí will find it hard to compete
in the future.

VI. PRODUCT DISTRIBUTION

In terms of the distribution of products, high fructose corn syrup, and corn oil will be sent
directly from the manufacturing plant to the target markets, other businesses, and corporations
that need them. For those areas that can be reached by land-based vehicles, Rugi Incorporation
will specifically transport and export products across long distances through land transportation.
Water-based transportation, on the other hand, will be used to transport products to locations
that are inaccessible by land-based vehicles.

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VII. FACTORS AFFECTING THE MARKET
The Philippines' corn oil and high fructose corn syrup market will be profoundly impacted
by the following elements, such as traditional/commercial products and natural disasters.
1. Traditional/Commercial Products
There are both domestic and foreign competitors for the corn syrup and corn oil
product, each of which is export to various parts of the world. Alternative sweeteners are
also being produced by local producers, which reduces overall marketability and
increases competition. People regularly consume goods made both traditionally and
industrially. Additionally, companies of all sizes are actively growing the global markets
for sugar alternatives such as corn oil and high fructose corn syrup.

2. Natural Calamities
Natural disasters will have a substantial impact on the collection and availability
of raw materials, which will lead to a decrease in corn production and inconsistency in
satisfying the demand for commodities. Both transportation and the balance of supply
and demand can be disrupted when natural disasters like earthquakes and typhoons
strike. As a direct consequence of this, Rugí Incorporation will discover that ensuring the
supply of raw materials will be a challenging factor.

3. Related Markets
One of the things you need to know in order to successfully design and develop
the manufacturing plant is this particular factor. The potential competitors and the
products or services they give to customers, which, if you can outperform them in any
manner, will allow you to win more business from customers and perform more
effectively on the market than both global and local competitors. It may be able to
increase company earnings and keep up with your competitors by developing production
procedures that have reduced costs, which you can then pass on to your customers in
order to take advantage of the savings you have achieved. The process of discovering
client demands and producing new goods or services to meet those demands can also
be facilitated for businesses by the presence of competitive markets.

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4. Fluctuation Rate
Since other commodities appear to be switching back and forth in terms of value
and price due to significant circumstances in the market, the rate of market fluctuation
could affect the products that are being marketed. This is because the market appears to
be going through significant circumstances. This phenomenon is analogous to the rate of
inflation in that the value of income-oriented or high-dividend-paying enterprises tends to
decline whenever the inflation rate increases.

5. Inflation Rate
As the price of a product increases, the cost of its production processes,
including machines and equipment, also increases. In connection to this, if the rate of
inflation rises, there is a chance that manufactured products may be hoarded, which
could cause supply imbalances. In general, as the rate of inflation rises, the demand and
supply of items may decrease, resulting in economic failures.

6. TRAIN Law
As a direct result of the implementation of the TRAIN Law, the Philippines has
one of the highest corporation tax rates in all of Southeast Asia. The current tax rate for
corporations is 30%, and it is applied to any and all net profits derived from any and all
tax table sources. The rate of 30% is quite high when compared to that of other countries
in the region. Because of this, corporations, such as major firms, will be required to pay a
higher tax rate than small businesses or individuals.

7. Economic and Political Shocks

Both the growth of the economy and the value of the stock market are subject to
events on a global scale. For instance, an increase in the cost of energy can have a
detrimental effect on a company's operations as a whole, resulting in a decrease in
revenue, profitability, and share prices.

8. Exchange Rate of Peso

Changes in the exchange rate can have an impact not only on actual inflation but
also on expectations for future price fluctuations. The domestic pricing of imported
products and services is most likely to react immediately and predictably to shifts in the
value of the currency exchange rate. A stronger peso results in cheaper pricing in pesos

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for imported commodities as well as services that rely heavily on imports, such as
transportation, which in turn results in a reduced rate of inflation.

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 CHAPTER IV

PROJECT SCHEDULE
This chapter presents the project schedule of the Rugí Manufacturing Plant. It includes
important information about before and after the construction of the project until the start of the
plant's normal operation by January 2028 through the guidance of the Gantt Chart presented in
figure 4.1.

FRONT-END LOADING (FEL) 1 – OPPORTUNITY IDENTIFICATION

During this stage, ideas for a desirable manufacturing facility will be discussed. The raw
materials to be used, the site of the plant, the plant's primary function, and the completed
products that will be produced will all be specified during this phase. The objective or anticipated
year of operation will also be indicated here.

A. Project Conceptualization (August 2022 - September 2022)

At this point, the proponents have done extensive research and analysis to
determine the kind of manufacturing plant designed to be established in the country.
Many factors were taken into account when designing the factory; this included the
accessibility of raw materials, the products' worldwide and regional demand, and the
procedures that would be used. Proponents of the proposed manufacturing plant in the
Philippines found that corn is one of the most significant crops after conducting extensive
research and evaluation. Thus, conducted in-depth research on the raw material
components, narrowing in on the maize cob, germ, and endocarp as the two most
promising parts for the plant. The chemical components, such as cellulose, starch,
enzyme content, and other features, were examined when selecting the raw materials to
produce the desired products. The planned manufacturing plant's primary goal is to
develop safe and effective products such as high fructose corn syrup and corn oil by
taking into account the various factors that must be considered.
Nevertheless, the ideal location for the plant's construction was chosen by
thoroughly evaluating and examining the historical production of the raw materials and
finding which province has the maximum production capacity. Specifically, the proposed
factory would be located in Iligan City, Isabela. It was also determined that the projected
production factory will have a 30-year lifespan, from 2028 to 2058. In sum, the
 suggested manufacturing plant will be built after extensive research and analysis into a
number of elements that would contribute to higher output.

FRONT-END LOADING (FEL) 2 – CONCEPTUAL ENGINEERING

In this phase, the activities to be applied were precisely intended for the product to be
produced and for the flow of other activities. Basically, the activities offered in this phase include
the market study analysis, product specification, process flow development, and preliminary
material and energy balance calculations. Moreover, this phase also includes schedule
preparation which signifies the specific dates or target dates from where a certain activity will
start and at the same time, when it will end.

A. Market Study Analysis (September 2022 - October 2022)

In this stage, it will determine the tactical investigation of market demand and
supply for the product. This will categorize all of the facets that will be present in the
market and may have an influence on the product's demand. This will cover everything
from price to location to competition to general economic activity. It will permit
businesses to evaluate and grasp the product's demand and feasibility, as well as initiate
whether or not it has the potential to make a substantial effect. This will be crucial to its
success and expansion.

B. Schedule Planning (October 2022)

In this stage, it contains the description of activities, objectives, and indicators
within a project. A timetable typically includes an arranged start and finish date, as well
as the period of each activity and the resources allotted to it. This will help with
development tracking, reporting, and communication, as well as guaranteeing that
everyone is on the same page about tasks, dependencies, and deadlines. This will also
allow you to manage resources competently for your project and predict when resources
will be available for other projects.

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C. Product Specification (October 2022 - November 2022)
In this stage, it will plan the most significant requirements for developing high
fructose corn syrup 55 and corn oil. This contains the technical description, performance
specification, and technical standards, as well as all of the data needed to develop a
product with certain features and functionalities. This will be determined by the features
that may impact the product's formulation, such as manufacturing, physical, and
chemical considerations. The product will be created using the process list provided.

D. Process Flow Development (October 2022 - November 2022)

In this stage, it will include all procedures involved for the manufacturing of the
main product, corn oil and high fructose corn syrup. To recognize dependencies and
classify areas where the process may be enhanced, each phase should be studied both
independently and within the greater outline of end-to-end product creation. The
determination of a few internal joint factors or linkage parameters among methods falls
under this category.

E. Material and Energy Balance Calculations (October 2022 - January 2023)

In this stage, material and energy balance calculations will be determined.
Reliant on the process description section, the complete details for calculating material
and energy balances will be attained. This includes the exact settings and components
that will be used in a particular piece of equipment. Material balances are first
determined during the experimental phases of a new process, then enhanced during
pilot plant trials while the process is being deliberated and tested, checked out when the
plant is commissioned, and then refined and maintained as a control instrument as
production continues. Energy balances are very significant in a manufacturing company,
it is fundamental to the control of processing, mainly in the control of yields of the
products. Energy balances are determined in the experimental stages of a new process,
improved during pilot plant trials when the process is being deliberated and tested,
checked out when the plant is commissioned, and then refined and maintained as a
control instrument as production continues.

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FRONT-END LOADING (FEL) 3 – BASIC ENGINEERING DESIGN
In this phase, the activities shall be finished in detailed and precise designs. The outlines
from FEL 1 and FEL 2 are the guiding concepts to be finalized for the anticipated process flow
of the manufacturing plant. Moreover, this phase will also include the technical definition
revisions and improved project plan.

A. Refined Material and Energy Balances (January 2023)

During this phase, the preliminary material and energy balances will be
thoroughly evaluated and analyzed in great depth. Moreover, information is provided
concerning product specifications, annual operating factors, material and energy
balances, as well as a description of the equipment. The necessary details will be
obtained to guarantee that the relevant quantities are indicated on each piece of
equipment and that the collected details for calculating the material and energy balances
correspond with the process description that has been provided. In relation to this, the
final utility flow diagrams and balances will be computed, in addition to an estimate of the
capital cost and an analysis of the possible returns on the required investments. These
balances will also be of use in the process of determining projected values, which will
establish the company's influence in the market on a global as well as a local scale. To
sum it up, the improvement of the descriptions of the entire process will be necessary for
the refinement of the material and energy balances.

B. Hazard and Operability Analysis (January 2023-February 2023)

A thorough evaluation of the equipment and machinery that are intended to be
utilized in the production process will occur at this stage. This will be done in order to
determine whether or not hazards are present, as well as the employee's situation and
the operation as a whole, that could be negatively impacted by those hazards.
Additionally, to evaluate the potential hazard and take the necessary precautions to
eliminate it as soon as possible so that it does not have an adverse impact on the
manufacturing or production facility as a whole or its workforce. During the design and
development of equipment or the designing process, safety and reliability are ensured by
considering codes of practice and standards. The development of machinery requires
engineering and safety knowledge, as well as the expertise of industry professionals.

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 Also, hazard and operational analysis will be a very important part of the manufacturing
plant in order to prevent hazards, provide safe and reliable machinery and equipment,
and keep the workplace safe.

C. Equipment Design and Specification (February 2023-March 2023)

At this stage, the design and specifications of all of the machinery that will be
employed in the manufacturing plant's various processes will be finalized. Equipment
specifications outline the method of production capacity, power requirements, fabrication
methods, and other finer details that consider the equipment suitable for use. To prevent
equipment breakage, an engineer must have a comprehensive understanding of
equipment specifications. Moreover, it is necessary to have the design process flow
diagram, as well as the specifications for the materials and equipment that will be used,
for the key piece of equipment. This will also serve as the basis for the procurement of
necessary materials and equipment that will be used prior to the execution phase of the
project. The specifications and designs of the equipment are directly related to how well
the manufacturing processes are done, and the proposed paper will show calculations
based on material and energy balances.

D. Process and Instrumentation Design (P&ID) Layouting (March 2023)

The layout of the manufacturing plant for the process and instrumentation design
(P&ID) will be completed at this stage of the process. P&IDs are essential to the
maintenance and modification of the process they graphically depict. The diagram also
serves as the basis for the development of system control schemes during the design
phase. P&IDs are schematic diagrams of the functional relationship between piping,
instrumentation, and system equipment components used in the field of instrumentation,
control, or automation. Typically, they are created by engineers who are designing a
physical plant's production process. Process Flow Diagrams, or PFDs, are commonly
utilized during the design phase of a manufacturing plant in order to capture the
fundamental flow of a process. PFD is therefore a diagram of the conceptual workflow
that outlines how the fully operational equipment will function after it has been installed.
When used in accordance with a process flow diagram, a P&ID provides engineers with
the information they need to develop control strategies that ensure production

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 requirements are achieved while also complying with all applicable safety and
environmental regulations. In addition, a comprehensive analysis of the controlled
streams should be carried out in order to prevent the controls from interfering with one
another in any situation.

E. Engineering Plant Design Layouting (March 2023- April 2023)

During this phase, a detailed construction plan will be adhered to in order to finish
the final comprehensive design for the project. Inlet and outlet flow, operating
temperature, and pressure ranges, as well as other factors that have the potential to
influence product quality, will be taken into consideration. The layout of a manufacturing
plant entails the development of physical relationships between the building, equipment,
and production operations to facilitate the efficient execution of the manufacturing
process. In addition, a contractor will be in charge of the construction plans, which will
include an effective strategy that will be used to determine how they can handle and
conduct a construction project. This strategy will cover everything from the design of the
framework to the acquisition of supplies and the designation of people to complete
various tasks. Thus, instructions and blueprints for the construction of the plant will be
the primary considerations during the finalization of the manufacturing plant's
comprehensive layout.

F. Financial Analysis (May 2023)

In this phase, the financial assumptions, cost estimation, and financial analysis of
Rugí Manufacturing Inc. will be thoroughly discussed to determine whether the
manufacturing plant is financially feasible. Due to their influence on the overall cost of
the project, the quality, quantity, and availability of raw materials and equipment are the
most significant factors during this phase. Raw materials will be acquired from local
sources, and the machinery and equipment required for the plant's processes will be
ordered and purchased on time, with particular consideration given to the products
whose delivery will take a significant amount of time. In order to accomplish the desired
level of production, it is necessary to organize and ensure that all of the essential
components, including the raw materials and the machinery, are in proper working
condition. Also, the financial assessment includes budgets for each piece of equipment

89
 and machinery, in addition to the raw materials, which will be purchased in the province
of Isabela, which is the top corn producer in the country.

EXECUTION PHASE OF THE DESIGN

This stage will discuss the flow structure and other requirements for the Rugí
Manufacturing Plant. It includes the bidding for contractors and construction, loaning and
capitalization, legal registration with government regulations, and construction planning.

A. Bidding for Contractors and Construction (June 2023 - November 2023)

This phase involves hiring a contractor who can supply the materials and install
the equipment acquired. A project manager is tasked with selecting contractors who can
join the bidding and provide a selection of cost-effective facilities and equipment. The
contractor should be able to collaborate with licensed and authorized engineering and
construction companies in the local market to qualify. Furthermore, the selected
contractor should be capable of offering appropriate solutions to governmental and
commercial customers. After the bidding, the terms and conditions of the contract will be
negotiated and handed a one-year contract.

B. Loaning and Capitalization (November 2023 - February 2024)

In the financial assessment, the economic evaluation, site location, and the
distribution of the budget for the construction, equipment, machinery, and raw materials
will be thoroughly evaluated. The Rugí Manufacturing Plant is to be built at Iligan City,
Isabela, the top producer of corn in the country which is the main raw material of the
plant. This will ensure the quality with the minimum production cost of the raw materials.
Furthermore, the pilot plant will be built to collect real data that can help to ensure
that the full-scale production of the plant runs properly. It will allow the company to
experiment with inputs, outputs, and processing time, and streamline the process. Thus,
it will ensure that the technical aspects of the plant are in optimal conditions and ready
for large-scale production.

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 C. Legal Registration with the Government Regulations (March 2024 - May 2024)
This is one of the important stages of building a manufacturing plant as it will take
place prior to the formal and official operations. Before building a manufacturing plant,
legal issues, such as government rules and guidelines, should be taken into account and
checked because it will serve as a tool for managing a business problem, which arises
from the complexity of the applicable legal provisions and management standard
requirements, coupled with the complexity of the company’s operational activities. Thus,
it will determine the operation of the Rugí Manufacturing Plant.

D. Construction Planning (June 2024-October 2024)

The in charge of construction planning is the selected contractor from the
bidding. Their tasks include the execution and overseeing of the construction project
from the development of the time framework, to designing, purchasing the materials, and
providing the manpower to complete the tasks. Prior to the construction, all the plans
made by the contractor, project manager, and engineers overseeing the project will be
presented to the boards of directors and investors to finalize every detail needed in order
to build the Rugí Manufacturing Plant, particularly the project budget and the materials
and equipment that will be used.

PRE-OPERATION PHASE OF THE DESIGN

This phase highlights the preliminary activities for the development and construction of
the Rugí Manufacturing Plant. It includes site development and building construction,
procurement of equipment and raw materials, installation and testing of equipment, and hiring
and training of employees.

A. Site Development and Building Construction (November 2024 - January 2027)

When the preparation and all the requirements are done the construction of the
Rugí Manufacturing Plant can begin. The project managers, engineers, and contractors
will be overseeing the ongoing construction of the manufacturing plant to ensure the
quality of the work and the progress is aligned with the target time frame. And, the
project engineers will only answer questions from contractors about the project.

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 B. Procurement of Equipment and Raw Materials (January 2025-January 2027)
The procurement of equipment and raw materials is a critical stage because this
will determine the project cost while considering their availability, quality, quantity, and
their ease to transport. The equipment, particularly those only available overseas, will be
purchased while considering the project’s time frame to ensure that they will arrive on
time. Furthermore, the raw materials will be purchased locally which will guarantee the
minimum production cost. The quality of all the equipment and raw materials will be
thoroughly evaluated to verify if they are in optimal working condition and achieve the
target production.

C. Installation and Testing of Equipment (January 2027-April 2027)

After the design details have been finalized and all the purchased equipment
arrived, they will be pre-installed and subject to testing before moving to their final
location. This phase will ensure the proper system operation and equipment quality
before transitioning to the operational phase.

D. Hiring and Training of Employees (July 2025 - December 2026)

The human resources department will be in charge of hiring the employees. All
the personnel and staff of the Rugí Manufacturing Plant will undergo seminars and
training in operating and maintaining the plant's facilities depending on their job
descriptions before actually working in the plant. This will guarantee the safety of the
employees and the manufacturing plant itself.

OPERATION PHASE OF THE DESIGN

This phase includes the implementation, supervision, planning, and modification of the
established Rugí manufacturing plant. Accordingly, this phase will monitor and calculate the
capacity of the manufacturing plant to improve its performance and efficacy. Thus, the actions
comprising this phase are the following– Marketing budget and strategy, pilot testing, and
operation process.

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A. Development of Marketing Budget and Strategy (March 2024- August 2027)
The marketing budget outlines the estimated financial expenses and
procurements for the project. This includes the possible cash inflows and outflows to be
utilized for the purpose of publicity and advertisements. Marketing strategy, on the other
hand, targets the promotion of the manufacturing plant through different platforms. The
goal of Rugí’s marketing strategy is to influence the decision process of the consumers
for healthier, and more sustainable products. It includes marketing in social media,
websites, prints, infomercials, portfolios, and other public and social platforms.

B. Pilot Plant (August 2027 - December 2027)

The flowsheet created by Rugí Inc. is demonstrated and validated in pilot plant
testing. Rugi will conduct tests in all unit operations working together to deliver
continuous feed or product in an integrated manner. Piloting reduces technical risk by
demonstrating operational viability and producing the anticipated result. It also produces
data that is utilized to reduce design capital hazard, and construction costs for the
full-scale facility.

C. Operation Process (January 2028 - 2058)

The manufacturing plant is designed to begin its regular operation in January
2028 during the peak season of corn supply in the Philippines. This phase will be
executed after complying with all the requirements prior to the operation process. The
plant shall have 330 working days per year, including plant and equipment maintenance.
The maintenance will be done every month and every quarter to ensure efficiency and
safety. Moreover, the plant will be conserved by process engineers and maintenance
officers to assist in the troubleshooting of processes.

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 CHAPTER V
PRODUCT SPECIFICATION AND PROCESS DESCRIPTION

PROCESS DESCRIPTION AND PRODUCT SPECIFICATION

This chapter presents an in-depth discussion of the manufacturing process, wastewater
management, and water treatment plan for the Rugi Inc Manufacturing Plant.

I. MANUFACTURING PROCESS
The Rugi Inc. manufacturing plant utilizes a batch process to produce its products. There
are two main products to be obtained, namely high-fructose corn syrup 55 and corn oil . The
entire process is divided into five areas which include: Mechanical Pretreatment, Corn milling,
high-fructose corn syrup, corn oil process, and wastewater treatment plan.

Figure 5.1 Summary Flow Diagram for the High-Fructose Corn Syrup and Corn Oil
Manufacturing Plant
 A. AREA 100– CORN MILLING

Figure 5.2 Block Diagram for the Area 100

Process Description
a. Steeping
The cleaned corn kernels will be steeped using steeping tanks for about 42 hours
at 52°C (125°F) in an insulated hopper-bottomed tank. The interconnected tank have a
specific number of over 50 tanks with the size of 633 Mt. Steep tanks can store from
~40, 000 corn kernels, which are subsequently submerged in a stream 2% sulfurous
acid solution and 3% lactic acid concentration. During the steeping process, sulfur
dioxide and water react to generate sulfurous acid, which inhibits undesired fermentation
and prevents excessive bacterial development in a warm environment, whereas lactic
acid helps the separation of starch from the protein matrix. Lactic acid fermentation
results in rapid hydration of the kernel to near equilibrium conditions (42–52%, wb), and
leaching of soluble material from the germ into the steepwater causing a concentration of
the oil from 35% to 50%. Lactic Acid increased 1.5% in steepwater (Rausch et al., 2016).

b. Degerminating
To accomplish this, attrition mills (224 kW) with specially designed intermeshing
teeth using relatively loose gap settings that allow one or two whole kernels per handful.
The steeped corn is milled in an equal volume of water (Eckhoff et al., 2016). The
attrition grinding machine used was a 5-inch-diameter unit, which originally analyzed 2-
to 3-percent loss (911 Metalurgist, 2017). After attrition milling, an average of 99.58%

96
 mass of corn kernel will be recovered (Adu-Poku, 2020). The milled maize slurry is
pumped through a hydrocyclone system to recover germ. These germ hydrocyclones are
15.25–22.86 cm diameter and 0.6–1.1 m tall. Operating pressures are generally
275–310 kPa with the specific density of the slurry adjusted to between 8 and 9 Baume´.
In-plant experimental data show that 85% of the germ is recovered by the first-grind.
Then discharged in a press dewatering screen and the slurry is set to transfer in the fine
grinding process. Corn germ is the embryo of the kernel found in its center and is
composed of fat (50%), starch (14%) and protein (13%).

c. Germ Washing

To get the high purity germ, the isolated germs are washed in a hydrocyclone
with water. By using a counter-current flow principle, the amount of freshwater used is
small. After this process, almost all contaminants are washed out. This coarse residue is
repeatedly washed in a counter‐ current fashion, with a final squeezing stage to remove
a maximum amount of very light concentration starch water in the press.

d. Germ Drying

The germ must be <3% moisture to prevent oxidation of the oil during transport.
The germ fraction contains 42–55% oil depending on a number of factors including the
amount of residual pericarp that floats with the germ, steep time, and maize hybrid or
variety. Rotary dryers are commonly used to dry germs because the exposure time for
any individual germ to be in contact with a steam tube is minimal. The germ was dried
for 9.4 minutes at 80 degrees Celsius. The drying temperature should not exceed 80 C
for extended periods of time to avoid heat-damaged to oil and extraction efficiencies and
oil quality decreased.

e. Oil Extracting

The corn germ from the wet milling process is brought to the horizontal rotary
cooker through a pipe and conditioned for a short time at a temperature of 80 to 82°C for
1.20 hours. Steam requirement for cooking corn germ is 17% (Maza, 2012). The
conditioning step is a heat treatment step which helps to soften the corn germ prior to
expeller pressing. The heating medium is steam and the ratio of the corn germ to steam
is 4.8:1. Losses in rotary cookers is 1.20% (Wiley-Blackwell, 2013).
Expeller pressing is an extrusion cooking technique which will consist of heating
the flakes at 90-105°C and mixing with live steam. Steam requirement for expeller
pressing is 15% (Maza, 2012). The ratio of the softened corn germ to steam is 5.7:1 at
5.9 to 9.9 atm gauge pressure and then pushing them through a restriction. The
equipment itself consists of a horizontal barrel through which the material is pushed
forward by means of a rotating worm assembly. Live steam is introduced inside the

97
 barrel by means of nozzles and mixed with the product. Then the material is pushed
through the outlet section in the form of a hydraulic cone. The residence time in this
process is 1.20 hours. 65% recovered oil by pressing (Shad, 2020). Losses in expeller
press is 1.17 (Harmanto et al., 2009).
The approximate composition of crude corn oil is: 95.6% triglycerides, 2.5% free
fatty acids, 1.5% phospholipids, 0.39% unsaponifiable, and 0.01% wax
(Barrera-Arellano, 2019).

f. Grinding

Fine grinding is done using an impact mill in order to liberate loose starch and
gluten from the fiber and bound starch and gluten. Rotating pins installed in the impact
mills impact the fiber and starch particles, breaking starch free from the fiber and
reducing the particle size of starch grits. After milling, 50 micron screen is used to
prevent fine fibers from entering the starch slurry. This stage is fed at 4.08 atm pressure
for maximum capacity for 0.36 hours. The equipment loss in this process is 1.10%.
A 1-g loss of solids while milling 100 g of corn reduces total solids recovery by
1%; whereas, solids recovery is reduced only 0.1% when 1 g is lost while milling 1 kg of
corn.

g. Screening

The finely ground slurry is pumped onto the screen. The finely ground
fiber–starch–protein slurry is sprayed across the top of the screen at a pressure of 275
kPa. Then the underflow is passed over a 50 mm 120 gravity screen to dewater slurry
and to allow starch that has already been released from the fiber to go directly into the
gluten recovery section of the process. Corn flour remaining after fiber separation was
termed "enhanced corn flour". Of the total weight of corn flour, 3.8% was obtained as
fiber and 96.2% was obtained as enhanced corn flour (Srinivasan et al., 2008). This
stage is fed at 4.08 atm pressure for a maximum capacity for 0.36 hours. The equipment
loss in this process is 1.10%.

h. Centrifuging
Since the gluten has a lower density than the starch, centrifuge can be used to
spin out the gluten from the solution. 33.33% w/v of water is introduced into the
centrifuge where it washes the solubles from the starch via displacement washing at
0.48 atm for 0.51 hours. 2.00% of the total mass input is lost in this process..

i. Washing
The next step is washing the starch. Using 10–14 stages of 10 mm diameter
hydrocyclones, starch is washed in a countercurrent approach. Each stage of the starch
washing system is equipped with sufficient hydrocyclones to manage the starch slurry

98
 flow rate at that level. To counter currently wash the starch to a protein level of
0.25–0.5%, approximately 1200–1500 of freshwater per Mt of corn is required. The
residence time in the hydrocyclone is 0.50 hours at a pressure of 0.48 atm. A bushel (25
kg) of corn will yield an average of 31.5 pounds (14.3 kg) of starch, which in turn will
yield about 33.3 pounds (15.1 kg) of syrup (Vikaspedia, 2022).
The purified starch slurry is discharged to a peeler centrifuge for dewatering. The
dewatered starch is batch-wise peeled off and discharged by gravity to the moist starch
hopper.

B. AREA 200– HIGH FRUCTOSE CORN SYRUP 55

Figure 5.3 Block Diagram for the Area 200

99
 Figure 5.4 Block Diagram for the Area 200

Process Description
a. Gelatinization
In a mixing tank, cornstarch slurry will be mixed with water at a ratio of 1:0.5 to
make a starch slurry, and the pH will be adjusted from 5.7 to 6.3 by adding soda ash at a
ratio of 6.23% w/v per unit of feed (Deleyn, 2009). Then, a 0.31% w/v calcium chloride
(CaCl2) solution will be added to the starch slurry to produce between 50 and 70 ppm of
free calcium (Carrol, 2007). And, the starch slurry will be heated to 90°C for 0.23 hours.
The starch slurry will be added 0.01% w/v of Bacillus stearothermophilus
alpha-amylase to hydrolyze the starch. Equipment loss during this process is 1%
(Carrol, 2007).

b. Liquefaction
From the mixing tank, the enzyme-containing starch slurry will be pumped to a jet
cooker and consequently added with steam at 103°C – 107°C for 0.56 hours and 0.35
atm. The ratio of the starch slurry to steam is 1:0.20. The steam in this process will be
generated by a steam boiler which operates at 350°C for 1.11 hours and 3.36 atm. The
steam will be injected by a steam injector at 10-11 bar feed pressure and 0.6-0.8 bar
back pressure at 108°C for 0.27 hours. This gives the enzyme time to efficiently break
down the starch into glucose, maltose, and oligosaccharides. No additional heating is
required to maintain the temperature and maximize the performance of the enzyme. It
will hold for 10 minutes in order to produce the first liquefact. Equipment loss during this
process is 1.50%.

100
c. Flash Cooling
After the initial liquefaction, the liquefact will be flash cooled at 1 atm, and the
temperature dropped rapidly to a temperature of 97°C. The pressure is released within 1
to about 5 seconds and the temperature is dropped within about 1 to 5 seconds. And the
flash-cooled liquefact will be transferred to a liquefaction tank, where the solution is held
for 90 minutes to reach a dextrose equivalent of 10-12 units. When the liquefaction
process is done, adjust the pH between 4 and 5 and cool the liquid to around 60°C. This
inactivates the liquefaction enzyme and creates conditions suitable for the
saccharification enzymes. Equipment loss during flash cooling is 5.00%.

d. Saccharification
Then, the liquefact will be pumped into the saccharification tank and Asperigillus
niger glucoamylase with 0.05 w/v concentration will be added to the tank (Ahmed et al.,
2017). The temperature of the tank should be maintained at 60°C and the pH should be
controlled around 4-5. And the maximum level of conversion possible with these
enzymes is about 96% in a period of 60–90 h.

e. Filtration
Following the saccharification, the saccharified starch will be filtered at 80°C with
a 4.76% w/v filter aid and screened for 0.85 hours to remove insoluble materials such as
fat and protein. Equipment loss is 1.35% (Svarovsky, 2013).

f. Decolorizing
Next, the saccharified starch is transferred to a pulsed-bed adsorber carbon
column and decolored using activated carbon with 0.50% w/v of activated carbon for 1
hour and the temperature during the process is 80°C. Equipment loss is 2.00% (Kyzas,
2012).

g. Demineralization
Then, the minerals will be removed using 0.08% of ion exchange resin to purify
the saccharified starch at 30-50°C and 0.10% w/v of mono anion exchange resin, and
0.05% w/v of polishing the resin for final ion exchange and will take 2.40 hours (Guyer et
al., 2018).

h. Evaporation
After demineralization, the saccharified starch is pumped in the evaporator, After
decolorizing, to remove 25-30% of the water is before isomerization. Equipment loss, on
the other hand, is 1.35% (Ahmed et al., 2019).

i. Isomerization

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 To produce high-fructose corn syrups, the glucose syrups (DE 95–98; 40–50%,
DS) will be pumped to in-column reactors with Streptomyces murinus glucose
isomerase. The pH of reactors is between 7.5 and 8.0, and the temperature is between
55 and 60°C.

j. Filtration
A rotary vacuum filter will be used to refine the HFCS 42. It will be filtered at 80°C
with a 4.76% w/v filter aid and screened for 0.85 hours to remove insoluble materials
such as fat and protein. 1.35% of the total mass input is lost during this process.

k. Mixing
In a mixing tank, the glucose syrup with 85.37% input will be mixed with water
having 14.63% composition. The output of the process is a 99% diluted HFCS while the
equipment loss is 1%.

l. Decolorization
HFCS 42 is again transferred to a pulsed-bed adsorber carbon column and
decolored using activated carbon with 0.50% w/v of activated carbon for 1 hour, and the
temperature during the process is 80°C. Equipment loss is 2.00%.

m. Evaporation
After decolorizing, Diluted HFCS with 100% composition will be sent to an
evaporator to produce an HFCS-90 solution. Water loss in this process is 0.03%.
Equipment loss, on the other hand, is 1.35% (Ahmed et al., 2019).

n. Mixing
In a mixing tank, HFCS-90 is mixed with the remaining HFCS-42 to produce
HFCS-55 with a 99% composition. In addition, 1.00% of the total mass input is lost
during this process.

o. Decolorization
After mixing, the HFCS-55 solution will be sent to the decolorization column
together with activated carbon having 0.50%. The equipment loss in this process is
1.35%.

p. Evaporator
Following the decolorization, the HFCS-55 solution with 100% input will then be
transferred to an evaporator. The water loss in this process is 57.64% while the
equipment loss is 0.50%.

q. Ultrafiltration

102
 The HFCS-55 and Glucose solution will undergo to ultrafiltration to separate
HFCS-55 and unrefined glucose. And, 0.50% of the total mass input is lost during this
process.

103
 E. AREA 300 - CORN OIL REFINING

Figure 5.5. Block Diagram for the Area 300

a. Degumming
The corn oil and soft water will be mixed with a ratio of 98.8:1. Then, 0.20% w/v of
phosphoric acid will be added to the mixture which will react with free fatty acids in order to form
gums. And, the mixture will be preheated to 100°C and 0.0987 atm for 1.20 hours. The water
commonly added for effective degumming is about 1 or 2% in relation to crude oil
(Barrera-Arellano, 2019).
The gums formed are removed in the centrifugation with a loss of 3.88% of the total
mass input.

b. Neutralization
The degummed oil will be transferred to a second centrifuge. Then, 1.40% w/v of sodium
hydroxide will be added to neutralize the free fatty acids. Next, it will undergo washing with
water at 100°C and 0.0987 atm to produce neutral oil and soap stocks. The soapstocks will be
removed during the centrifugation for 1.11 hours with 3.66% of the total mass input lost.

c. Bleaching
The washed oil will enter the clarification reactor. Then, 2% w/v bleaching clay will be
added and operate at 95°C with a pressure of 0.05 to 0.2 atm. The dosage range of the
bleaching clay is between 1%and 2.0% (Saldivar, 2017). The reactor will operate for 1.20 hrs

104
and it contains a cold filter which will aid the clay removal from bleached oil. Equipment loss is
1.59%.

d. Dewaxing
Corn oil contains between 15 and 50 mg/kg of wax before winterizing (Serna, 2014). The
bleached oil will enter the crystallizer through a pipe and 0.50% w/v dicalite will be added. The
operating temperature and pressure during the process is 105°C and 0.07 atm respectively, and
will operate for 1.20 hours. The waxes formed will be separated and the dewaxed oil will
proceed to the next refining process. Equipment loss is 3%.

e. Deodorization
The dewaxed oil will enter the deaerator to remove the air with an operating temperature
of 110°C and operating pressure of 0.07 atm. Then, it will proceed to the deodorization tower
and 4% of steam will be introduced and subjected to heating at 220°C and 0.005 atm for 1.20
hours to remove the volatile odorants from deodorized oil. Equipment loss during deodorization
is 3.87%.

f. Filtration
The deodorized oil will undergo a vacuum filtration system using a polyester felt filter
material, a synthetic felt stronger than filter paper. The filtration will take 1.20 hrs and the
equipment loss is 0.80%. The proximate composition of refined corn oil is 98.8% triglycerides,
0.05% free fatty acids, and 1.15% unsaponifiable (Barrera-Arellano, 2019). The resulting refined
corn oil will have a purity of 98.80% and is comparable to the commercially produced corn oil -
of which 98.80% is the triglycerides content, 0.05% free fatty acids and 1.15% unsaponifiables.

g. Packaging
The refined corn oil will be packed in bottles through a packaging machine. The 1% loss
in the packaging machine is assumed.

105
 F. AREA 400– WASTEWATER TREATMENT

Figure 5.6. Block Diagram for the Area 400

a. Wastewater Collection

Wastewater Collection from area 200 amounting to 231,996.65 𝑘𝑔, area 300
with 5.34 𝑘𝑔 of Insoluble Materials and area 400 with 3,062.30 𝑘𝑔 supernatants will all
proceed directly to the wastewater storage tank for collection purposes, before
proceeding to the grit chamber.

b. Grit Removal
Collected wastewater from specific areas that is stored in wastewater storage
tanks will proceed directly to the grit chamber. The grit chamber will be used to remove
grits and other fine solid particles from filtered wastewater. Grit is defined as sand,
gravel, cinder, or other heavy solid materials with higher specific gravity than the organic
biodegradable particles in the wastewater. Grit removal prevents mechanical equipment
friction and wear, grit deposition in pipelines and channels, and grit accumulation in
anaerobic digesters and aeration basins. The grit chamber has 51.40 minutes of
retention time.

c. Neutralization
The accumulated wastewater from the corn milling process produced an acid
which is H2SO3. And to neutralize this acid, in the neutralization tank NaOH will be

106
 deployed. The accumulated amount of H2SO3 is 2,303.01kg and the needed amount of
NaOH to neutralize it is 4,283.60kg.

d. Sedimentation
In a circular center-feed clarifier, the inlet baffle should have a diameter of 15 to
20 percent of the clarifier diameter and should not extend more than 3 feet below the
water surface. With 100 percent recirculation, circular center-feed clarifier inlet baffles
should not be less than 20 percent of the clarifier diameter and have a depth of 55 to 65
percent of the side water depth. The maximum inlet velocity to a center inlet well should
not exceed 3 feet per second. The outflow velocity should not exceed 15 feet per minute.
In a circular peripheral-feed clarifier, the inlet baffles shall extend at least 12 inches
below the flowline of the inlet and shall be located above the sludge blanket zone at a
distance where the critical horizontal velocity will just begin to produce scour.
Surface-loading rates for this clarifier should not exceed 1,000 gallons per day per
square foot at average design flow and shall not exceed 1,500 gallons per day per
square foot at peak hourly flow. Primary clarifiers not followed by secondary treatment
should not exceed 600 gallons per day per square foot for plants with average design
flows of 1.0 MGD or less (TOPRAK, 2019).

e. Aeration
Oxygen is delivered to wastewater as a component to make aerobic
biodegradation of organic substances and contaminants easier. To absorb, adsorb, and
remove the bacteria and contaminants in the wastewater, the microorganisms in the
aeration system require 23.86 minutes of detention time and operate at a given condition
of 10℃ that results in 185,740.92 aerated wastewater. Aeration treatment involves
pumping enormous amounts of air into water and then venting it outdoors, allowing
microbes to treat and stabilize the wastewater with oxygen. The efficiency observed in
an aeration tank was 99%.

f. Microfiltration
The process of physically removing suspended solids from water, usually across
a membrane, is known as microfiltration. To remove germs and suspended particles from

107
 the process liquid, disinfected water will be filtered through a membrane for 50.65
minutes. Microfiltration has a 99% removal rate.

g. Ultraviolet Disinfection
UV radiation disinfection will be used to destroy microorganisms' genetic
material, preventing them from reproducing. It is a cost-effective, safe, and ecologically
friendly method of wastewater disinfection. The purpose of wastewater disinfection is to
eliminate pathogens that cause waterborne illnesses. UV radiation disinfection has 99%
removal rate and retention time of 50 minutes.

h. Reverse Osmosis
Before being re-used in the system, the wastewater will be purified by a reverse
osmosis system. Reverse osmosis is a water purification method that uses a
semi-permeable membrane (synthetic liner) to filter out pollutants and big particles such
as chlorine, salt, and dirt from drinking water. Reverse osmosis can remove 99% or more
of dissolved salts (ions), particles, colloids, organics, microorganisms, and pyrogens
from feed water at a retention time of 50 minutes.
II. PRODUCT SPECIFICATIONS

108
Table 5.1. Product Specification for Rugi Manufacturing Plant

109
 CHAPTER VI

PROCESS FLOW DIAGRAM AND MATERIAL BALANCE

This chapter presents the flow diagrams, qualitative and quantitative process flows as
well as the summaries of material balances.

Figure 6.1. Schematic Diagram of the Manufacturing Processes of Rugi Incorporation

Rugí Incorporation contains noble and modern equipment capable of producing

high-fructose corn syrup 55, and corn oil. It has a batch system in which high-fructose corn
syrup operates 90 batches every year, meanwhile, corn oil operates 102 batches every year in
five areas: Mechanical Pretreatment, Corn Milling, High-Fructose Corn Syrup 55 Production,
Corn Oil Production, and Wastewater Treatment.
 Table 6.1. Summary of Corn Wet Milling
AREA 100: CORN WET MILLING
Total Mass Input 100.00% 175,000.00 Total Mass 100.00% 175,000.00
Output
Corn Kernels 40.00% 70,000.00 Softened Corn 53.00% 92,751.51
Kernels
Moisture 10.00% 7,000.00 Moisture 33.96% 31,500.00
Starch 53.85% 37,695.00 Starch 55.68% 51,646.00
Ash 1.30% 910.00 Ash 0.07% 63.00
Fiber 1.71% 1,197.00 Fiber 0.41% 382.44
Protein 10.10% 7,070.00 Protein 7.39% 6,857.90
Germ 4.14% 2,898.00 Germ 2.48% 2,302.17
Steeping 60.00% 105,000.00 Steep Water 44.20% 77,348.49
Solution Steeping Tank
Water 97.50% 102375 H2SO3 3.27% 2,528.58
SO2 2.00% 2,100.00 Lactic Acid 1.36% 1,050.02
Lactic Acid 0.50% 525.00 Carbohydrates 5.80% 4,486.21
Protein 24% 18,563.64
Fats 1% 773.48
Minerals 8.20% 6,342.58
Residual
Solubles 6.37% 4,929.74
Water 50.00% 38,674.24
Losses 2.80% 4,900.00
Total Mass Input 100.00% 170,100.00 Total Mass 100.00% 170,100.00
Output
Softened Corn 54.53% 92,751.51 Dewatering Softened Corn 54.03% 91,901.01
Kernels Gravity Kernels
Screen
Steep Water 45.47% 77,348.49 Steep Water 44.97% 76,497.99
Losses 1.00% 1,701.00
Total Mass Input 100.00% 183,802.03 Total Mass 100.00% 183,802.03
Output
Softened 50% 91,901.01 Corn Slurry 98.00% 180,125.98
Kernels
Moisture 34.28% 31,500.00 Coarse Ground 50.81% 91,515.03
Kernel
Starch 56.20% 51,646.00 Moisture 24.40% 22,327.26
Ash 0.07% 63.00 Starch 56.24% 51,470.40
Attrition Mill
Fiber 0.42% 382.44 Ash 0.06% 55.76
Protein 7.46% 6,857.90 Fiber 3.99% 2,055.03
Germ 2.51% 2,302.17 Protein 7.42% 6,788.64
Water 50% 91,901.01 Germ 7.89% 7,219.10
Water 49.19% 88,610.96
Losses 2.00% 3,676.04

111
Continuation of Table 6.1
Total Mass Input 100.00% 180,125.98 Total Mass 100.00% 180,125.98
Output
Corn Slurry 100% 180,125.98 Corn Slurry 89.45% 161,122.69

Coarse Ground Coarse Ground

Kernel 50.81% 91515.02845 Kernel 46.39% 74,744.82
Moisture 24.40% 22,327.26 Moisture 23.20% 17,338.82
Starch 56.24% 51,470.40 Starch 66% 49,411.59
Ash 0.06% 55.76 Ash 0.26% 193.52
Fiber 2.25% 2,055.03 Fiber 2.58% 1,931.73
Protein 7.42% 6,788.64 Protein 7.16% 5,353.10
Germ 7.89% 7,219.10 Hydrocyclone Germ 0.69% 516.06
Water 49.19% 88,610.96 Water 53.61% 86,377.88
Germ Slurry 8.55% 15,400.77
Germ 70.18% 10,807.56
Moisture 23.00% 2,485.74
Starch 14.00% 1,513.06
Protein 13.00% 1,404.98
Fat 50.00% 5,403.78
Water 29.82% 4,593.21
Losses 2.00% 3,602.52
Total Mass Input 100.00% 15,400.77 Total Mass 100.00% 15,400.77
Output
Germ Slurry 100.00% 15,400.77 Dewatered 70.23% 10,815.96
Germ
Dewatering
Germ 70.18% 10,807.56 Screen Wastewater 28.77% 4,430.80
Water 29.82% 4,593.21 Losses 1.00% 154.01
Total Mass Input 100.00% 10,815.96 Total Mass 100.00% 10,815.96
Output
Dewatered 100.00% 10,815.96 Dried Germ 80.14% 8,667.99
Germ
Moisture 22.98% 2,485.74 Moisture 3.74% 324.48
Starch 13.99% 1,513.06 Starch 13.99% 1,517.00
Protein 12.99% 1,404.98 Drier Protein 12.99% 1,408.65
Fat 49.96% 5,403.78 Fat 49.96% 5,417.87
Wastewater 19.46% 2,104.70
Losses 0.40% 43.26
Total Mass Input 100.00% 10,443.37 Total Mass 100.00% 10,443.37
Output
Dried Germ 83.00% 8,667.99 Dried Germ 80.94% 8,452.37
Horizontal
Moisture 3.74% 324.48 Rotary Cooker Moisture 3.72% 314.75
Starch 17.50% 1,517.00 Starch 17.41% 1,471.49

112
Continuation of Table 6.1
Protein 16.25% 1,408.65 Protein 15.41% 1,302.45
Fat 62.50% 5417.865998 Fat 63.46% 5363.687338
Steam 17% 1,775.37 Steam 17.86% 1,865.67
Losses 1.20% 125.32
Total Mass Input 100.00% 9,943.97 Total Mass 100.00% 9,943.97
Output
Dried Germ 85.00% 8,452.37 Corn Oil 87.97% 8,748.06
Moisture 2.95% 314.75 Triglycerides 94.67% 8,281.79
Starch 17.32% 1,471.49 Free Fatty Acids 2.50% 218.70
Protein 16.58% 1,302.45 Expeller Press Phospholipids 1.50% 131.22
Fat 63.15% 5363.687338 Unsaponifiables 1.32% 115.47
Steam 15% 1,491.60 Waxes 0.01% 0.87
Steam 10.86% 1,079.57
Losses 1.17% 116.34
Total Mass Input 100.00% 149,752.68 Total Mass Input 100.00% 149,752.68
Fine Ground
Corn Slurry 100.00% 161,122.69 Slurry 94.81% 141,982.74

Fine Ground
Coarse Ground 43.12% 69,470.27 Mill 47.07% 66,830.40
Moisture 25% 17,338.82 Moisture 8.34% 5,573.66
Starch 71.13% 49,411.59 Starch 84.20% 56,271.19
Ash 0.28% 193.52 Ash 0.20% 133.66
Fiber 6.67% 1,931.73 Impact Mill Residual Fiber 0.56% 374.25
Protein 7.71% 5,353.10 Protein 6% 4,009.82
Germ 0.74% 516.06 Gluten 73.58% 2,950.43
Water 115.56% 80,282.41 Soluble Protein 0.2642 1,059.40
Residual Germ 0.70% 467.81
Water 52.93% 75152.33982
Fiber Slurry 4.09% 6,122.66
Losses 1.10% 1,647.28
Total Mass Input 100.00% 148,105.40 Total Mass 100.00% 148,105.40
Output

Fine Ground Fine Ground

Slurry 95.87% 141,982.74 Mill 85.23% 66,162.09

Fine Ground Press

Mill 47.07% 66,830.40 Dewatering Moisture 5.86% 3,880.26
Screen
Moisture 8.34% 5,573.66 Starch 71.57% 47,350.41
Starch 84% 56,271.19 Ash 0.17% 112.47
Ash 0.20% 133.6607956 Residual Fiber 0.56% 370.99

113
Continuation of Table 6.1
Residual Fiber 0.56% 374.25 Protein 1.35% 891.45
Protein 1.59% 1,059.40 Gluten 3.75% 2,482.69
Gluten 4.41% 2950.428403 Residual Germ 0.74% 491.49
Residual Germ 0.70% 467.81 Fiber Cake 1.72% 2,540.90
Water 52.93% 75152.33982 Wastewater 52.61% 77,921.35
Fiber Slurry 5.86% 6,122.66 Losses 1.00% 1,481.05
Total Mass Input 100.00% 99,238.18 Total Mass 100.00% 99,238.18
Output
Fine Ground Mill 66.67% 66,162.09 Fine Ground 57.14% 56,704.70
Moisture 5.86% 3,880.26 Moisture 2.14% 1,212.97
Starch 72% 47,350.41 Starch 95% 53,811.75
Ash 0.17% 112.47 Ash 0.20% 112.47
Fiber 0.56% 370.99 Fiber 0.65% 370.99
Disk Nozzle
Protein 1.35% 891.45 Centrifuge Gluten 1.20% 680.46
Gluten 3.75% 2,482.69 Germ 0.91% 516.06
Overflow Moist
Germ 0.74% 491.49 Gluten 40.86% 40,548.72
Water 33.33% 33,076.09 Gluten 6.64% 2,693.68
Water 72.15% 29,257.00
Residues 21.20% 8,598.04
Losses 2.00% 1,984.76
Total Mass Input 100.00% 85,052.79 Total Mass 100.00% 85,052.79
Output
Pure Starch
Slurry
Fine Ground 66.67% 56,704.70 (Underflow) 64.75% 55,072.63
Moisture 2.14% 1,212.97 Moisture 4.24% 2,337.12
Starch 95% 53,811.75 Starch 95.8% 52,735.51
Hydrocyclone
Ash 112.47 Washing Wastewater
0.20% (Overflow) 33.98% 28,903.92
Fiber 0.65% 370.99 Losses 1.27% 1,076.24
Gluten 1.20% 680.46
Germ 0.91% 516.06
Water 33.33% 28,348.10
Total Mass Input 100.00% 85,052.79 Total Mass 100.00% 85,052.79
Output
Pure Starch Pure Starch
Slurry 64.75% 55,072.63 Slurry 64.70% 55,029.16
Moisture 4.24% 2,337.12 Peeler Moisture 5.28% 2,905.54
Centrifuge
Starch 95.8% 52,735.51 Starch 94.72% 52,123.62
Water 33.98% 28,903.92 Wastewater 35.25% 29,981.11
Losess 0.05% 42.53

114
 Table 6.2. Summary of High-Fructose Corn Syrup 55 Production
AREA 200: HIGH-FRUCTOSE CORN SYRUP 55 PRODUCTION
Total Mass Input 100.00% 88,329.30 Total Mass 100.00% 88,329.30
Output
Pure Starch 62.30% 55,029.16 Gelatinized 99.00% 87,446.01
Slurry Starch Slurry
Starch 94.72% 52,123.62 Starch 25.58% 22,368.69
Amylase 15.00% 7,818.54 Moisture 68.26% 59,690.65
Amylopectin 85.00% 44,305.07 Mixing Tank Soda ash 5.60% 4,896.98
Moisture 5.28% 2,905.54 Alpha-amylase 0.01% 8.74
Water 31.15% 27,514.58 CaCO3 0.27% 236.10
Soda ash 6.23% 5,502.92 NaCl 0.28% 244.85
Calcium chloride 0.31% 273.82 Losses 1.00% 883.29
Alpha-amylase 0.01% 8.83
Total Mass Input 100.00% 104,939.41 Total Mass 100.00% 104,939.41
Output
Gelatinized 83.33% 87,446.01 Liquefied Starch 99.00% 103,890.01
Starch Slurry
Starch 25.58% 22,368.69 Starch 32.05% 33,296.75
Moisture 68.26% 59,690.65 Glucose 0.30% 99.89
Soda ash 5.60% 4,896.98 Maltose 2.00% 665.93
Alpha-amylase 0.01% 8.74 Jet Cooker Oligosaccharide 97.70% 32,530.92
s
CaCO3 0.27% 236.10 Moisture 63.0000% 65,450.71
NaCl 0.28% 244.85 Soda ash 4.62% 4,798.58
Steam 16.67% 17,493.40 Alpha-amylase 0.001% 1.14
CaCO3 0.19% 197.39
NaCl 0.14% 145.45
Losses 1.00% 1,038.90
Total Mass Input 100.00% 103,890.01 Total Mass 100.00% 103,890.01
Output
Liquefied Starch 100.00% 103,890.01 Liquefied Starch 78.08% 81,117.32
Starch 32.05% 33,296.75 Starch 32.05% 25,998.10
Glucose 0.30% 99.89 Glucose 0.30% 77.99
Maltose 2.00% 665.93 Maltose 2.00% 519.96
Oligosaccharide 97.70% 32,530.92 Oligosaccharide 97.70% 25,400.15
s Flash Cooler s
Moisture 63.00% 65,450.71 Moisture 63.00% 51,103.91
Soda ash 4.62% 4,798.58 Soda ash 4.62% 3,746.73
Alpha-amylase 0.0011% 1.14 Alpha-amylase 0.001% 0.89
CaCO3 0.19% 197.39 CaCO3 0.19% 154.12
NaCl 0.14% 145.45 NaCl 0.14% 113.56

115
Continuation of Table 6.2
Vapor 16.92% 17,578.19
Losses 5.00% 5,194.50
Total Mass Input 100.00% 81,157.90 Total Mass 100.00% 81,157.90
Output
Liquefied Starch 99.95% 81,117.32 Unrefined 99.00% 80,346.32
Glucose Syrup
Starch 32.05% 25,998.10 Starch 32.05% 25,751.00
Glucose 0.30% 77.99 Glucose 99.97% 25,743.27
Maltose 2.00% 519.96 Oligosaccharide 0.03% 7.73
s
Oligosaccharide 97.70% 25,400.15 Moisture 62.99% 50,610.15
s Saccharification
Moisture 63.00% 51,103.91 Soda ash 4.61% 3,703.97
Soda ash 4.62% 3,746.73 Alpha-amylase 0.001% 0.80
Alpha-amylase 0.001% 0.89 CaCO3 0.18% 144.62
CaCO3 0.19% 154.12 NaCl 0.13% 103.65
NaCl 0.14% 113.56 Glucoamylase 0.04% 32.14
Glucoamylase 0.05% 40.58 Losses 1.00% 811.58
Total Mass Input 100.00% 84,361.95 Total Mass 100.00% 84,361.95
Output
Unrefined 95.24% 80,346.32 Filtered Glucose 89.29% 75,326.03
Glucose Syrup Syrup
Starch 32.05% 25,751.00 Starch 33.4550% 25,200.32
Glucose 99.97% 25,743.27 Glucose 99.97% 25,192.76
Oligosaccharide 0.03% 7.73 Oligosaccharide 0.03% 7.56
s s
Moisture 62.99% 50,610.15 Rotary Vacuum Moisture 66.5440% 50,124.95
Filter
Soda ash 4.61% 3,703.97 NaCl 0.001% 0.75
Alpha-amylase 0.001% 0.80 Soda ash 4.39% 3,703.49
CaCO3 0.18% 144.62 Alpha-amylase 0.0009% 0.68
NaCl 0.13% 103.65 CaCO3 0.17% 143.42
Glucoamylase 0.04% 32.14 Glucoamylase 0.04% 33.74
Filter Aid 4.76% 4,015.63 Filter Aid 4.76% 4,015.63
Losses 1.35% 1,138.89
Total Mass Input 100.00% 75,704.55 Total Mass 100.00% 75,704.55
Output
Filtered Glucose 99.50% 75,326.03 Decolorized 97.50% 73,811.94
Syrup Glucose Syrup
Starch 33.46% 25,200.32 Starch 33.46% 24,693.78
Decolorizing
Glucose 99.97% 25,192.76 Column Glucose 99.97% 24,686.38
Oligosaccharide 0.03% 7.56 Oligosaccharide 0.03% 7.41
s s
Moisture 66.54% 50,124.95 Moisture 66.54% 49,117.42

116
Continuation of Table 6.2
NaCl 0.001% 0.75 NaCl 0.001% 0.74
Activated 0.50% 378.52 Activated 0.50% 378.52
Carbon Carbon
Losses 2.00% 1,514.09
Total Mass Input 100.00% 73,811.94 Total Mass Input 100.00% 73,811.94
Decolorized 100.00% 73,811.94 Demineralized 99.50% 73,442.14
Glucose Syrup Glucose Syrup
Starch 33.46% 24,693.78 Starch 33.46% 24,570.43
Glucose 99.97% 24,686.38 Demineralizing Glucose 99.97% 24,563.06
Column
Oligosaccharide 0.03% 7.41 Oligosaccharide 0.03% 7.37
s s
Moisture 66.54% 49,117.42 Moisture 66.54% 48,871.70
NaCl 0.001% 0.74 NaCl 0.001% 0.74
Losses 0.50% 369.06
Total Mass Input 100.00% 73,442.14 Total Mass 100.00% 73,442.14
Output
Demineralized 100.00% 73,442.14 Glucose Syrup 72.90% 53,540.79
Glucose Syrup
Starch 33.46% 24,570.43 Starch 45.65% 24,441.37
Glucose 99.97% 24,563.06 Evaporator Glucose 99.97% 24,434.04
Oligosaccharide 0.03% 7.37 Oligosaccharide 0.03% 7.33
s s
Moisture 66.54% 48,871.70 Moisture 54.35% 29,099.42
Water Loss 26.60% 19,534.14
Losses 0.50% 367.21
Total Mass Input 100.00% 53,546.14 Total Mass 100.00% 53,546.14
Output
Isomerized
Glucose Syrup 99.99% 53,540.79 HFCS 42 99.00% 53,010.68
Solution
Starch 45.65% 24,441.37 HFCS 42 41.08% 21,778.91
Glucose 99.97% 24,434.04 Fructose 42.00% 9,147.14
Oligosaccharide 0.03% 7.33 Isomerizing Glucose 53.00% 11,542.82
s Column
Moisture 54.35% 29,099.42 Other Sugar 5.00% 1,088.95
Glucoisomerase 0.01% 5.35 Moisture 54.35% 28,811.31
Glucose 4.56% 2,415.17
Gluco Isomerase 0.010% 5.30
Losses 1.00% 535.46
Total Mass Input 100.00% 55,660.10 Total Mass 100.00% 55,660.10
Output
Isomerized Filtered HFCS
HFCS 42 95.24% 53,010.68 Rotary Vacuum 42 Solution 93.88% 52,254.05
Solution Filtration
HFCS 42 41.08% 21,778.91 HFCS 42 41.08% 21,467.70

117
Continuation of Table 6.2
Fructose 42.00% 9,147.14 Fructose 42.00% 8,819.65
Glucose 53.00% 11,542.82 Glucose 53.00% 11,377.88
Other Sugar 5.00% 1,088.95 Other Sugar 5.00% 1,073.39
Moisture 54.35% 29,452.23 Moisture 54.35% 28,401.82
Glucose 4.56% 2,468.89 Glucose 4.56% 2,384.53
Glucoisomerase 0.010% 5.42 Glucoisomerase 0.01% 5.34
Filter Aid 4.76% 2,649.42 Filter Aid 4.76% 2,649.42
Losses 1.35% 751.41
Total Mass Input 100.00% 30,737.67 Total Mass 100.00% 30,737.67
Output
Filtered HFCS 85.00% 26,127.02 Filtered HFCS 99.00% 30,430.30
42 Solution 42 Solution
HFCS 42 41.08% 10,733.85 HFCS 42 35.42% 10,778.41
Fructose 42.00% 4,508.22 Fructose 42.00% 4,526.93
Mixing Tank
Glucose 53.00% 5,688.94 Glucose 53.00% 5,712.56
Other Sugar 5.00% 536.69 Other Sugar 5.00% 538.92
Moisture 54.35% 14,200.91 Moisture 60.70% 18,471.19
Glucose 4.56% 1,192.26 Glucose 3.88% 1,180.70
Water 15.00% 4,610.65 Losses 1.00% 307.38
Total Mass Input 100.00% 30,583.21 Total Mass 100.00% 30,583.21
Output
Filtered HFCS Decolorized
42 Solution 99.50% 30,430.30 HFCS 42 97.50% 29,818.63
Solution
HFCS 42 35.42% 10,778.41 HFCS 42 35.42% 10,561.76
Fructose 42.00% 4,526.93 Fructose 42.00% 4,435.94
Glucose 53.00% 5,712.56 Decolorizing Glucose 53.00% 5,597.73
Column
Other Sugar 5.00% 538.92 Other Sugar 5.00% 528.09
Moisture 60.70% 18,471.19 Moisture 60.70% 18,099.91
Glucose 3.88% 1,180.70 Glucose 3.88% 1,156.96
Activated 0.50% 152.92 Activated 0.50% 152.92
Carbon Carbon
Losses 2.00% 611.66
Total Mass Input 100.00% 29,818.63 Total Mass 100.00% 29,818.63
Output
Decolorized HFCS 90
HFCS 42 100.00% 29,818.63 Solution 89.79% 26,774.15
Solution
HFCS 42 35.42% 10,561.76 HFCS 90 39.82% 10,661.47
Evaporator
Fructose 42.00% 4,435.94 Fructose 90.00% 9,595.32
Glucose 53.00% 5,597.73 Glucose 10.00% 1,066.15
Other Sugar 5.00% 528.09 Moisture 55.82% 14,945.33

118
Continuation of Table 6.2
Moisture 60.70% 18,099.91 Glucose 4.36% 1,167.35
Glucose 3.88% 1,156.96 Water Loss 9.71% 2,895.39
Losses 0.50% 149.09

Total Mass Input 100.00% 52,901.17 Total Mass 100.00% 52,901.17

Output
HFCS 90 50.61% 26,774.15 HFCS 55 99.00% 52,372.16
Solution Solution
HFCS 90 39.82% 10,661.47 HFCS 55 40.74% 21,336.42
Fructose 90.00% 9,595.32 Fructose 55.00% 11,735.03
Glucose 10.00% 1,066.15 Glucose 42.00% 8,961.30
Moisture 55.82% 14,945.33 Other Sugar 3.00% 640.09
Glucose 4.36% 1,167.35 Moisture 54.80% 28,699.94
Mixing Tank
HFCS 42 49.39% 26,127.02 Glucose 4.46% 2,335.80
Solution
HFCS 42 41.68% 10,889.74 Losses 1.00% 529.01
Fructose 42.00% 4,573.69
Glucose 53.00% 5,771.56
Other Sugar 5.00% 544.49
Moisture 53.76% 14,045.89
Glucose 4.56% 1,191.39
Total Mass Input 100.00% 52,372.16 Total Mass 100.00% 52,372.16
Output
HFCS 55 100.00% 52,372.16 HFCS 55 86.96% 45,542.83
Solution
HFCS 55 40.74% 21,336.42 HFCS 55 99.90% 45,497.29
Fructose 55.00% 11,735.03 Fructose 55.00% 25,023.51
Glucose 42.00% 8,961.30 Evaporator Glucose 42.00% 19,108.86
Other Sugar 3.00% 640.09 Other Sugar 3.00% 1,364.92
Moisture 54.80% 28,699.94 Glucose 0.10% 45.54
Glucose 4.46% 2,335.80 Water Loss 12.54% 6,569.67
Losses 0.50% 261.86
Total Mass Input 100.00% 45,542.83 Total Mass 100.00% 45,542.83
Output
HFCS 55 100.00% 45,542.83 HFCS 55 99.70% 45,406.20
HFCS 55 99.90% 45,497.29 Fructose 55.00% 24,973.41
Fructose 55.00% 25,023.51 Ultrafiltrator Glucose 42.00% 19,070.61
Glucose 42.00% 19,108.86 Other Sugar 3.00% 1,362.19
Other Sugar 3.00% 1,364.92 Glucose 0.10% 45.54
Glucose 0.10% 45.54 Losses 0.20% 91.09

119
 Table 6.3. Summary of Corn Oil Production
AREA 300: CORN OIL REFINING
Total Mass
Total Mass Input 100.00% 8,854.31 100.00% 8,854.31
Output
Degummed
Corn Oil 98.80% 8,748.06 92.09% 8,153.93
Corn Oil
Triglycerides 95.60% 8,363.14 Triglycerides 95.59% 7,794.35
Free Fatty Acids 2.50% 218.70 Free Fatty Acids 2.00% 163.08
Centrifuge 1
Phospholipids 1.50% 131.22 Phospholipids 1.12% 91.32
Unsaponifiables 0.39% 34.12 Unsaponifiables 1.28% 104.37
Waxes 0.01% 0.87 Waxes 0.01% 0.82
Water 1.00% 88.54 Gums 4.03% 356.83
Phosphoric Acid 0.20% 17.71 Losses 3.88% 343.55
Total Mass
Total Mass Input 100.00% 9,753.51 100.00% 9,753.51
Output
Degummed Neutralized Corn
83.60% 8,153.93 66.34% 6,470.48
Corn Oil Oil
Triglycerides 95.59% 7,794.35 Triglycerides 95.92% 6,206.48
Free Fatty Acids 2.00% 163.08 Free Fatty Acids 1.79% 115.82
Centrifuge 2
Phospholipids 1.12% 91.32 Phospholipids 1.03% 66.65
Unsaponifiables 1.28% 104.37 Unsaponifiables 1.25% 80.88
Waxes 0.01% 0.82 Waxes 0.01% 0.65
Water 15.00% 1,463.03 Soapstocks 30.00% 2,926.05
NaOH 1.40% 136.55 Losses 3.66% 356.98
Total Mass
Total Mass Input 100.00% 6,602.53 100.00% 6,602.53
Output
Neutralized Corn Clarified Corn
98.00% 6,470.48 95.68% 6,317.30
Oil Oil
Triglycerides 95.92% 5,766.91 Triglycerides 97.28% 6,145.47
Free Fatty Acids 1.79% 107.62 Clarifying Free Fatty Acids 1.23% 77.70
Reactor
Phospholipids 1.03% 61.93 Phospholipids 0.26% 16.42
Unsaponifiables 1.25% 75.15 Unsaponifiables 1.22% 77.07
Waxes 0.01% 0.60 Waxes 0.01% 0.63
Bleaching Clay 2.00% 132.05 Bleaching Clay 2.73% 180.25
Losses 1.59% 104.98

120
Continuation of Table 6.3
Total Mass Input 100.00% 6,349.04 Total Mass Input 100.00% 6,349.04
Clarified Corn Crystallized
99.50% 6,317.30 97.00% 6,158.57
Oil Corn Oil
Triglycerides 97.28% 5,710.22 Triglycerides 97.44% 6,000.91
Free Fatty Acids 1.23% 72.20 Crystallizer Free Fatty Acids 1.12% 68.98
Phospholipids 0.26% 15.26 Phospholipids 0.23% 14.16
Unsaponifiables 1.22% 71.61 Unsaponifiables 1.21% 74.52
Waxes 0.01% 0.59 Losses 3.00% 190.47
Filter Aid 0.50% 31.75
Total Mass
Total Mass Input 100.00% 6,415.18 100.00% 6,415.18
Output
Crystallized Deodorized Corn
96.00% 6,158.57 95.93% 6,154.08
Corn Oil Oil
Triglycerides 97.44% 6,000.91 Triglycerides 97.66% 6,010.08
Free Fatty Acids 1.12% 68.98 Distillation Free Fatty Acids 0.93% 57.23
Phospholipids 0.23% 14.16 Phospholipids 0.21% 12.92
Unsaponifiables 1.21% 74.52 Unsaponifiables 1.20% 73.85
Volatile
Steam 4.00% 0.20% 12.83
256.61 Odorants
Losses 3.87% 248.27
Total Mass
Total Mass Input 100.00% 6,154.08
Output 100.00% 6,154.08
Deodorized Corn Polished Corn
100.00% 6,154.08
Oil Oil 99.20% 6,104.85
Triglycerides 97.66% 6,010.08 Polish Filter Triglycerides 98.80% 6,031.59
Free Fatty Acids 0.93% 57.23 Free Fatty Acids 0.05% 3.05
Phospholipids 0.21% 12.92 Unsaponifiables 1.15% 70.21
Unsaponifiables 1.20% 73.85 Losses 0.80% 49.23
Total Mass Input 100.00% 6,104.85 Total Mass Input 100.00% 6,104.85
Deodorized Corn Deodorized Corn
Oil 100.00% 6,104.85 Oil 99.00% 6,043.80
Triglycerides 98.80% 6,031.59 Packaging Triglycerides 98.80% 5,971.28
Free Fatty Acids 0.05% 3.05 Free Fatty Acids 0.05% 3.02
Unsaponifiables 1.15% 70.21 Unsaponifiables 1.15% 69.50
Losses 1.00% 61.05

121
 Table 6.4. Summary of Wastewater Treatment
AREA 400: WASTEWATER TREATMENT
Feed In(%) Mass(kg) Equipment Product Out(%) Mass (kg)
Total Mass
Total Mass Input 100.00% 205,261.78 100.00% 205,261.78
Output
Wastewater
98.51% 202,194.14 Wastewater 205,056.52
(Area 100) 99.90%
Wastewater 34.92% 190,239.89 Wastewater 92.68% 190,049.65
Water 2.42% 4,900.00 Water 2.39% 4,895.10
H2SO3 1.25% 2,528.58 H2SO3 1.23% 2,526.05
Fiber Cake 1.72% 2,540.90 Fiber Cake 1.24% 2,538.36
Moist Gluten 2.00% 1,984.76 Moist Gluten 0.97% 1,982.78
Collection
Area 300 1.49% 3,062.30 Glucoisomerase 0.00% 5.33
Gums 4.03% 331.56 Gums 0.16% 331.23
Soapstocks 30.00% 2,718.82 Soapstocks 1.32% 2,716.10
Volatile Volatile
11.92 0.01% 11.91
Odorants 0.20% Odorants
Insoluble
Materials (Area 0.00% 5.34
200)
Glucoisomerase 100% 5.34 Losses 0.10% 205.2617798
Total Mass
Total Mass Input 100.00% 205,056.52 100.00% 205,056.52
Output
Wastewater 100.00% 205,056.52 Wastewater 97.77% 200,487.69
Wastewater 92.68% 190,049.65 Wastewater 93.85% 188,149.15
Water 2.39% 4,895.10 Water 2.42% 4,846.15
H2SO3 1.23% 2,526.05 H2SO3 1.25% 2,500.79
Fiber Cake 1.24% 2,538.36 Moist Gluten 0.98% 1,962.95
Grit Chamber
Moist Gluten 0.97% 1,982.78 Gums 0.16% 327.92
Glucoisomerase 0.00% 5.33 Soapstocks 1.34% 2,688.94
Volatile
0.16% 331.23 11.79
Gums Odorants 0.01%
Soapstocks 1.32% 2,716.10 Grits 1.23% 2,518.26
Volatile
0.01% 11.91 2,050.57
Odorants Losses 1.00%
Total Mass
Total Mass Input 100.00% 204,771.29 100.00% 198,054.74
Output
Neutralization Neutralized
Waste 100.00% 200,487.69 196,007.03
Tank Water 98.97%
Wastewater 93.85% 188,149.15 Wastewater 95.03% 186,267.66

122
Continuation of Table 6.4
Water 2.42% 4,846.15 Water 2.45% 4,797.69
H2SO3 1.25% 2,500.79 Moist Gluten 0.99% 1,943.32
Moist Gluten 0.98% 1,962.95 Gums 0.17% 324.64
Gums 0.16% 327.92 Soapstocks 1.36% 2,662.05
Volatile
2,688.94 11.67
Soapstocks 1.34% Odorants 0.01%
Volatile
11.79 2,047.71
Odorants 0.01% Losses 1.00%
NaOH 2.14% 4,283.60
Total Mass Total Mass
Output 100.00% 197,986.90 Output 100.00% 197,986.90
Wastewater 100.00% 197,986.90 Wastewater 97.85% 193,739.07
Wastewater 95.03% 188,149.15 Water 98.62% 191,065.35
Center-Feed
2,662.05
Water 2.45% 4,846.15 Clarifier Soapstocks 1.37%
Volatile
11.67
Moist Gluten 0.99% 1,962.95 Odorants 0.01%
Gums 0.17% 327.92
Soapstocks 1.36% 2,688.94 Sludge 1.15% 2,267.96
Volatile
Odorants 0.01% 11.79 Losses 1.00% 1979.868993
Total Mass Total Mass
Output 100.00% 416,883.33 Output 100.00% 416,883.33
Aerated
Wastewater 47.11% 196,412.79 Wastewater 46.64% 194,448.67
Water 98.64% 193,739.07 Water 98.64% 191,801.68
Packed Tower
2,662.05 2,635.43
Soapstocks 1.36% Aerator Soapstocks 1.36%
Volatile Volatile
11.55
Odorants 0.01% 11.67 Odorants 0.01%
Oxygen 52.36% 218,265.83
Oxygen 52.89% 220,470.54 Losses 1.00% 4,168.83
Total Mass Total Mass
Output 100.00% 194,448.67 Output 100.00% 197,069.18
Aerated Filtered
192,504.18
Wastewater 100.00% 194,448.67 Wastewater 97.68%
Water 98.64% 191,801.68 Impurities 1.33% 2,620.51
Soapstocks 1.36% 2,635.43 Microfiltration Soapstocks 99.56% 2,609.08
Volatile Volatile
11.44
Odorants 0.01% 11.55 Odorants 0.44%

123
Continuation of Table 6.4
Losses 1.00% 1,944.49
Total Mass Total Mass
Output 100.00% 192,504.18 Output 100.00% 192,504.18
Filtered Ultraviolet Disinfected
190,579.14
Wastewater 100.00% 192,504.18 Disinfection Wastewater 99.00%
Losses 1.00% 1,925.04
Total Mass Total Mass
Output 100.00% 190,579.14 Output 100.00% 190,579.14
Filtered Reverse
188,673.35
Wastewater 100.00% 190,579.14 Osmosis Treated Water 99.00%
Losses 1.00% 1,905.79

124
SUMMARY
Based on the calculations in material balance, the production level of High Fructose
Corn Syrup 55 and Corn Oil is 45.54 MT/batch and 6.04 MT/batch, respectively. Accordingly, the
total annual production of HFCS 55 is 4,098.85 MT with a percentage recovery of 87.37%%.
Meanwhile, the total annual production of corn oil is 1,813.14 MT with a percentage recovery of
69.73%%. The total percentage yield of HFCS 55 and corn oil is 73.70%%.

Table 6.5. Total Annual Production of High Fructose Corn Syrup 55 and Corn Oil
HIGH-FRUCTOSE CORN
SUMMARY SYRUP 55 CORN OIL
Total Annual Production (kg) 4,098,854.92 1,813,140.40
Total Annual Production (MT) 4,098.85 1,813.14

RESIDENCE TIME

The tables below present the equivalent residence time of each equipment used on each
area in the production of high-fructose corn syrup 55 and corn oil.

125
 Table 6.6. Residence Time
AREA Equipment Residence Time Residence Time
(hr) (min)
Steeping Tank 1.83 109.69
Dewatering Gravity Screen 6.14 368.13
Attrition Mill 1.52 91.35
Hydrocyclone 3.34 200.13
Dewatering Gravity Screen 0.69 41.47
Drier 1.62 96.91
Horizontal Rotary Cooker 1.74 104.67
AREA 100: CORN
MILLING Expeller Press 1.75 105.16
Impact Mill 3.57 214.13
Press Dewatering Screen 1.72 102.98
Disk Nozzle Centrifuge 1.15 68.97
Hydrocyclone 1.32 79.15
Peeler Centrifuge 1.34 80.39
TOTAL 27.72 1,663.17
Mixing Tank 4.37 261.91
Jet Cooker 1.01 60.48
Flash Cooler 2.80 167.94
Saccharification Tank 75.00 4500.00
Rotary Vacuum Filter 2.58 154.61
Decolorizing Column 2.56 153.75
Demineralizing Column 2.56 153.61
Evaporator 2.56 153.60
AREA 200: HIGH
FRUCTOSE CORN Isomerizing Column 2.56 153.63
SYRUP 55
Rotary Vacuum Filter 2.78 166.88
Mixing Tank 2.92 175.15
Decolorizing Column 2.75 165.00
Evaporator 2.75 164.86
Mixing Tank 5.60 335.76
Evaporator 2.78 167.03
Ultrafiltration 2.94 176.58
TOTAL 118.51 7110.77
Centrifuge 1 0.92 54.96
Centrifuge 2 1.08 65.04
Clarifying Reactor 0.92 55.13
Crystallizer 0.90 54.27
AREA 300: CORN OIL
Distillation Column 0.90 54.20
Polish Filter 0.90 54.20
Packaging 0.90 54.20
TOTAL 6.53 392.01

126
Continuation of Table 6.6
AREA Equipment Residence Time (hr) Residence
(min)
Time

Collection 4.82 289.43

Grit Chamber 9.91 594.39
Neutralization Tank 7.77 466.17
Center-Feed Clarifier 4.64 278.37
AREA 400: Packed Tower Aerator 29.08 1744.69
WASTEWATER
Microfiltration 4.56 273.40
Ultraviolet Disinfection 1 60
Reverse Osmosis 1 60
TOTAL 62.77 3766.46

127
 CHAPTER VII
ENERGY BALANCE AND UTILITY REQUIREMENTS
This chapter shows the energy required for the manufacturing plant processes including
the utility requirements for various operations.

ENERGY BALANCE
The law of conservation of energy states that energy can neither be created nor
destroyed and only be converted from one form of energy to another. This means that a system
always has the same amount of energy unless it is added from the outside. This is particularly
confusing in the case of non-conservative forces, where energy is converted from mechanical
energy into thermal energy, but the overall energy does remain the same.
Energy balance is highly significant in various industrial operations. It generally intends
to identify the amounts of energy needed to execute all different processes involved as well as
maintain the operating conditions of the manufacturing plant. With this, the Table 7.1- Table
presents 7.2 the summary of the energy requirement data of the manufacturing plant for
process equipment, which involves chemical energy, mechanical energy, and energies for
cooling and heating, pumps, and conveyor belts respectively. As well as the plant’s utility
including water, electricity, steam, fuel, and air.

Table 7.1 Summary of Energy Requirement of Equipment

ENERGY REQUIREMENT (kW)

EQUIPMENT CODES CHEMICAL MECHANICAL
ENERGY ENERGY HEATING COOLING
Aerated Grit A-401 - 7,692.75 - -
Chamber
Attrition Mill A-101 - 96.93 - -
Center Feed V-401 - 378.28 - -
CLarifier
Centrifuge C-301 - 24.18 - -
Centrifuge C-302 - 5.45 - -
Clarifying R-301 - 35.41 - -
Reactor
Conveyor MH-101 - 11.15 - -
Conveyor MH-104 - 23.31 - -
Conveyor MH-105 - 20.52 - -
Conveyor MH-106 - 8.12 - -
Conveyor MH-107 - 7.85 - -
 Microfiltrator FL-401 - 87.72 - -
Crystallizer R-302 - 34.32 - -
Decolorizing T-201 - 76.03 - -
Column
Decolorizing T-204 - 20.00 - -
Column
Demineralizer T-202 - 74.74 - -
Column
Dewatering FL 101 - 18.72 - -
Gravity Screen
Dewatering FL-102 - 17.99 - -
Gravity Screen
Disk Nozzle C-101 - 31.67 - -
Centrifuge
Distillation A-301 - 26.39 1,395.94 -
Column
Drier V-101 - 250.98 120.61 -
Evaporator E-202 - 54.43 1,845.85 -
Evaporator E-203 - 40.18 749.44 -
Evaporator E-204 - 58.74 1,316.29 -
Expeller Press A-103 - 8.67 - -
Flash Cooler E-201 - 78.19 - 26.40
Hopper-bottome TK-101 129.84 94.28 - -
d Tank
Horizontal A-102 - 63.35 260.16 -
Rotary Cooker
Hydrocyclone MH-104 - 2.94 - -
Hydrocyclone MH-108 - 3.51 - -
Washing
Impact Mill A-104 - 20.21 - -
Isomerizing T-203 9.08 48.79 - -
Column
Jet Cooker A-201 5.61 49.59 144.79 -
Mixing Tank TK-201 - 149.59 677.57 -
Mixing Tank TK-203 - 22.18 - -
Mixing Tank TK-204 - 39.57 - -
Neutralization TK-401 - 1,089.48 - -
Tank
Pack Tower A-402 - 262.23 - -
Aerator
Peeler C-102 - 71.78 - -
Centrifuge
Polish Filter FL-301 - 21.93 - -
Press FL-103 - 17.48 - -
Dewatering

129
 Screen
Reverse U-402 - 37.55 - -
Osmosis
Rotary Vacuum FL-202 - 43.86 - -
Filter
Rotary Vacuum FL-201 - 43.86 - -
Filter

Table 7.2 Summary of Energy Requirement of Pumps

ENERGY REQUIREMENT
EQUIPMENT CODE
(kW)
Centrifugal Pump P-101 A/B 11.96
Centrifugal Pump P-102 A/B 25.84
Centrifugal Pump P-103 A/B 21.29
Centrifugal Pump P-104 A/B 11.55
Centrifugal Pump P-105 A/B 9.01
Centrifugal Pump P-106 A/B 8.88
Centrifugal Pump P-107 A/B 23.59
Centrifugal Pump P-108 A/B 7.37
Centrifugal Pump P-109 A/B 6.00
Centrifugal Pump P-110 A/B 63.57
Centrifugal Pump P-111 A/B 12.82
Centrifugal Pump P-112 A/B 8.65
Centrifugal Pump P-113 A/B 13.62
Centrifugal Pump P-114 A/B 7.10
Centrifugal Pump P-115 A/B 14.80
Centrifugal Pump P-116 A/B 10.88
Centrifugal Pump P-117 A/B 9.81
Centrifugal Pump P-201 A/B 34.35
Centrifugal Pump P-202 A/B 32.18
Centrifugal Pump P-203 A/B 73.63
Centrifugal Pump P-204 A/B 19.55
Centrifugal Pump P-205 A/B 21.81
Centrifugal Pump P-206 A/B 16.82
Centrifugal Pump P-207 A/B 22.77
Centrifugal Pump P-208 A/B 16.67

130
Centrifugal Pump P-209 A/B 28.85
Centrifugal Pump P-210 A/B 6.56
Centrifugal Pump P-211 A/B 21.11
Centrifugal Pump P-2012 A/B 20.66
Centrifugal Pump P-213 A/B 12.15
Centrifugal Pump P-214 A/B 26.97
Centrifugal Pump P-215 A/B 19.41
Centrifugal Pump P-216 A/B 10.09
Centrifugal Pump P-217 A/B 5.81
Centrifugal Pump P-218 A/B 5.39
Centrifugal Pump P-219 A/B 5.87
Centrifugal Pump P-220 A/B 5.02
Centrifugal Pump P-221 A/B 5.50
Centrifugal Pump P-222 A/B 19.41
Centrifugal Pump P-223 A/B 5.19
Centrifugal Pump P-224 A/B 6.01
Centrifugal Pump P-225 A/B 13.41
Centrifugal Pump P-226 A/B 5.15
Centrifugal Pump P-227 A/B 11.97
Centrifugal Pump P-228 A/B 5.49
Centrifugal Pump P-301 A/B 5.98
Centrifugal Pump P-302 A/B 7.04
Centrifugal Pump P-303 A/B 7.09
Centrifugal Pump P-304 A/B 8.21
Centrifugal Pump P-305 A/B 6.15
Centrifugal Pump P-306 A/B 7.01
Centrifugal Pump P-307 A/B 5.01
Centrifugal Pump P-308 A/B 5.00
Centrifugal Pump P-309 A/B 5.20
Centrifugal Pump P-310 A/B 5.02
Centrifugal Pump P-311 A/B 25.00
Centrifugal Pump P-312 A/B 19.00
Centrifugal Pump P-313 A/B 7.01
Total 857.26

131
UTILITY REQUIREMENTS
1. Water
The Rugi Incorporation ensures that there is enough water supply intended for the
different demands such as industrial, emergency, and sanitary at any given period of time. The
total batch consumption of water will be 288,463.45 kg which will be computed 25,961,710.84
kg, annually. It is mainly used as a raw material, and for chemical reactions in other processes.
The water will mainly be sourced from Isabela Water District which manages an average water
production of about 10,321 cu.m.

2. Electricity
Electricity plays an important role in supplying energy to the plant. It is necessary for
adequate operation and production in the industry. Specifically,electricity is widely used for
providing power to electric devices, buildings, machineries, equipment and some automobiles.
The electricity of Rugi Manufacturing Plant Inc. will mainly be sourced from Cagayan Electric
Cooperative (CAGELCO) which produces an average of 20 MW of electricity daily. Other
sources of electricity will be sources from other provinces such as Isabela Electric Cooperative
(ISELCO), Quirino Electric Cooperative (QUIRELCO), and Nueva Vizcaya Electric Cooperative
(NUVELCO). Based on the information given, there will be an adequate electrical supply to
provide energy for Rugi Inc. which will consume 2,687.96 kW or 2.69 MW daily and 241,916.37
kWh kWh or 241.92 MW, annually.

3. Steam
Steam system is an efficient, energy saving system used by the manufacturing industry,
as steam is regarded as a cost-effective energy source. The primary purpose of effective steam
generation is to produce steam under the flow rates and pressures necessary for the system's
end-use requirements. It is important to generate steam at the highest possible generator
efficiency. In addition, it contains a large amount of stored energy which will eventually be
transferred to the process or space to be heated. The temperature of the steam that will be
utilized depends on the operating conditions. The plant’s steam consumption will be based on
the operation’s requirements.

132
 The Rugi Inc. will be using steam obtained from boilers in HFCS 55 and corn oil
production which is 46,960.98 kg and 4,226,488.60 kg on its daily and annual basis respectively.

4. Air
Air will be used as a heating medium in all drying processes involved in manufacturing of
HFCS 55 and corn oil. The Rugi Inc will utilize 5,182.36 kg of air daily and 466,412.45 kg of air
annually which can ensure higher quality of the materials to be produced by the manufacturing
plant.
Table 7.3 Summary of Utility Requirements
SUMMARY

WATER STEAM ELECTRICITY

CODES EQUIPMENT REQUIREMENT REQUIREMENT (kW/day) FUEL (kg/day) AIR (kg/day)
(kg/day) (kg/day)

A-401 Aerated Grit - - 509.50 - -

Chamber
A-101 Attrition Mill 91,901.01 - 96.93 - -

V-401 Center Feed - - 378.28 - -

Clarifier
C-301 Centrifuge 88.54 - 24.18 - -
C-302 Centrifuge 1,463.03 - 5.45 - -
R-301 Clarifying Reactor - - 35.41 - -
MH-101 Conveyor - - 11.15 - -
MH-104 Conveyor - - 23.31 - -
MH-105 Conveyor - - 20.52 - -
MH-106 Conveyor - - 8.12 - -
MH-107 Conveyor - - 7.85 - -
R-302 Crystallizer - - 34.32 - -

T-201 Decolorizing - - 76.03 - -

Column
T-204 Decolorizing - - 20.00 - -
Column
T-202 Demineralizer - - 74.74 - -
Column
FL 101 Dewatering - - 18.72 - -
Gravity Screen
FL-102 Dewatering - - 17.99 - -
Gravity Screen
C-101 Disk Nozzle - - 31.67 - -
Centrifuge
A-301 Distillation 8.90 256.61 26.39 - -
Column
V-101 Drier - - 250.98 - 5,182.36
E-202 Evaporator 424.76 12,242.80 54.43 - -

133
E-203 Evaporator 172.46 4,970.77 40.18 - -
E-204 Evaporator 302.90 8,730.44 58.74 - -
A-103 Expeller Press - 1,491.60 8.67 - -
E-201 Flash Cooler - - 26.40 - -

TK-101 Hopper-bottomed 102375.00 - 129.84 - -

Tank
A-102 Horizontal Rotary 113.35 1,775.37 63.35 - -
Cooker
MH-104 Hydrocyclone - - 2.94 - -

MH-108 Hydrocyclone 28348.10 - 3.51 - -

Washing
A-104 Impact Mill - - 20.21 - -

T-203 Isomerization - - 0.62 - -

Column
A-201 Jet Cooker 606.93 17,493.40 5.61 - -
FL-401 Microfiltration - - 87.72 - -
TK-201 Mixing Tank 27,514.58 - 149.59 - -
TK-203 Mixing Tank 4,610.65 - 22.18 - -
TK-204 Mixing Tank - - 39.57 - -

TK-401 Neutralization - - 1,089.48 - -

Tank
A-402 Pack Tower - - 262.23 - -
Aerator
C-102 Peeler Centrifuge 28,903.92 - 71.78 - -
FL-301 Polish Filter - - 21.93 - -

FL-103 Press Dewatering - - 17.48 - -

Screen
U-402 Reverse Osmosis - - 37.55 - -

C-203 Rotary Vacuum - - 43.86 - -

Filter
FL-201 Rotary Vacuum - - 43.86 - -
Filter
TK-202 Saccharification - - 3.61 - -
Tank
F-101 Steam Boiler 113.35 - - 124.68 -
F-201 Steam Boiler 606.93 - - 667.62 -
F-202 Steam Boiler 424.76 - - 467.24 -
F-203 Steam Boiler 172.46 - - 189.71 -
F-204 Steam Boiler 302.90 - - 333.19 -
F-301 Steam Boiler 8.90 - - 9.79 -
C-203 Ultrafiltrator - - 43.86 - -
U-401 UV Radiation - - 176.60 - -
TOTAL 288,463.45 46,960.98 4,197.38 1,792.23 5,182.36

134
 Table 7.4 Summary of the Overall Utility Requirements
UTILITIES GENERATION
BATCH ANNUALLY
Water, kg 288,463.45 25,961,710.84
Electricity, kW 4,197.38 3,179,709.62
Steam, kg 46,960.98 4,226,488.60
Fuel, kg 3,584.45 322,600.91
Air, kg 5,182.36 466,412.45

135
 CHAPTER VIII
HEALTH SAFETY AND ENVIRONMENTAL
This chapter discusses the presentation of environmental problem elimination and
problems with the application of appropriate methods for their reduction. It also tackles
hazardous equipment, techniques, and solutions for unexpected incidents or injuries that may
affect critical units' selected equipment, ETP protocol, and designs.

HAZARD INDEX BASED ON TEMPERATURE PROFILE

The temperature profile for each equipment is shown in Table 8.1, with the temperatures
listed in descending order from highest to lowest. This temperature profile will be used in the
manufacturing of HFCS 55 by Rugi Incorporation.

Table 8.1. Temperature Profile for Equipment

CODE EQUIPMENT TEMPERATURE
A-301 Distillation Column 220°C
A-201 Jet Cooker 107°C
R-302 Crystallizer 105°C
C-301 Centrifuge 100°C
C-302 Centrifuge 100°C
E-201 Flash Cooler 97°C
R-301 Clarifying Reactor 95°C
TK-201 Mixing Tank 90°C
A-102 Horizontal Rotary Cooker 82°C
T-201 Decolorizing Column 80°C
T-204 Decolorizing Column 80°C
V-101 Drier 80°C
C-203 Rotary Vacuum Filter 80°C
FL-201 Rotary Vacuum Filter 80°C
T-203 Isomerizing Column 60°C
TK-202 Saccharification Tank 60°C
TK-101 Hopper-bottomed Tank 52°C
T-202 Demineralizer Column 50°C
E-202 Evaporator 40°C
E-203 Evaporator 40°C
E-204 Evaporator 40°C
A-401 Aerated Grit Chamber 25°C
A-101 Attrition Mill 25°C
V-401 Center Feed CLarifier 25°C
FL-401 Crossflow Filtration 25°C
FL 101 Dewatering Gravity Screen 25°C
Continuation of Table 8.1
FL-102 Dewatering Gravity Screen 25°C
C-101 Disk Nozzle Centrifuge 25°C
A-103 Expeller Press 25°C
MH-104 Hydrocyclone 25°C
MH-108 Hydrocyclone Washing 25°C
A-104 Impact Mill 25°C
TK-203 Mixing Tank 25°C
TK-204 Mixing Tank 25°C
TK-401 Neutralization Tank 25°C
C-102 Peeler Centrifuge 25°C
FL-301 Polish Filter 25°C
FL-103 Press Dewatering Screen 25°C
U-402 Reverse Osmosis 25°C
C-203 Separator 25°C
U-401 UV Radiation 25°C
A-402 Pack Tower Aerator 10°C

IDENTIFICATION PROCEDURE AND MITIGATION TECHNIQUES FOR UNDESIRABLE

ACCIDENTS/EVENTS
A. Provide Hazard Checklists
This is a list used in performing hazard assessments such as points to complete,
consider, meet the requirements of, or be reminded of. Checklists can quantify things you have
accomplished with refined processes. A checklist can be used to identify design hazards
throughout the process design process, or it can be used prior to process operation. The main
purpose of checklists is to identify potential health and safety hazards during the early part of a
systems development program. They can be used as a standalone technique, or integrated into
other more structured techniques such as a creative checklist.
Rugi Incorporation methodology was developed to identify various hazards in processing
and storage facilities. It contains a system-specific checklist that was developed by combining
general checklists, and brainstorming system perturbations, risks, and events that could result in
property damage or personnel injuries. This may help to plan any safety actions to lessen
accidents and even deaths brought by hazards. The manufacturing plant’s hazard checklist is
reflected in Appendix.

137
 B. Administrative Controls
Administrative controls establish work practices that reduce the duration, frequency, or
intensity of exposure to hazards. This may include, work process training, job rotation, ensuring
adequate rest breaks, limiting access to hazardous areas or machinery, and adjusting line
speeds. These varieties of regulations are usually used in combination with other controls that
explicitly prevent hazard exposure.
In order to protect its workers from accidents and potential harm, Rugi Inc. prioritizes the
safety of its employees. It makes sure that daily operations or routine maintenance must be
finished before production can start, safe work practices and other administrative controls offer
sufficient protection, and the use of protective clothing or equipment is an additional means of
control. The monitoring checklist for administrative control is reflected in Appendix .

C. Preventive Maintenance System

Maintenance strategy is the act of performing regularly scheduled maintenance activities
to help prevent unexpected failures in the future. It is critical in ensuring that hazard controls
keep functioning effectively. Also, it also prevents new dangers from arising as a result of
equipment failure. The plan must be dependent on knowing what needs to be managed and
how frequently. Generally, the goal of preventive maintenance is to complete the work before
repairs or replacement is required.
Rugi Inc. ensures to thoroughly plan, schedule and document the maintenance activity
of the plant. It starts with an event occurring and then creates sequences of events illustrating
potential accidents, taking into consideration both the successes and failures of the safety
mechanisms as the accident happens.

D. Emergency Preparations
Emergencies and disasters such as include hurricanes, tornadoes, earthquakes, floods,
wildfires, weather, chemical spills or releases, disease outbreaks, releases of biological agents,
explosions involving nuclear or radiological sources, and many other hazards can strike
anywhere, and any time bringing workplace injuries and illnesses with them. Employers and
workers may be required to deal with an emergency when it is least expected and proper
planning before an emergency is necessary to respond effectively.
Rugi Inc. carefully develops an emergency action plan to guide everyone in the
workplace when immediate action is necessary. The emergency action plan includes surveying

138
potential emergencies, planning initiatives to minimize the impact on the workplace, and
providing employee information, training, and drills. This will ensure that everyone knows what
to do when an emergency occurs. The plant’s specific flow of emergency planning is presented
in Appendix
a. Hazard and Operability (HAZOP) Study
Hazard and Operability Analysis (HAZOP) is a structured and systematic technique for
system examination and risk management. It is often used as a technique for identifying
potential hazards in a system and identifying operability problems likely to lead to
nonconforming products. HAZOP is based on a theory that assumes risk events are caused by
deviations from design or operating intentions. The identification of such deviations is facilitated
by using sets of “guide words” as a systematic list of deviation perspectives. The table below is
the guide word and their description used.

139
 Table 8.2. Hazard and Operability (HAZOP) Study Guide Word
GUIDE WORD DESCRIPTION
More Quantitative increase
Less Quantitative decrease
All the design intention is achieved together
As well as
with additions
Only some of the design intention is
Part of
achieved
The logical opposite of the design intention is
Reverse
achieved
Complete substitute, where no part of the
Other than original intention is achieved but something
quite different happens
Something happens earlier than expected,
Early
relating to other sequence
After something happens after it is expected,
Late
relating to order or sequence

The table below shows the HAZOP analysis of the Rugi Inc. manufacturing process.

140
 Table 8.3. Area 100 Hazard and Operability (HAZOP) Study
AREA 100
PROCESS GUIDE WORD DEVIATION POSSIBLE CAUSES CONSEQUENCE ACTION REQUIRED
The corn kernels'
Too much distilled moisture content may
water, sulfur dioxide, exceed making it
More
and lactic acid was Inaccurate impossible to grind. And Ensure the correct ratio
Steeping added measurement of the too much reagent may of water and steeping
added reagent danger the workers solutions.
Less distilled water,
The steeping process
Less sulfur dioxide, and lactic
may not be achieved.
acid was added
The process may not
Misuse of equipment completely separate Use the equipment
Components might be
Dewatering No and possible equipment steep water making it properly and regularly
incompletely separated
malfunction impossible to proceed monitor the equipment
with expeller pressing
Inaccurate The desired quality of
Too much distilled water Ensure the correct ratio
Degerming More measurement of the corn slurry may not be
was added of water
added reagent achieved
The process may not
Misuse of equipment completely separate Use the equipment
Components might be
Dewatering No and possible equipment germ slurry making it properly and regularly
incompletely separated
malfunction impossible to proceed monitor the equipment
with expeller pressing
The process may
Regular monitoring of
produce unsoftened
Inaccurate time and equipment as well as
Germ Drying No More uncooked germ corn germ making it
temperature temperature and
impossible to proceed
pressure
with expeller pressing
Incorrect level of Regular maintenance of
Oil extracting No Equipment Malfunction Longer residence time
pressure applied equipment

141
Continuation of Table 8.3

No proper maintenance
Some corn kernels are of equipment in terms of Regular monitoring and
Grinding No Equipment Malfunction
left in the machine sanitation may lead to cleaning of equipment
spoilage
The process may not
completely separate fine
Misuse of equipment Use the equipment
Components might be ground mil and fiber
Screening Less and possible equipment properly and regularly
incompletely separated cake making it
malfunction monitor the equipment
impossible to proceed
with centrifuge
Misuse of equipment Use the equipment
Components might be Fine ground might not
Centrifugation No and possible equipment properly and regularly
incompletely separated be achieved
malfunction monitor the equipment
The moisture
content value of the
corn kernels will be
Inaccurate inaccurate
Too much water is Regular monitoring and
Washing No measurement of the Corn kernels may be
added cleaning of equipment
added water exposed to
microorganisms since it
is more susceptible
when wet

142
 Table 8.4. Area 200 Hazard and Operability (HAZOP) Study
AREA 200
PROCESS GUIDE WORD DEVIATION POSSIBLE CAUSES CONSEQUENCE ACTION REQUIRED
The process does not Incorrect ratio of starch Equipment malfunction Ensure accurate ratio of
Gelatinization More produced starch slurry and water resulting to process the raw material
interruptions
Equipment malfunction It may cause leakage Proper and regular
Liquefaction Part of Steam leak from the and inaccurate resulting into physical monitoring of equipment
equipment temperature hazards. as well as time and
temperature.
Steam will not be
recovered. Proper checking,
Flash Cooling No Improper cooling Inaccurate level of monitoring, and
process temperature and steam Target dextrose calibration of equipment
equivalent may not be and temperature
achieved
The process does not Incorrect measurement Equipment malfunction Ensure accurate ratio of
Saccharification More produce glucose syrup of enzyme resulting to process the raw material
interruptions
Rotary Vacuum Filtration More More insoluble material Equipment malfunction It may cause Regular and proper
left contamination monitoring of equipment
The process does not Inaccurate Ensure accurate
Decolorizing More decolorized the glucose measurement of Increase in equipment measurement of
syrup activated carbon and loss activated carbon
temperature
The process does not Inaccurate It may still contain
Demineralizing More completely measurement of minerals resulting Monitor the temperature
demineralized the temperature process interruption
glucose syrup
Equipment malfunction Target dextrose Proper checking,
Evaporation No Excess water and inaccurate time and equivalent may not be monitoring, and
temperature achieved calibration of equipment
and temperature
The process does not Incorrect measurement Equipment malfunction
Isomerizing More produce HFCS 42 of enzyme resulting to process
interruptions

143
Continuation of Table 8.4
Proper and regular
The desired quality of monitoring
Filtration More More insoluble material Equipment malfunction the product may not be of equipment
left achieved as well as time and
temperature.

Table 8.5. Area 300 Hazard and Operability (HAZOP) Study

AREA 300
PROCESS GUIDE WORD DEVIATION POSSIBLE CAUSES CONSEQUENCE ACTION REQUIRED
Regular and proper
Phosphoric acid was Process may be
Degumming Late Malfunction of equipment monitoring of raw
added too late interrupted
materials and equipment
No free-fatty acids will be
Ensure accurate
Sodium hydroxide was Inaccurate measurement neutralized and the
Neutralization Late measurement of sodium
added too late of sodium hydroxide process will be
hydroxide
interrupted
Longer residence time Ensure accurate
Less activated carbon Inaccurate measurement
Bleaching Less and no oil will be measurement of activated
was added of activated carbon.
bleached carbon
Less Ensure that accurate
Inaccurate temperature Increase in mass input
Dewaxing Equipment malfunction temperature and pressure
More and pressure applied loss
were applied
Less Volatile odorants might Regular and proper
Deodorizing Inaccurate steam applied Equipment malfunction
More not separate from oil monitoring of equipment

Oil can't be filtered Regular and proper

Filtration No Equipment malfunction It may cause spoilage
properly monitoring of equipment

144
 Table 8.6. Area 400 Hazard and Operability (HAZOP) Study

AREA 400

PROCESS GUIDE WORD DEVIATION POSSIBLE CAUSES CONSEQUENCE ACTION REQUIRED

The process may not
completely separate grits
Misuse of equipment and Use the equipment
Components might be and other solid particles
Grit Removal No possible equipment properly and regularly
incompletely separated making it impossible to
malfunction monitor the equipment
proceed with
neutralization
Longer residence time
Inaccurate measurement Ensure accurate
Neutralization Less Less NaOH was added and no H2SO3 will be
of NaOH measurement of NaOH
neutralized
The process may not
Misuse of equipment and completely sedimented Use the equipment
Sludges might be incompletely
Sedimentation No possible equipment the solid particles making properly and regularly
sedimented
malfunction it impossible to proceed monitor the equipment
with aeration
Longer residence time
and the aerobic
Inaccurate measurement biodegradation of organic Ensure accurate
Aeration Less Less oxygen was added
of oxygen substances and measurement of oxygen
contaminants will not be
completed
It may cause Regular and proper
Filtration More More insoluble material left Equipment malfunction
contamination monitoring of equipment
Regular and proper
UV radiation was activated too Process may be
Disinfection Late Malfunction of equipment monitoring of effluent and
late interrupted
equipment
It may cause Regular and proper
Diffusion More More insoluble material left Equipment malfunction
contamination monitoring of equipment

145
 b. Hazard Analysis Critical Control Points
HACCP is a management method that addresses food safety by analyzing and
controlling biological, chemical, and physical hazards throughout the production, handling, and
distribution of raw materials as well as the manufacture, distribution, and consumption of
finished goods. The success of a HACCP system depends on educating and training
management and employees in the importance of their role in producing safe foods. This should
also include information on the control of foodborne hazards related to all stages of the food
chain.
Rugi Inc. is strongly committed to the HACCP concept as the company aims to train
company employees with a sense of the importance of producing safe food. With this, the
manufacturing facility was able to pinpoint a number of critical control points for the production
of HFCS 42 and corn oil. This ensures that the crucial variables will be maintained to guarantee
the products' consistency and safety. And preventive measures will be conducted to ensure the
efficient operation of all the processes involved in the manufacturing plant. The critical control
points (CCP) on each processing area are listed in the table below for monitoring.

146
 Table 8.7. Critical Control Points
CRITICAL LIMITS
PROCESS/CCP SIGNIFICANT FOR EACH WHAT HOW WHO
FREQUENCY PRODUCTION CORRECTIVE VERIFICATION RECORDS
HAZARDS CRITICAL ACTIONS
MEASURE
AREA 100
Addition of 0.1 Accurate
Biological sulfur dioxide to measurements
water to prevent of the chemical
bacterial growth Monitor the solutions Monitoring
Time, temperatur and
Used of the Temperat e and Proper time Conduct verification
CCP 1 operating ure, and observe Every 30 Production and laboratory test record
(Steeping) Physical temperature and Chemical accurate minutes Manager temperature relative to the
time of 52℃ and 42 Solution measurem must be equipment
hrs, respectively ent observed
Used of lactic Acid Equipment
Chemical to increase steep maintenance ective Action re
water
Used of steam at Monitor the
operating temperatur Proper time Conduct
CCP 2 temperature and Temperat e and Production and laboratory test g and verificatio
(Horizontal Physical time of 82℃ and ure, and observe Every batch Manager temperature relative to the
Rotary Cooker) 1.20 hrs, Time accurate must be equipment
respectively measurem observed
ent
Used of steam at Monitor the
operating temperatur Proper time,
temperature, Temperat e, pressure pressure and Conduct
CCP 3 (Expeller Physical ure,
pressure, and time Pressure and Every batch Production temperature laboratory test g and verificatio
Press) of 105℃, 9.9 atm and Time observe Manager must be relative to the
and 1.20 hrs, accurate observed equipment
respectively measurem
ent
Accurate
Biological measurements
of the chemical
solutions Monitoring
0.5% protein Observe Conduct of and
CCP 4 (Starch should remain and accurate Every 30 Production Proper time microbial test verification
Dewatering) diluted, Protein measurem minutes Manager and to the record
washed 14 times to ent temperature frequency of
Physical remove the protein must be equipment
observed
Routine ective Action re
Observation

147
Continuation of Table 8.7
AREA 200
Bacillus Monitoring Precise
Biological stearothermo of measurements g and verificatio
philus and alpha - temperatur of the chemical
amylase at 0.02% e solutions
The pH of the Observatio
starch slurry should n of
Physical be adjusted at 5.7 pH, pressure Conduct of
to 6.3 with 10% of Chemical used microbial test
CCP 5 soda ash Solution, Every batch Production to the
(Gelatinization) Enzymes, Manager Proper time
and Accurate and frequency of
equipment Corrective
Bacteria measurem temperature Action record
ent of must be
Calcium chloride is chemical observed
Chemical at 50 to 70 ppm solution,
enzymes,
and
bacteria
doses
The
enzyme-containing
starch slurry will be
pumped to a jet
cooker at 103°C – Monitor the
107°C for 0.56 temperatur
hours and 0.35 Temperat e, pressure Proper time, Conduct Monitoring
CCP 6 atm. ure, and Production pressure and laboratory test and
(Liquefaction) Physical Every batch temperature
The steam will be Pressure observe Manager must be relative to the verification
injected by a steam and Time accurate observed equipment record
injector at 10-11 measurem
bar feed pressure ent
and 0.6-0.8 bar
back pressure at
108°C for 0.27
hours.
The liquefact is Correct Conduct of roduction Recor
CCP 7 (Flash Time and Monitoring
flash cooled at atm Temperat of Every 70 Production equipment set microbial test
Cooling) Physical pressure to reduce temperatur minutes Manager up and regular to the
the temp to 95 ℃. ure e equipment frequency of g of equipment a
maintenance equipmen

148
Continuation of Table 8.7
Aspergillus niger
glucoamylase with
Precise
0.05 w/v
Biological Monitor the measurements g and verificatio
concentration will
temperatur of enzymes
be added to the Time, Conduct of
tank e, pressure
CCP 8 Pressure, microbial test
and Every 15 Production
(Saccharificatio The temperature of Temperat to the
observe hours Manager
n) the tank should be ure, and Proper time, frequency of
accurate
maintained at 60°C Enzymes measurem pressure and equipment
Physical and the pH should ent temperature ective Action re
be controlled must be
around 4-5 in a observed
period of 60–90 h.
The used of Monitoring Proper pH and
Biological Streptomyces of temperature g and verificatio
murinus glucose temperatur must be
isomerase pH, e and pH observed Conduct of
CCP 9 Enzymes, Production microbial test
The pH of reactors and Every batch to the
(Isomerization) is between 7.5 and Temperat Accurate Manager frequency of
8.0, and the measurem Precise
Physical ure measurements equipment ective Action re
temperature is ent of of enzymes
between 55 and enzymes
60°C.
AREA 300
Monitoring
Ratio of water that of
Biological will be added to the temperatur
crude oil is 98.8:1 e and
Time, pressure Conduct of
Pressure, used Exact microbial test Cleaning of
CCP 10 and Every 30 Production proportion of to the equipment
(Degumming) The mixture will be minutes Manager chemical
preheated to 100 Temperat Accurate materials frequency of after use
Physical ℃ and 0.0987 atm ure measureme equipment
for 1.11 hours nt of
chemical
0.20% w/v solution
Chemical phosphoric acid is doses
added

149
Continuation of Table 8.7
1.40 % w/v sodium Proper time
hydroxide is added and
Biological
to neutralize free temperature
fatty acids Monitoring
must be Conduct of
Temperat of
Physical 100 ℃ temperature observed microbial test Cleaning of
CCP 11 ure, temperatur Every 30 Production
of the water is used to the equipment
(Neutralization) in washing while Pressure e and minutes Manager
frequency of after use
0.0987 atm and Time pressure
Routine equipment
Chemical pressure is used to used
produce soap Observation
stocks for 1.11
hours
Physical Washed for 1 hr w/ Monitoring
a pressure of of Proper time Conduct of
0.0493 to 0.197 Temperat temperatur and microbial test Cleaning of
CCP 12 atm & temp of 95 ure, e, Every 30 Production temperature to the equipment
(Bleaching) Chemical ℃ wherein 2% w/v Pressure pressure, minutes Manager must be frequency of after use
acid and Time and steam observed equipment
activated/bleaching used
clay
Physical Dewaxed oil will
enter the deaerator Monitoring
to remove the air of Proper time Conduct of
and will enter the Temperat temperatur and microbial test Cleaning of
CCP 13 deodorization ure, e, Every 40 Production temperature to the equipment
(Deodorization) Chemical water wherein 4% Pressure pressure, minutes Manager must be frequency of after use
steam is introduced and Time and steam observed equipment
and heated to 220 used
℃ at 0.0493 atm at
1.11 hours

150
c. Methods for Hazardous Waste Management
The accumulation, handling, and removal of waste that, if not handled
appropriately, can seriously impact the environment or human health and safety.
Hazardous wastes are typically produced by chemical production, manufacturing, and
other industrial operations. They might be solids, liquids, sludges, or enclosed gasses.
Inadequate procedures for storage, transportation, treatment, or disposal might result in
harm. Improper handling, storage, or disposal of hazardous material commonly causes
harmful water pollution by contaminating groundwater and surface water supplies and
can also cause hazardous land contamination.
Rugi Inc. produces several types of wastes that can be hazardous to the
environment and health. Accordingly, this wastes can be treated and managed through
different methods that are suitable for its disposal. The following are the waste disposal
treatments that will be used by the manufacturing plant for the waste management from
the production of HFCS 55: Physical Treatment, Chemical Treatment, Thermal
Treatment and Biological Treatment. Physical treatment of hazardous waste includes
processes such as evaporation, sedimentation, flotation, and filtration. Precipitation,
oxidation and reduction, neutralization, and ion exchange are the processes used for
chemical waste management. An example of thermal waste treatment is
high-temperature incineration. This treatment can detoxify or destroy waste material
however, it may pose air-pollution. Biological treatment uses land farming as a method
for disposing of organic wastes. In this process, wastes can be transformed or degraded
to environmentally safe materials using microorganisms.
The Rugi Inc. manufacturing plant is bound to comply with the requirements
enforced by the Environmental Quality Division-Hazardous Waste Management Section
(EQD-HWMS). Additionally, the R.A. 6969 or the Toxic Substances and Hazardous and
Nuclear Wastes Control Act of 1990 shall also serve as a guiding regulation for the
operations in the plant.The legislation mandates the establishment of rules, regulations,
and programs by the DENR for the management of hazardous wastes and chemical
compounds in the Philippines.

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 d. Methods of Reducing Equipment Hazard
Rugi Inc. can control emissions from equipment leaks through preventive maintenance
and the implementation of a leak detection and repair (LDAR) program. This program identifies
unintended or fugitive emissions from equipment in an oil and gas, chemical, or petrochemical
installation, modifying this equipment and installing components that promote a “leakless”
design and function. With these programs, leakages and their potential risks with the production,
as well as the environment, may be reduced or prevented altogether.

Table 8.8. Methods of Reducing Equipment Hazard

EQUIPMENT
TYPE MODIFICATION
Appropriate bearing lubrication between rollers
Monitoring of equipment before production
Conveyors
Safeguards for of nip and shear points
Side guards and secondary safeguards such as railings

Pressure Relief Leak-less design

Valves Closed-vent system
Maintain proper bearing lubrication
Pumps Closed-vent system
Seal-less design
Using pressure-vacuum relief valve to protect tank against rupturing or
Storage Tanks imploding
Installation of a closed-loop instrumentation control system that would
Reactors control temperature
Using a relief valve or pressure relief valve to control or limit the pressure
Boiler in a system
Valves Seal-less design

152
POTENTIAL HAZARDS IN THE WORKPLACE AND THE WAY OF CONTROLLING THEM
Identifying and determining hazards in the workplace is essential for ensuring the safety
of workers. Manufacturing plants can pose a variety of hazards, including physical, chemical,
biological, and environmental risks. Identifying and addressing these hazards requires a
comprehensive approach that involves careful observation, analysis, and action. Moreover, the
first step in identifying hazards in a manufacturing plant is to conduct a thorough assessment of
the facility. This can involve reviewing safety records, conducting interviews with workers, and
performing physical inspections of the premises. During this process, it is important to consider
all potential sources of harm, including equipment, materials, and work processes.
Once hazards have been identified, they must be prioritized according to their level of
risk. After hazards have been identified and prioritized, appropriate measures must be taken to
address them. This may involve modifying work processes, implementing safety procedures,
providing personal protective equipment, or making physical modifications to the workplace.
Rugi Inc. ensures the identification of all physical, chemical, and even biological hazards.
Therefore, it aims to provide preventive measures of any kind. Table = provides a list of potential
workplace hazards and the preventive measures to monitor them.

Table 8.9. Equipment’s Potential Hazard and their Preventive Measures

POTENTIAL HAZARDS PREVENTIVE MEASURES

● Use equipment that is designed to minimize potential hazards,
and ensure that it is installed properly and in accordance with
manufacturer instructions.
● Regularly inspect equipment and machinery for signs of wear
and tear or potential hazards, and perform maintenance as
needed.
● Install appropriate machine guards and other protective
Equipment and devices to prevent accidental contact with moving parts.
Operation ● Properly label hazardous equipment and machinery, and
communicate the risks associated with them to employees to
help prevent accidents.
● Maintain a clean and organized workplace to prevent clutter or
debris from obstructing equipment or machinery.
● Ensure that employees have access to and use appropriate
PPE, such as gloves, goggles, and hard hats, to protect
against potential hazards during equipment operation.

153
Continuation of Table 8.9

● Regularly clean and sanitize equipment and machinery to

prevent the buildup of bacteria or other contaminants.

● Provide employees with proper training on contamination

Contaminations prevention, including spill response and cleanup procedures.

● Provide employees with proper training on personal hygiene,

including hand washing and proper clothing, to prevent
contamination.

● Ensure that employees are provided with appropriate PPE,

such as goggles, gloves, respirators and other protective
clothing, and that they are trained in their proper use.

● Continuously monitor the facility for any signs of hazards or

Hazardous Materials leaks, and promptly address any issues that are identified.

● Regularly inspect storage areas, equipment, and

transportation vehicles to ensure that they are in good
condition and free of leaks or other hazards.
● Store hazardous materials in secure and well-ventilated areas
that are clearly marked and separated from other materials.

● Regular inspections of equipment, pipelines, and storage

tanks can help identify potential leaks and spills before they
occur.

● Store and handle chemicals and other hazardous materials

properly to minimize the risk of leaks and spills.
● Provide employees with proper training on how to handle
Leaks and Spills hazardous materials, including spill response and cleanup
procedures.
● Properly dispose of contaminated materials and waste in
accordance with local, state, and federal regulations.
● Compliance with government regulations and industry
standards can help ensure that proper measures are in place
to prevent spills and protect the environment and human
health.

154
Continuation of Table 8.9

● Develop a fire prevention plan that identifies potential sources

of ignition and puts measures in place to prevent fires.
● Store flammable materials properly in a designated area that
is well-ventilated, dry, and away from sources of ignition.
● Provide employees with proper training on fire safety,
including how to use fire extinguishers and evacuate the
building in case of fire.
Fire and Flammability ● Install and maintain appropriate fire suppression equipment
Hazards such as fire extinguishers, sprinkler systems, and fire alarms.
● Ensure that electrical equipment is properly maintained,
grounded, and not overloaded to prevent electrical fires.
● Regularly inspect the plant for potential fire hazards and
ensure that fire suppression equipment is in good working
order.
● Properly label flammable materials and communicate the risks
associated with them to employees to help prevent fires.

INHERENT SAFETY TECHNIQUES IN ACCIDENT PREVENTION

Inherent safety is a concept that has gained significant attention as a way to improve
safety in the design and operation of chemical plants and other industrial facilities. The principle
behind inherent safety is to eliminate or reduce hazards by designing a process or system that
is inherently safe, rather than relying on safety measures such as personal protective equipment
(PPE) or emergency response systems. Furthermore, the inherent safety approach involves
identifying and eliminating potential hazards at the design stage, rather than relying on adding
safety features later in the process.
The benefits of inherent safety are numerous. First and foremost, it can help prevent
accidents and incidents that can cause harm to people, the environment, and property. It can
also reduce the costs associated with safety measures such as PPE and emergency response
systems, as well as reduce the likelihood of fines and legal liability resulting from safety
incidents. In addition, inherent safety can improve overall efficiency and productivity by
simplifying the process and reducing the likelihood of unplanned shutdowns and maintenance.

155
 Implementing inherent safety can be challenging, as it involves a substantial investment
of time and resources to identify and eliminate potential hazards. It also necessitates a
comprehensive grasp of the involved process and materials, as well as an organization
commitment to safety. Moreover, inherent safety is not a one-time effort, but requires continuous
monitoring and improvement to ensure that no new hazards are added as the process or
materials evolve. Despite various challenges, some companies are utilizing inherent safety as a
means of enhancing operational safety and productivity. Various intrinsic safety techniques have
been employed and considered for the safe working environment and design of the
manufacturing plant for high-fructose corn syrup 55 and corn oil, as shown in Table 8.10.

Table 8.10. Inherent Safety Approaches

INHERENT SAFETY
TECHNIQUES AREAS INVOLVED
APPROACHES
● Reduce the size of equipment
operating under dangerous
conditions, such as high temperature
or pressure, and use the smallest
Minimize (Intensification) possible quantity of hazardous Area 100-400
materials
● Ensure that areas have well
ventilation
● Use materials, chemistry, and less
Substitute (Substitution) Area 100-400
hazardous processes
● Minimize the possibility of an
accident by putting hazardous
facilities away from people and other
property
Moderate (Attenating and
● Select equipment that require less Area 100-400
Limitation)
maintenance
● In all parts of the manufacturing
facility, design control panels that
are clear and simple to comprehend
● Selecting equipment with low failure
rates
Simplify (Simplification and ● Eliminate complexity from processes Area 100-400
Error Tolerance) that is not necessary
● To improve workers' understanding,
label equipment and controls

156
DELIVERY, HANDLING AND STORAGE OF RAW MATERIALS
The success of a manufacturing company depends largely on the quality of its products,
which in turn depends on the quality of the raw materials used in the production process. Rugi
Inc. will transport raw materials using vehicles such as bulk tanks and delivery trucks. A
warehouse will be used to store raw materials, which must be kept at room temperature.
Therefore, it is essential that these raw materials be transported, handled, and stored properly
to ensure their quality and readiness for use. Moreover, the handling and storage of raw
materials must comply with Rugi Inc. requirements.
In connection to this, the raw materials must be properly packaged, labeled, and secured
for transport. The transportation vehicles must be suitable for the particular type of raw material
being transported. Before loading the raw materials, the transportation vehicles must be
thoroughly cleaned and sanitized to prevent contamination. Additionally, it is essential to adhere
to all applicable regulations and guidelines regarding the safe transportation of hazardous
materials. In order to prevent accidents and injuries, it is also essential to use the proper
equipment and tools for handling raw materials and to train employees on safe handling
procedures.
In addition, raw materials must be stored in a clean, dry, and secure location.
Temperature and humidity levels must also be adhered to in order to prevent the materials from
deteriorating or expiring. To prevent confusion and cross-contamination, raw materials must be
properly labeled and arranged. Furthermore, the raw materials must be inspected and
inventoried routinely to ensure that they are in good condition. In relation, Rugi Inc. will have a
complete documentation of each shipment and production will be monitored in order to create a
daily inventory of the delivered quantity of products.

STORAGE TANK AND PIPING LEAK DETECTION

One of the most significant concerns associated with storage tanks and pipelines is the
potential for leaks. Leaks can lead to environmental damage, safety hazards, and financial
losses. Therefore, it is essential to have an effective leak detection system in place to mitigate
these risks. The pipe system and storage tanks must be further inspected and monitored for
leaks. Leaks in pipelines and storage tanks have long been a source of concern due to the
associated dangers and costs. Its influence could hinder human lives and the environment.
Rugi Inc. will utilize the following leak detection methods:

157
 ● Utilizing sensors is a common form of automated technology. Sensors can detect
variations in pressure, temperature, and flow rates, which may indicate a leak. These
sensors can be installed in a variety of locations, such as the tank or pipeline itself, as
well as at critical points such as valves and joints.
● Utilizing certified or authorized integrity testing methods on piping or tank systems on a
regular basis, particularly for those with critical conditions involving high temperature and
pressure.

COMMUNITY AND HEALTH SAFETY

Rugi Incorporation must be adapted to the needs of the local community. To avoid
putting the environment at risk, complete consideration must be given to the plant's safe
placement and one of the primary objectives of the plant will be hygiene and sanitation.
A. Medical Services
When a health emergency occurs, the company will supply a health care facility with
expert employees to guarantee that there is rapid assistance. The health care facility includes
equipment, medical supplies, medical workers, and an ambulance in the event that a patient
needs to be transported immediately to the nearest hospital.
B. Fire
In the case of a serious emergency or catastrophic events, the company will assess the
extent of local firefighting capabilities and the equipment's suitability for deployment. Personnel
training will be employed to increase firefighting capability.
C. Disease Prevention
Various health issues may arise with manufacturing high-fructose corn syrup 55 and corn
oil. To avoid such illnesses, the health safety measures that will be utilized are as follows.
● Medical care, routine monitoring, and comprehensive pre-employment screening
and treatment are all provided to employees.
● Education on disease treatment by health experts, medical missions, and
immunization programs for local community workers to enhance health and avoid
illness. Health care services are part of local community workers' disease
prevention programs.
● Constructive collaboration with the local government to guarantee inexpensive
public health services for the company workers and their families.

158
 D. Environmental Health
The corporation will support regulations involving environmental protection and
awareness statistics, as well as activities intended to prevent accidents. It shall also abide by all
of the federal government's regulatory laws controlling community safety and health, including
those governing pollution control and prevention.

HAZARD AND HAZARD CONTROL

Physical, chemical, safety, ergonomic, and psychological concerns will all be taken into
consideration by RUGI Manufacturing Inc. Hazardous Material Management. The initial strategy,
which often focuses on the person who is exposed to the hazard, is to control the threat at its
source. Fundamentally, the concept is that the job and work environment should be created in a
way that minimizes or eliminates the risk of hazards. In order to achieve this, several hazardous
items must be used and managed on the plant, and strategies and policies must be put in place
to ensure that future occurrences of these threats are prevented.
The technical plant personnel of RUGI Manufacturing Inc. is responsible for
understanding and creating the following when creating an in-plant hazardous material
management plan:
● Hazardous substance classification
● Analysis of hazardous samples
● Measuring instruments for environmental protection especially in wastewater treatment
and gas and steam emissions.
● Proper waste management of hazardous air, water, and solid in all areas of the plant
● Management of environmental hazards through preparation of life cycle assessment

Methods for Hazardous Waste Management

With relation to industrial plants, hazardous wastes have emerged as a
significant concern for the environment and public health. The RUGI Inc. Manufacturing
Plant has developed a four-pronged approach to hazardous waste management in the
current era:

1. Minimizing the quantity of Waste

Attempts are made to reduce the amount of resources and energy used during
production. Often, it calls for in-depth familiarity with the waste composition as well as

159
the manufacturing process. Process modification, waste concentration, and waste
segregation are the three main waste reduction strategies that are frequently utilized.

2. Recycling of industrial Waste

It is safe and efficient to recycle a variety of industrial hazardous wastes. Many
trash may now be recycled and reused due to technological advances. Nonetheless, in
certain cases more effort will be put towards recovery than the worth of the recovery
justifies. RUGI Inc. Manufacturing plants will use waste reuse and waste recycling as the
two main methods of handling hazardous waste.

3. Treatment of the Waste

After material recovery, the wastewater containing hazardous waste compounds
has to undergo treatment to be detoxified and neutralized. The kind of waste, the desired
qualities of the output stream, and energy and economic concerns are just a few of the
numerous variables that must be taken into account when choosing a treatment method.
The treatment technologies might be physical, chemical, biological, solidification, and
incineration CHAPTER VIII Health, Safety and Environmental Issues 173.

4. Collection, Transport and Disposal of Waste in an Environmentally Sound

Manner
A crucial link in the chain connecting the sources of hazardous waste with the
locations where it is treated and disposed of is the safe collection and transportation of
the garbage. The same precautions that are taken when transporting dangerous goods
also apply in many ways to hazardous waste, although some wastes pose extra issues
due to their potential for harm. A suitable collection, transport, and storage system is
necessary for the safe and secure disposal of hazardous waste. Wastes that are
incompatible must be separated and transported separately.

5. Disposal of Hazardous Waste

The most typical technique to get rid of a dangerous material is to release it far
enough away from humans so that no one is directly harmed. Both liquid and solid waste
streams are pumped into a deep well or dumped into the surrounding ocean or river for
disposal.

160
PERSONAL PROTECTIVE EQUIPMENT
Personal protective equipment, or "PPE," is a set of equipment worn to reduce exposure
to risks that might result in significant workplace diseases and injuries. These injuries and
illnesses may result from contact with chemical, radiological, physical, electrical, mechanical, or
other workplace hazards. PPE’s may include gloves, safety goggles, shoes, earplugs or muffs,
hard hats, respirators, or coveralls, vests, and full body suits. All personal protective equipment
should be safely designed and constructed, and should be maintained in a clean and reliable
fashion. It should fit comfortably, encouraging worker use. If the personal protective equipment
does not fit properly, it can make the difference between being safely covered or dangerously
exposed.
With this, the Rugi manufacturing plant will conduct an in-depth evaluation of the
equipment required to protect against workplace hazards to establish an ideal PPE
management program. This assessment would be used to establish a standard operating
procedure for personnel, and required employees to undergo training and seminar about the
protective limitations of the PPE, as well as its proper use and maintenance. Employees must
understand that the equipment does not eliminate the risk.
Generally, wearing personal protective equipment (PPE) is a basic requirement of an
employee in order to avoid future instances of injuries and accidents in which the Rugi
manufacturing plant will be strictly observed in all its process operations relevant to the
production of HFCS 55 and corn oil, especially those involved in the equipment that is subjected
to high temperatures or steam.

161
 Table 8.11. Summary of Recommended PPE According to Hazard
OBJECTIVES WORKPLACE HAZARD SUGGESTED PPE AREAS INVOLVED
Safety glasses,
Eye and Face Liquid, Gases, Chemicals safety goggles and
Protection and Flying Particles face shields 100-400
Industrial helmets
and Bump
Flying objects (heavy caps/any head
materials) and bumping protection materials
Head Protection heads on a fixed objects for heavy materials 100-400
Earplugs and
Hearing Protection Noise earmuffs 100-400
Foot and Leg Falling pointed objects and Safety toed shoes
Protection rolling broken materials or boots 100-400
Leather, canvas or
metal mesh gloves
to protect against
cuts, burns and
Skin absorption of harmful punctures
substances, chemical or insulating rubber
thermal burns, electrical gloves for
dangers, bruises, abrasions, protection against
Hand Protection cuts electrical hazards 100-400
Face masks with
Respiratory Protection Gasses, dust and fumes appropriate filters 100-400
Protective clothing
such as a vest,
apron, lab gown
Skin Protection Liquids and slurries etc. 100-400

ENERGY CONSERVATION
The energy management of the Rugi Manufacturing Plant will assess the general
patterns of usage, including those associated with manufacturing processes and supporting
utilities, as well as the overall impacts of power source pollution. The mitigation strategies and
planning development on energy cost reduction will be conducted to ensure the excessive

162
expenditure on the energy utilization. Observations among the process equipment inside the
manufacturing plant will also be accomplished.
Table 8.12. Energy Conservation Techniques of Rugi Manufacturing Plant
SYSTEM CONSERVATION TECHNIQUES
a. Maintain proper system boundaries to the areas with a high-temperature
profile such as steeping tanks, dryers, mixing tanks, jet cookers, enzymatic
hydrolysis reactors, evaporators, and distillation columns.
b. Schedule and maintain equipment properly in most equipment with
high-temperature profile (e.g. dryers, reactors, and columns).
Heating
c. Use the system for long runs near or at full capacity whenever possible as
observed in dryers.
d. In addition to isolating all hot valves and flanges, insulate all steam,
condensate, hot water, and thermal fluid transport up to and including 1" (25 mm)
diameter pipe.
a. Temperature will be precisely controlled to avoid overcooling as observed in
condensers and pressure screeners.
b. Maintain a slight positive pressure in cooling tunnels, and air seals to reduce
Cooling
airflow into the cooled system, thereby lowering energy consumption and the
energy required to cool this unwelcome air to the operating temperature of the
system's temperature as observed in condensers.

ENVIRONMENTAL ASPECT
Environmental risk factors may be attributed to the layout, design, and utilities of the
physical workspace. The following environmental factors must be considered in evaluating and
managing risks and minimizing potential hazards in the Rugi Inc. manufacturing plant. These
factors will aid to complete evaluation and management programs that identify the risks and
possible effects on the environment. The following are the potential environmental factors to the
Rugi Incorporation’s processing plant: Gas emission, particulate matter, wastewater, and
residual waste.

a. Gas Emission
Carbon dioxide is one of the most prevalent emissions observed. CO2 emissions
may be reduced by utilizing filters and restricting the number of pollutants emitted.
Additionally, maintaining the equipment and its component parts clean and clear of dirt is
critical, since this can have a significant influence on its efficiency. Energy-efficiency

163
 requirements have been implemented in the shipping sector, which include maintaining
the propellers and other underwater sections of the ships clean, lowering waste heat
output and reducing the need for regular new replacement parts.

b. Particulate Matter
Wind may carry particles over vast distances before they settle on the ground or
in water. The effects of this settling may include: making lakes and streams acidic,
changing the nutrient balance in coastal waters and large river basins, depleting
nutrients in the soil, damaging sensitive forests and farm crops, affecting the diversity of
ecosystems, and contributing to acid rain effects, depending on their chemical
composition.

c. Wastewater
The main contributors to natural water contamination are the effluents produced
by industrial operations. This places a significant strain on wastewater management and
may eventually result in a point-source pollution issue, which not only raises treatment
costs significantly but also exposes water supplies to a variety of chemical pollutants and
microbiological contaminants. The Rugi Incorporation has a wastewater management
system that treats wastewater used from the processing plant.

d. Residual Waste
The Rugi manufacturing plant utilizes most of its raw materials however, tons of
residual wastes from corn and other raw materials are still produced. Thus proper
disposal areas such as compost pits for organic materials will be provided. Hazardous
residues should also be managed and transported with proper handling to avoid
contaminations.

Occupational Safety
Occupational health and safety is a branch of public health that investigates trends in
workplace illnesses and injuries and recommends and implements prevention methods and
laws.
Rugi Incorporation obliquely provides occupational health and safety standards to
secure their workers and employees from any operational-phase issues and preventative

164
measures. As a result, the company will adhere to Republic Act No. 11058, also known as the
"Occupational Safety and Health Standards" Law, which was passed to give all employees and
managers more rights to provide pleasant workplaces and high-quality PPE. In addition, the
company will ensure that employees are aware of any hazards in the workplace and have the
right to reject harmful employment. Accidents, illnesses, lost wages, premiums for insurance,
hiring new employees, damaged equipment, and delayed output are all costly for businesses
and the economy as a whole. However, it is more common for larger businesses to have their
own workplace health and safety programs.

165
 Table 8.13. Occupational Safety with Preventive Measures
Hazard Source Preventive Measure
Ensure that the installation is properly
inspected and tested.
Electrical Hazard
The wiring of equipment should be validated
before tested.
Equipment must be well-designed, ideally
with a cover, and installed in such a way that
regular maintenance, such as lubricating,
cleaning, and calibrating motor and other
Physical Open Machine/Moving Machine
parts before and after use, is reinforced on a
regular basis. This is to ensure the safety of
the workers and other machines in the
vicinity.
Employees are required to wear hearing
protection to minimize their per-day decibel
Noise noise standard within OSHA's permissible
exposure limit (PEL) of 90 decibels for eight
hours each day.
Provide ventilation, particularly at
Inhalation of dust from bleaching workstations used for handling raw
earth, filter aid materials, milling, bleaching earth, and
solvent use.
Observe proper handling and storing of
Chemical
hazardous chemicals.

Hazardous Substance
Label each substance according to the
standards stated by the rules and
regulations of the government.

166
Identification of Procedure and Mitigation Technique for Undesirable Accidents/ Events
Process Hazard Checklist
A checklist compensates for potential limitations in hazard perception, human
memory, and attention to specific information. It also aids in ensuring consistency and
completeness in the execution of a task by an individual, a workgroup, or throughout an
organization.
Additionally, the Hazard Identification Checklist is provided to help identify potential
dangers related to the plant operation. Rugi Incorporation will be using Hazard Analysis Process
wherein it consists of five steps: first, identify the specific tasks that must be completed to meet
project goals; second, determine whether there are any hazards associated with completing
these tasks; third, identify the risks associated with the hazards; and fourth, develop a list of
controls to eliminate or minimize the risks. Lastly, design a safe operating process that outlines
how each task will be completed safely.

Preliminary Risk Analysis

In a well-defined situation including a possible hazard, a Preliminary Risk Analysis (PRA)
assesses the level of quantitative and qualitative risk involved. Although PRA is a relatively
painless and rapid process, it should incorporate all factors that can influence a situation,
including technological, operational, administrative, physical, and personnel factors. Before the
procedure, a risk analysis is carried out to identify potential difficulties and devise a strategy for
dealing with them.
Each Preliminary Risk Assessment (PRA) is unusual depending on the situation under
consideration. It should, in each case, identify the system's or project's variables, as well as the
hazards that could affect each of them. Then, for each threat-vulnerability pair, it should
calculate the probability of each one. To establish which existing systems countermeasures,
lessen the threat of the possible hazard, these vulnerability-threat pairs are furthermore
assessed.
Relevance: Having a Preliminary Risk Assessment (PRA) will help determine all the
possible risks in the plant operations. Some examples that may be a source of risk are tank
spillage, handling and storing of chemicals, improper utilization of personal protective equipment
(PPE), wet surfaces, overlooked holes and stairways, improper guarding of machinery, leaks,
and other damaged surfaces.

167
 Table 8.14. Methods of Reducing Equipment Hazard

POTENTIAL HAZARDS PREVENTIVE ACTION

● Corrosion ● Proper wearing of Personal Protective

● Misaligned fittings for pipes Equipment (PPE)
● Seal failure ● Use of corrosion proof equipment
● Chemical leak materials
● Structural failure ● Get enough knowledge in operating
● Valve leak machineries
● Personnel’s injury in machine moving ● Know the machinery requirements
parts Equipment failure ● Determination of the potential cause
of hazardous chemicals
● Regular inspection and maintenance
of equipment, pipes, and facilities
● Prepare safety measure containment
if chemical leaks occurred
● Cover the moving parts in the
equipment
● Proper storage of hazardous materials
● Emergency planning
● Conduction of safety audit

168
PERSONAL PROTECTIVE EQUIPMENT
Personal protective equipment, generally known as PPE, is protection intended to avoid
or reduce exposure to dangers including biological, chemical, radioactive, electrical, and
mechanical risks. These contacts can lead to injuries and diseases. Equipment like gloves,
safety goggles, shoes, earplugs or muffs, hard hats, respirators, or coveralls, vests, and full
body suits are examples of personal protection equipment. All personal protective equipment
must be designed and built safely, and it must be kept in a hygienic and efficient condition. It
should be comfortable enough to encourage worker usage. Fit issues with personal protective
equipment might be the difference between being securely covered and being dangerously
exposed.
The standard practice of wearing PPEs in the working areas of RUGI Inc. manufacturing
Plant will be strictly implemented. These protective equipment are a requirement for workers to
avoid accidents especially in high temperature and steam areas. The following table 8.14 is a
list of summary of recommended PPE according to the potential hazard.

169
 Table 8.15. Methods of Reducing Equipment Hazard

Objectives Workplace Hazard Suggested PPE Areas Involved

Eye and Face Gasses, chemicals, Face shields, safety 100-400

Protection fine particles, and goggles, and eye
liquids protection

Head Protection Falling objects, and Bump caps, industrial 100-400

bumping fixed things helmets, and other
with their heads types of headwear for
heavy materials

Hearing Protection Loud noise Earplugs and 100-400

earmuffs

Foot and Leg Sharp objects and Safety shoes or boots 100-400
Protection moving debris on the
floor

Hand Protection Toxic chemicals Gloves made of 100-400

absorbing into the leather, canvas, or
skin, thermal or metal mesh provide
chemical burns, protection against
electrical risks, cuts, burns, and
bruising, abrasions, punctures. Insulating
and cuts rubber gloves shield
wearers from
potential electrical
risks.

Respiratory Gasses, dust and Face masks with 100-400

Protection fumes appropriate filters

Skin Protection Liquids and slurries Vest, apron, lab gown 100-400
and other protective
suits.

170
 CHAPTER IX
EQUIPMENT LIST AND SPECIFICATION SHEET
This chapter presents the equipment list and specification sheet to be used by Rugi Inc.
for the production of HFCS 55 and corn oil.

I. EQUIPMENT SPECIFICATION SHEET

Equipment specification is the written documents or manuals that describe the
production capacity method, fabrication methods and other details of the equipment to be used
in various processing or manufacturing operations. Below are the equipment specifications of
the Rugi Manufacturing Inc. that will be used for the production of HFCS 55 and corn oil.

Table 9.1. AREA 100: Specification Sheet No 1

AREA 100: Specification Sheet No 1
Identification: TK-101

Type: Hopper bottomed tank

No. Required: 1

Function: Steeping of corn kernels.

Stainless Steel Type 316 (HB 7th
Material of Construction Edition)
Operating Temperature 25°C
Operating Pressure (kPa) 208.93
Design Data
H/D 1.27
D (m) 4.73
H (m) 6.00
Volume (m3) 114.87
Capacity (m3) 95.72
Factor of Safety 13%
Operation Batch

Power Consumption (kWh) 94.28

American Society of Mechanical Engineers (ASME) Codes and
Standard:
Standards - SA - 240: Carbon and Stainless Steel Flanges
 Table 9.2. AREA 100: Specification Sheet No 2
Specification Sheet No 2
Identification: FL-101
Type: Dewatering Gravity Screen
No. Required: 1
Function: Draining water from steeped corn kernels.
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1 atm
Design Data
L (m) 3.84
W (m) 2.18
H (m) 2.63
Volume (m3) 33.27
Capacity (m3) 27.72
Factor of Safety 13%
Operation Batch

Power Consumption (kWh) 18.72

American Standard for Testing and Materials' (ASTM) Geotechnical

Standard:
Engineering Standards D6128-14 for Screener

172
 Table 9.3. AREA 100: Specification Sheet No 3
Specification Sheet No 3
Identification: A-101
Type: Attrition Mill
No. Required: 1
Function: Coarse grinding of corn kernels
Material of Construction Stainless Steel
Operating Temperature 107°C
Operating Pressure 1 atm
Design Data
H/D (m) 2
D (m) 2.90
H (m) 5.80
Volume (m3) 144.87
Capacity (m3) 120.72
Factor of Safety 13%
Operation Batch

Power Consumption (kWh) 96.93

Standard: Miller ANSI Z359. 14-2012 Compliant Products

173
 Table 9.4. AREA 100: Specification Sheet No 4
Specification Sheet No 4
Identification: MH-104
Type: Hydrocyclone
No. Required: 1
Function: Separation of coarse particles and water.
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1 atm
Design Data
Length of entrance tube (m) 1.00
Height (m) 2.65
Dc (m) 5.30
Inlet Diameter (m) 0.88
Outlet Diameter (m) 1.33
Volume (m3) 64.80
Capacity (m3) 54.00
Factor of Safety 13%
Operation Batch
Power Consumption (kWh) 10.07
Standard: American Society of Mechanical Engineers (ASME)

174
 Table 9.5. AREA 100: Specification Sheet No 5
Specification Sheet No 5
Identification: FL-102
Type: Dewatering Gravity Screen
No. Required: 1
Function: Draining water from steeped corn kernels.
Material of Construction Stainless Steel
Operating Temperature 80°C
Operating Pressure 1 atm
Design Data
L (m) 3.8
W (m) 2.18
H (m) 2.63
Volume (m3) 26.74
Capacity (m3) 22.28
Factor of Safety 13%
Operation Batch

Power Consumption (kWh) 17.99

American Standard for Testing and Materials' (ASTM) Geotechnical

Standard:
Engineering Standards D6128-14 for Screener

175
 Table 9.6. AREA 100: Specification Sheet No 6
Specification Sheet No 6
Identification: V-101
Type: Drier
No. Required: 1
Function: Drying of corn germ
Material of Construction Stainless Steel
Operating Temperature 60°C
Operating Pressure 1 atm
Design Data
H/D 2.00
D (m) 1.72
H (m) 3.45
Surface Area (m2) 23.32
Volume (m3) 8.04
Capacity (m3) 6.70
Factor of Safety 13%
Operation Batch
Power Consumption (kWh) 250.98
American Society of Mechanical Engineers (ASME) Codes and Standards for
Standard:
Industrial Dryers

176
 Table 9.7. AREA 100: Specification Sheet No 7
Specification Sheet No 7
Identification: A-102
Type: Horizontal Rotary Cooker
No. Required: 1
Function: Drying of corn germ.
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure (kPa) 181.15
Design Data
H/D 2.20
D (m) 1.32
H (m) 2.90
Volume (m3) 7.18
Capacity (m3) 5.99
Factor of Safety 13%
Operation Batch
Power Consumption (kWh) 63.35
American Society of Mechanical Engineers (ASME) Codes and Standards -
Standard:
SA - 240: Carbon and Stainless Steel Flanges

177
 Table 9.8. AREA 100: Specification Sheet No 8
Specification Sheet No 8
Identification: A-103
Type: Expeller Press
No. Required: 1
Function: Extraction of Corn Oil
Material of Construction Stainless Steel
Operating Temperature 86°C
Operating Pressure 1 atm
Design Data
W (m) 1.28
H (m) 2.01
L (m) 4.88
Thickness (m) 0.10
Filter Area (m2) 37.26
Number of Plates 65.67
Filter Area (m2) 26320.68
Volume (m3) 6.81
Capacity (m3) 5.67
Factor of Safety 13%
Operation Batch
Power Consumption (kWh) 8.67
Formulas used were from Plant Design and Economics by Timmerhaus et,
Standard:
at.

178
 Table 9.9. AREA 100: Specification Sheet No 9
Specification Sheet No 9
Identification: A-104
Type: Impact Mill
No. Required: 1
Function: Grinding of Corn Slurry
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1 atm
Design Data
H/D 2.00
D (m) 1.20
H (m) 2.40
Volume (m3) 50.35
Capacity (m3) 41.96
Factor of Safety 13%
Operation Batch

Power Consumption (kWh) 20.21

Standard: Miller ANSI Z359. 14-2012 Compliant Products

179
 Table 9.10. AREA 100: Specification Sheet No 10
Specification Sheet No 10
Identification: FL-103
Type: Press Dewatering Screen
No. Required: 1
Function: Screening of Fine Ground Slurry
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1 atm
Design Data
H/D 2.00
D (m) 1.32
H (m) 2.63
Dock Area (m2) 13.58
Volume (m3) 103.55
Capacity (m3) 86.29
Factor of Safety 13%
Operation Batch
Power Consumption (kW) 17.48
American Standard for Testing and Materials' (ASTM) Geotechnical
Standard:
Engineering Standards D6128-14 for Screener

180
 Table 9.11. AREA 100: Specification Sheet No 11
Specification Sheet No 11
Identification: C-101
Type: Disk Nozzle Centrifuge
No. Required: 1
Function: Centrifugation of Fine Ground Mill
Material of Construction Stainless Steel
Operating Temperature 80°C

Operating Pressure 1 atm

Design Data

H/D 2.00

D (m) 1.80

H (m) 3.60

Width (m) 1.80

Length (m) 3.20

Volume (m3) 103.59

Capacity (m3) 86.33

Factor of Safety 13%

Operation Batch

Power Consumption (kW) 31.67

International Organization for Standardization (ISO) 6178:1983: Centrifuges
Standard:
Construction and Safety Rules

181
 Table 9.12. AREA 100: Specification Sheet No 12
Specification Sheet No 12
Identification: MH-108
Type: Hydrocyclone
No. Required: 1
Function: Washing of Fine Ground
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1 atm
Design Data
Length of entrance tube (m) 1
Height (m) 2.65
Dc (m) 5.30
Inlet Diameter (m) 0.88
Outlet Diameter (m) 1.33
Volume (m3) 77.37
Capacity (m3) 64.47
Factor of Safety 13%
Operation Batch
Power Consumption (kW) 3.51
Standard: American Society of Mechanical Engineers (ASME)

182
 Table 9.13. AREA 100: Specification Sheet No 13
Specification Sheet No 13
Identification: C-102
Type: Peeler Centrifuge
No. Required: 1
Function: Washing of Pure Starch Slurry
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1 atm
Design Data
H/D 1.17
D (m) 2.89
H (m) 3.40
Width (m) 3
Length (m) 4.6
Volume (m3) 76.18
Capacity (m3) 63.48
Factor of Safety 13%
Operation Batch
Power Consumption (kW) 71.78
International Organization for Standardization (ISO) 6178:1983: Centrifuges
Standard:
Construction and Safety Rules

183
 Table 9.14. AREA 200: Specification Sheet No 14
Specification Sheet No 14
Identification: TK-201
Type: Mixing Tank
No. Required: 1
Function: Gelatinization of Starch
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1 atm
Design Data
H/D 4.0
D (m) 1.7
H (m) 6.8
Volume (m3) 15.13
Capacity (m3) 12.61
Factor of Safety 13%
Operation Batch

Power Consumption
37.40
(kWh)

American Society of Mechanical Engineers (ASME) Codes and Standards -

Standard:
SA - 240: Carbon and Stainless Steel Flanges

184
 Table 9.15. AREA 200: Specification Sheet No 15
Specification Sheet No 15
Identification: A-201
Type: Jet Cooker
No. Required: 1
Function: Liquefaction of Starch
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1 atm
Design Data
H/D 2.00
D (m) 4.05
H (m) 8.09
Volume (m3) 104.11
Capacity (m3) 86.76
Factor of Safety 13%
Operation Batch

Power Consumption
49.59
(kWh)

American Society of Mechanical Engineers (ASME) Codes and Standards -

Standard:
SA - 240: Carbon and Stainless Steel Flanges

185
 Table 9.16. AREA 200: Specification Sheet No 16
Specification Sheet No 16
Identification: E-201
Type: Flash Cooler
No. Required: 1
Function: Cooling of Liquefact Starch
Material of Construction Stainless Steel
Operating Temperature 86°C
Operating Pressure 1 atm
Design Data
H/D 2.00
D (m) 3.05
H (m) 6.10
Volume (m3) 44.54
Capacity (m3) 37.12
Factor of Safety 13%
Operation Batch

Power Consumption (kWh) 26.40

American Society of Mechanical Engineers (ASME) Codes and Standards - SA

Standard:
- 240: Carbon and Stainless Steel Flanges

186
 Table 9.17. AREA 200: Specification Sheet No 17
Specification Sheet No 17
Identification: TK-202
Type: Saccharification Tank
No. Required: 1
Function: Saccharification of Liquefact Starch
Material of Construction Stainless Steel Type 316 (HB 7th Edition)
Operating Temperature 25°C
Operating Pressure 1 atm
Design Data
H/D 2.00
D (m) 3.70
H (m) 7.40
Volume (m3) 34.77
Capacity (m3) 28.97
Factor of Safety 13%
Operation Batch

Power Consumption (kWh) 115.15

American Society of Mechanical Engineers (ASME) Codes and Standards - SA

Standard:
- 240: Carbon and Stainless Steel Flanges

187
 Table 9.18. AREA 200: Specification Sheet No 18
Specification Sheet No 18
Identification: FL-201
Type: Rotary Vacuum Filter
No. Required: 1
Function: Filtration of Unrefined Glucose Syrup
Material of Construction Stainless Steel
Operating Temperature 80°C
Operating Pressure 1 atm
Design Data
H/D 2.00
D (m) 2.81
H (m) 4.21
Filter Area (m2) 61.91
Volume (m3) 34.77
Capacity (m3) 28.97
Factor of Safety 13%
Operation Batch
Power Consumption (kWh) 43.86
Standard: American Society of Mechanical Engineers (ASME)

188
 Table 9.19. AREA 200: Specification Sheet No 19
Specification Sheet No 19
Identification: T-201
Type: Decolorizing Column
No. Required: 1
Function: Decolorizing of Filtered Glucose Syrup
Material of Construction Stainless Steel Type 316 (HB 7th Edition)
Operating Temperature 82°C
Operating Pressure 1 atm
Design Data
H/D 2.00
D (m) 2.83
H (m) 5.65
Volume (m3) 35.45
Capacity (m3) 29.54
Factor of Safety 13%
Operation Batch

Power Consumption (kWh) 76.03

American Society of Mechanical Engineers (ASME) Codes and Standards - SA

Standard:
- 240: Carbon and Stainless Steel Flanges

189
 Table 9.20. AREA 200: Specification Sheet No 20
Specification Sheet No 20
Identification: T-202
Type: Demineralizing Column
No. Required: 1
Function: Demineralizing of Filtered Glucose Syrup
Material of Construction Stainless Steel Type 316 (HB 7th Edition)
Operating Temperature 80°C
Operating Pressure 1 atm
Design Data
H/D 2.00
D (m) 2.80
H (m) 5.61
Volume (m3) 34.60
Capacity (m3) 28.83
Factor of Safety 13%
Operation Batch

Power Consumption (kWh) 74.74

American Society of Mechanical Engineers (ASME) Codes and Standards - SA

Standard:
- 240: Carbon and Stainless Steel Flanges

190
 Table 9.21. AREA 200: Specification Sheet No 21
Specification Sheet No 21
Identification: E-202
Type: Evaporator
No. Required: 1
Function: Evaporation of Demineralized Glucose Syrup
Material of Construction Stainless Steel Type 316 (HB 7th Edition)
Operating Temperature 52°C
Operating Pressure 1 atm
Design Data
H/D 2.00
D (m) 2.80
H (m) 5.60
Volume (m3) 34.43
Capacity (m3) 28.69
Factor of Safety 13%
Operation Batch

Power Consumption (kWh) 54.43

American Society of Mechanical Engineers (ASME) Codes and Standards - SA

Standard:
- 240: Carbon and Stainless Steel Flanges

191
 Table 9.22. AREA 200: Specification Sheet No 22
Specification Sheet No 22
Identification: T-203
Type: Isomerizing Column
No. Required: 1
Function: Isomerization of Demineralized Glucose Syrup
Material of Construction Stainless Steel Type 316 (HB 7th Edition)
Operating Temperature 25°C
Operating Pressure 1 atm
Design Data
H/D 2.00
D (m) 2.52
H (m) 5.04
Volume (m3) 25.10
Capacity (m3) 20.91
Factor of Safety 13%
Operation Batch

Power Consumption (kWh) 48.79

American Society of Mechanical Engineers (ASME) Codes and Standards - SA
Standard:
- 240: Carbon and Stainless Steel Flanges

192
 Table 9.23. AREA 200: Specification Sheet No 23
Specification Sheet No 23
Identification: FL-202
Type: Rotary Vacuum Filter
No. Required: 1
Function: Filtration of Isomerized HFCS 42 Solution
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1 atm
Design Data
H/D 4.00
D (m) 1.97
H (m) 2.95
Volume (m3) 24.02
Capacity (m3) 20.01
Factor of Safety 13%
Operation Batch
Power Consumption (kWh) 43.86
American Society of Mechanical Engineers (ASME)

193
 Table 9.24. AREA 200: Specification Sheet No 24
Specification Sheet No 24
Identification: TK-203
Type: Mixing Tank
No. Required: 1
Function: Mixing Half of Filtered HFCS 42 Solution and Water
Material of Construction Stainless Steel Type 316 (HB 7th Edition)
Operating Temperature 25°C
Operating Pressure 1 atm
Design Data
H/D 2.00
D (m) 1.59
H (m) 3.18
Volume (m3) 12.64
Capacity (m3) 10.53
Factor of Safety 13%
Operation Batch

Power Consumption (kWh) 22.18

American Society of Mechanical Engineers (ASME) Codes and Standards -

Standard:
SA - 240: Carbon and Stainless Steel Flanges

194
 Table 9.25. AREA 200: Specification Sheet No 25
Specification Sheet No 25
Identification: T-204
Type: Decolorizing Column
No. Required: 1
Function: Decolorizing Filtered HFCS 42 Solution and Water
Material of Construction Stainless Steel Type 316 (HB 7th Edition)
Operating Temperature 80°C
Operating Pressure 1 atm
Design Data
H/D 2.00
D (m) 2.04
H (m) 4.08
Volume (m3) 13.35
Capacity (m3) 11.12
Factor of Safety 13%
Operation Batch

Power Consumption
0.16
(kWh)

American Society of Mechanical Engineers (ASME) Codes and Standards -

Standard:
SA - 240: Carbon and Stainless Steel Flanges

195
 Table 9.26. AREA 200: Specification Sheet No 26
Specification Sheet No 26
Identification: E-203
Type: Evaporator
No. Required: 1
Function: Evaporation of Decolorized HFCS 42 Solution and Water
Material of Construction 1
Operating Temperature 86°C
Operating Pressure 1 atm
Design Data
H/D 2.00
D (m) 2.02
H (m) 4.05
Volume (m3) 13.02
Capacity (m3) 10.85
Factor of Safety 13%
Operation Batch

Power Consumption (kWh) 40.18

American Society of Mechanical Engineers (ASME) Codes and Standards -

Standard:
SA - 240: Carbon and Stainless Steel Flanges

196
 Table 9.27. AREA 200: Specification Sheet No 27
Specification Sheet No 27
Identification: TK-204
Type: Mixing Tank
No. Required: 1
Function: Mixing of HFCS 90 and the Remaining Half of HFCS 42
Material of Construction Stainless Steel Type 316 (HB 7th Edition)
Operating Temperature 25°C
Operating Pressure 1 atm
Design Data
H/D 2.00
D (m) 1.53
H (m) 3.07
Volume (m3) 11.34
Capacity (m3) 9.45
Factor of Safety 13%
Operation Batch

Power Consumption (kWh) 39.57

American Society of Mechanical Engineers (ASME) Codes and Standards -

Standard:
SA - 240: Carbon and Stainless Steel Flanges

197
 Table 9.28. AREA 200: Specification Sheet No 28
Specification Sheet No 28
Identification: E-204
Type: Evaporator
No. Required: 1
Function: Evaporation of HFCS 55 Solution
Material of Construction Stainless Steel
Operating Temperature 86°C
Operating Pressure 1 atm
Design Data
H/D 2.00
D (m) 2.43
H (m) 4.86
Volume (m3) 22.58
Capacity (m3) 18.81
Factor of Safety 13%
Operation Batch

Power Consumption (kWh) 58.74

American Society of Mechanical Engineers (ASME) Codes and Standards - SA
Standard:
- 240: Carbon and Stainless Steel Flanges

198
 Table 9.29. AREA 200: Specification Sheet No 29
Specification Sheet No 29
Identification: C-203
Type: Ultrafiltrator
No. Required: 1
Function: Filtration of HFCS 55
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1 atm
Design Data
H/D 4.00
D (m) 1.81
H (m) 2.71
Filter Area (m2) 46.22
Volume (m3) 18.57
Capacity (m3) 15.48
Factor of Safety 13%
Operation Batch
Power Consumption (kWh) 43.86
Standard: American Society of Mechanical Engineers (ASME)

199
 Table 9.30. AREA 300: Specification Sheet No 30
Specification Sheet No. 30
Identification: C-301
Type: Centrifuge
No. Required: 1
Function: To remove the gums from the crude oil
Material of Construction Stainless Steel
Operating Temperature 100°C
Operating Pressure 0.10 atm
Design Data

H/D 0.78

D (m) 1.55

H (m) 1.20
Capacity (m3) 9.67
Volume (m3) 11.60
Factor of Safety 20%
Operation Batch
Power Consumption (kW) 24.18
International Organization for Standardization (ISO) 6178:1983:
Standard:
Centrifuges Construction and Safety Rules

200
 Table 9.31. AREA 300: Specification Sheet No 31
Specification Sheet No. 31
Identification: C-302
Type: Centrifuge
No. Required: 1
Function: To neutralize the corn oil and remove soap stocks
Material of Construction Stainless Steel
Operating Temperature 100°C
Operating Pressure 0.10 atm
Design Data

H/D 0.80

D (m) 1.51

H (m) 1.20
Capacity (m3) 9.00
Volume (m3) 10.80
Factor of Safety 20%
Operation Batch
Power Consumption (kW) 5.45
International Organization for Standardization (ISO) 6178:1983:
Standard:
Centrifuges Construction and Safety Rules

201
 Table 9.32. AREA 300: Specification Sheet No 32
Specification Sheet No. 32
Identification: R-301
Type: Clarifying Reactor
No. Required: 1
Function: To bleach/decolorize the corn oil
Material of Construction Stainless Steel
Operating Temperature 97°C
Operating Pressure 0.05 atm
Design Data
H/D 2.0
D (m) 1.8
H (m) 3.5
Volume (m3) 8.62
Capacity (m3) 7.19
Factor of Safety 20%
Operation Batch
Power Consumption (kWh) 35.41
American Society of Mechanical Engineers (ASME) Codes and
Standard:
Standards - SA - 240: Carbon and Stainless Steel Flanges

202
 Table 9.33. AREA 300: Specification Sheet No 33
Specification Sheet No. 33
Identification: R-302
Type: Crystallizer
No. Required: 1
Function: To remove waxes from the corn oil
Material of Construction Stainless Steel
Operating Temperature 90°C
Operating Pressure 0.07 atm
Design Data
H/D 2.0
D (m) 1.8
H (m) 3.5
Volume (m3) 8.42
Capacity (m3) 7.02
Factor of Safety 20%
Operation Batch
Power Consumption (kWh) 34.32
American Society of Mechanical Engineers (ASME) Codes and Standards - SA
Standard:
- 240: Carbon and Stainless Steel Flanges

203
 Table 9.34. AREA 300: Specification Sheet No 34
Specification Sheet No. 34
Identification: A-301
Type: Distillation Column
No. Required: 1
Function: To remove volatile odorants from the corn oil
Material of Construction Stainless Steel
H/D 4.0
D (m) 1.4
H (m) 5.6
Volume (m3) 8.52
Capacity (m3) 7.10
Factor of Safety 20%
Operation Batch

Power Consumption (kWh)

26.39
American Society of Mechanical Engineers (ASME) Codes and
Standard:
Standards - SA - 240: Carbon and Stainless Steel Flanges

204
 Table 9.35. AREA 300: Specification Sheet No 35
Specification Sheet No. 35
Identification: FL-301
Type: Polish Filter
No. Required: 1
Function: To remove impurities from the crude oil
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 0.10 atm
Design Data
H/D 1.32
D (m) 1.38
H (m) 1.81
Capacity (m3) 6.81
Volume (m3) 8.18
Factor of Safety 20%
Operation Batch
Power Consumption (kW) 21.93
Standard: American Society of Mechanical Engineers (ASME)

205
 Table 9.36. AREA 300: Specification Sheet No 36
Specification Sheet No. 36
Identification: U-301
Type: Packaging Machine
No. Required: 1
Function: To pack the refined corn oil
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1 atm
Design Data
Length (m) 2.21
Width (m) 1.11
Height (m) 3.32
Capacity (m3) 6.76
Volume (m3) 8.11
Factor of Safety 20%
Operation Batch
Power Consumption (kW) 32.64
Standard: American Society of Mechanical Engineers (ASME)

206
 Table 9.37. AREA 400: Specification Sheet No 37
Specification Sheet No. 37
Identification: ST-401
Type: Storage Tank
No. Required: 1
Function: To store wastewater
Material of Construction Stainless Steel
Operating Temperature
Operating Pressure 1
Design Data
Diameter (m) 9.10
Radius of Hemisphere (m) 1.27
Height (m) 10.13
Capacity (m3) 42.55
Volume (m3) 51.06
Factor of Safety 20%
Operation Batch
Power Consumption (kW) 12.86
Standard: American Society of Mechanical Engineers (ASME)

207
 Table 9.38. AREA 400: Specification Sheet No 38
Specification Sheet No. 38
Identification: A-401
Type: Aerated Grit Chamber
No. Required: 1
Function: Removes particles by forcing water into a grit chamber
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1 atm
Design Data
H/D 4.00
D (m) 8
H (m) 7.97
Dock Area (m2) 56.08
Capacity (m3) 20.70
Volume (m3) 24.84
Factor of Safety 13%
Operation Batch
Power Consumption (kW) 509.50
American Standard for Testing and Materials' (ASTM) Geotechnical
Standard:
Engineering Standards D6128-14 for Screener

208
 Table 9.39. AREA 400: Specification Sheet No 39
Specification Sheet No. 39
Identification: TK-401
Type: Neutralization Tank
No. Required: 1
Function: Used to alter the pH level of corrosive waste drainage by dilution
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1 atm
Design Data
H/D 4.00
D (m) 7.10
H (m) 7.65
Total Volume = 31.63
Capacity (m3) 23.36
Volume (m3) 31.63
Factor of Safety 13%
Operation Batch
Power Consumption (kW) 135.08
Standard: American Society of Mechanical Engineers (ASME)

209
 Table 9.40. AREA 400: Specification Sheet No 40
Specification Sheet No. 40
Identification: V-401
Type: Center Feed Clarifier
No. Required: 1
Function: Moves solids from the center of the tank to the outer wall
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1 atm
Design Data
H/D 1.36
D (m) 5.30
H (m) 7.22
Volume 51.21
Factor of Safety 20%
Operation Batch
Power Consumption = 5.75
American Society of Mechanical Engineers (ASME) Codes and
Standard:
Standards - SA - 240: Carbon and Stainless Steel Flanges

210
 Table 9.41. AREA 400: Specification Sheet No 41
Specification Sheet No. 41
Identification: A-402
Type: Packed Tower Aerator
No. Required: 1
Removes carbon dioxide while the VOCs are stripped from the
Function: water.
Material of Construction Stainless Steel
Operating Temperature 10°C
Operating Pressure 1 atm
Design Data
H/D 4.00
D (m) 1.76
H (m) 7.05
Volume 17.20
Factor of Safety 13%
Operation Batch

Power Consumption 86,577.42

American Society of Mechanical Engineers (ASME) Codes and
Standard:
Standards - SA - 240: Carbon and Stainless Steel Flanges

211
 Table 9.42. AREA 400: Specification Sheet No 42
Specification Sheet No. 42
Identification: FL-401
Type: Microfiltrator
No. Required: 1
Separates particles in solution by passing the solution along the
Function: surface of a membrane.
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1 atm
Design Data
H/D 0.55
W (m) 8.40
H (m) 4.60
Filter Area = 232.23
Capacity (m3) 100.69
Volume (m3) 120.82
Factor of Safety 20%
Operation Batch
Power Consumption (kW) 50.95
Standard: American Society of Mechanical Engineers (ASME)

212
 Table 9.43. AREA 400: Specification Sheet No 43
Specification Sheet No. 43
Identification: U-401
Type: Ultraviolet Disinfection
No. Required: 1
Function: Remove most forms of microbiological contamination from water.
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1 atm
Design Data
H/D 0.81
D (m) 7.80
H (m) 6.30
Volume 231.01
Factor of Safety 13%
Operation Batch
Power Consumption 50.95
American Society of Mechanical Engineers (ASME) Codes and
Standard:
Standards - SA - 240: Carbon and Stainless Steel Flanges

213
 Table 9.44. AREA 400: Specification Sheet No 44
Specification Sheet No. 44
Identification: U-402
Type: Reverse Osmosis Tank
No. Required: 1
Function: Remove most forms of microbiological contamination from water.
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1 atm
Design Data
H/D 1.05
D (m) 7.50
H (m) 7.90
Volume 228.69
Factor of Safety 20%
Operation Batch
Power Consumption = 37.55
American Society of Mechanical Engineers (ASME) Codes and
Standard:
Standards - SA - 240: Carbon and Stainless Steel Flanges

214
 Table 9.45. Specification Sheet No 45
Specification Sheet No 45
Identification: MH-102
Type: Conveyor
No. Required: 1
Function: Conveys Steeping Tanks to Dewatering Gravity Screen
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure
Design Data
Density (kg/m3) 5,597.00
Elevation (m) 2.34
Horizontal Length (m) 18.30
Mass (kg/hr) 2,916.67
Time (min) 0.12
Factor of Safety 20%
Operation Batch
Power Consumption (kW) 11.15

215
 Table 9.46. Specification Sheet No 46
Specification Sheet No 46
Identification: MH-103
Type: Conveyor
No. Required: 1
Function: Conveys Dewatering Gravity Screen to Attrition Mill
Material of Construction Stainless Steel
Operating Temperature 25
Operating Pressure
Design Data
Density (kg/m3) 12,378.40
Elevation (m) 2.21
Horizontal Length (m) 17.10
Mass (kg/hr) 7087.50
Time (min) 0.11
Factor of Safety 20%
Operation Batch
Power Consumption (kW) 23.31

216
 Table 9.47. Specification Sheet No 47
Specification Sheet No 47
Identification: MH-105
Type: Conveyor
No. Required: 1
Function: Conveyor from Impact Mill to Press Dewatering Screens
Material of Construction Stainless Steel
Operating Temperature 25
Operating Pressure
Design Data
Density (kg/m3) 9,127.31
Elevation (m) 2.21
Horizontal Length (m) 17.10
Mass (kg/hr) 6171.06
Time (min) 0.11
Factor of Safety 20%
Operation Batch
Power Consumption (kW) 20.52

217
 Table 9.48. Specification Sheet No 48
Specification Sheet No 48
Identification: MH-106
Type: Conveyor
No. Required: 1
Function: Conveyor from Dewatering Screens To Drier
Material of Construction Stainless Steel
Operating Temperature 25
Operating Pressure
Design Data
Density (kg/m3) 5,600.00
Elevation (m) 2.21
Horizontal Length (m) 17.10
Mass (kg/hr) 450.67
Time (min) 0.11
Factor of Safety 20%
Operation Batch
Power Consumption (k W) 8.12

218
 Table 9.49. Specification Sheet No 49
Specification Sheet No 49
Identification: MH-107
Type: Conveyor
No. Required: 1
Function: Conveyor from Drier to Horizontal Rotary Cooker
Material of Construction Stainless Steel
Operating Temperature 25
Operating Pressure
Design Data
Density (kg/m3) 5,450.00
Elevation (m) 2.21
Horizontal Length (m) 17.10
Mass (kg/hr) 361.17
Time (min) 0.11
Factor of Safety 20%
Operation Batch
Power Consumption (kW) 7.85

219
 Table 9.50. Specification Sheet No 50
Specification Sheet No. 50
Identification: ST-101
Type: Water Storage Tank
No. Required: 1
Function: To store water
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1
Design Data
Diameter (m) 4.31
Radius of Hemisphere
(m) 1.08
Height (m) 6.47
Capacity (m3) 105.00
Volume (m3) 126.00
Factor of Safety 13%
Operation Batch
Power Consumption
(kW) 39.77
Standard: American Society of Mechanical Engineers (ASME)

220
 Table 9.51. Specification Sheet No 51
Specification Sheet No. 51
Identification: ST-102
Type: SO2 Storage Tank
No. Required: 1
Function: To store SO2
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1
Design Data
Diameter (m) 4.00
Radius of Hemisphere
(m) 1.00
Height (m) 6.01
Capacity (m3) 84.00
Volume (m3) 100.80
Factor of Safety 13%
Operation Batch
Power Consumption
(kW) 0.70
Standard: American Society of Mechanical Engineers (ASME)

221
 Table 9.52. Specification Sheet No 52
Specification Sheet No. 52
Identification: ST-103
Type: Lactic Acid Storage Tank
No. Required: 1
Function: To store lactic acid
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1
Design Data
Diameter = 4.05
Radius of Hemisphere = 1.01
Height = 6.08
Capacity (m3) 87.06
Volume (m3) 104.48
Factor of Safety 13%
Operation Batch
Power Consumption
(kW) 0.18
Standard: American Society of Mechanical Engineers (ASME)

222
 Table 9.53. Specification Sheet No 53
Specification Sheet No. 53
Identification: ST-104
Type: Water Storage Tank
No. Required: 1
Function: To store water
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1
Design Data
Diameter = 5.20
Radius of Hemisphere = 1.30
Height = 7.80
Capacity (m3) 183.80
Volume (m3) 220.56
Factor of Safety 13%
Operation Batch
Power Consumption
(kW) 51.85
Standard: American Society of Mechanical Engineers (ASME)

223
 Table 9.54. Specification Sheet No 54
Specification Sheet No. 54
Identification: ST-105
Type: Water Storage Tank
No. Required: 1
Function: To store water
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1
Design Data
Diameter (m) 4.02
Radius of Hemisphere
(m) 1.01
Height (m) 6.03
Capacity (m3) 85.05
Volume (m3) 102.06
Factor of Safety 13%
Operation Batch
Power Consumption
(kW) 9.57
Standard: American Society of Mechanical Engineers (ASME)

224
 Table 9.55. Specification Sheet No 55
Specification Sheet No. 55
Identification: ST-106
Type: Water Storage Tank
No. Required: 1
Function: To store water
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1
Design Data
Diameter (m) 4.02
Radius of Hemisphere
(m) 1.01
Height (m) 6.03
Capacity (m3) 85.05
Volume (m3) 102.06
Factor of Safety 13%
Operation Batch
Power Consumption
(kW) 9.76
Standard: American Society of Mechanical Engineers (ASME)

225
 Table 9.56. Specification Sheet No 56
Specification Sheet No. 56
Identification: ST-201
Type: Water Storage Tank
No. Required: 1
Function: To store water
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1
Design Data
Diameter (m) 4.07
Radius of Hemisphere (m) 1.02
Height (m) 6.11
Capacity (m3) 88.33
Volume (m3) 106.00
Factor of Safety 13%
Operation Batch
Power Consumption (kW) 9.52
Standard: American Society of Mechanical Engineers (ASME)

226
 Table 9.57. Specification Sheet No 57
Specification Sheet No. 57
Identification: ST-202
Type: Soda Ash Storage Tank
No. Required: 1
Function: To store soda ash
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1
Design Data
Diameter (m) 4.07
Radius of Hemisphere (m) 1.02
Height (m) 6.11
Capacity (m3) 88.33
Volume (m3) 106.00
Factor of Safety 13%
Operation Batch
Power Consumption (kW) 1.90
Standard: American Society of Mechanical Engineers (ASME)

227
 Table 9.58. Specification Sheet No 58
Specification Sheet No. 58
Identification: ST-203
Type: Calcium Chloride Storage Tank
No. Required: 1
Function: To store calcium chloride
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1
Design Data
Diameter (m) 1.72
Radius of Hemisphere (m) 0.43
Height (m) 2.58
Capacity (m3) 6.67
Volume (m3) 8.00
Factor of Safety 13%
Operation Batch
Power Consumption (kW) 0.003
Standard: American Society of Mechanical Engineers (ASME)

228
 Table 9.59. Specification Sheet No 59
Specification Sheet No. 59
Identification: ST-204
Type: Alpha-amylase Storage Tank
No. Required: 1
Function: To store alpha amylase
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1
Design Data
Diameter (m) 3.78
Radius of Hemisphere (m) 0.94
Height (m) 5.67
Capacity (m3) 70.66
Volume (m3) 84.80
Factor of Safety 13%
Operation Batch
Power Consumption (kW) 0.003
Standard: American Society of Mechanical Engineers (ASME)

229
 Table 9.60. Specification Sheet No 60
Specification Sheet No. 60
Identification: ST-205
Type: Gluco-amylase Storage Tank
No. Required: 1
Function: To store gluco-amylase
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1
Design Data
Diameter (m) 3.20
Radius of Hemisphere (m) 0.80
Height (m) 4.80
Capacity (m3) 42.88
Volume (m3) 51.46
Factor of Safety 13%
Operation Batch
Power Consumption (kW) 0.009
Standard: American Society of Mechanical Engineers (ASME)

230
 Table 9.61. Specification Sheet No 61
Specification Sheet No. 61
Identification: ST-206
Type: Filter Aid Storage Tank
No. Required: 1
Function: To store filter aid
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1
Design Data
Diameter (m) 6.36
Radius of Hemisphere (m) 1.59
Height (m) 9.55
Capacity (m3) 337.45
Volume (m3) 404.94
Factor of Safety 13%
Operation Batch
Power Consumption (kW) 3.397
Standard: American Society of Mechanical Engineers (ASME)

231
 Table 9.62. Specification Sheet No 62
Specification Sheet No. 62
Identification: ST-207
Type: Activated Carbon Storage Tank
No. Required: 1
Function: To store activated carbon
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1
Design Data
Diameter (m) 4.97
Radius of Hemisphere (m) 1.24
Height (m) 7.46
Capacity (m3) 161.07
Volume (m3) 193.29
Factor of Safety 13%
Operation Batch
Power Consumption (kW) 0.20
Standard: American Society of Mechanical Engineers (ASME)

232
 Table 9.63. Specification Sheet No 63
Specification Sheet No. 63
Identification: ST-208
Type: Gluco Isomerase Storage Tank
No. Required: 1
Function: To store glucoisomerase
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1
Design Data
Diameter (m) 2.23
Radius of Hemisphere (m) 0.56
Height (m) 3.34
Capacity (m3) 14.47
Volume (m3) 17.37
Factor of Safety 13%
Operation Batch
Power Consumption (kW) 0.00055
Standard: American Society of Mechanical Engineers (ASME)

233
 Table 9.64. Specification Sheet No 64
Specification Sheet No. 64
Identification: ST-209
Type: Filter Aid Storage Tank
No. Required: 1
Function: To store filter aid
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1
Design Data
Diameter (m) 5.54
Radius of Hemisphere (m) 1.39
Height (m) 8.31
Capacity (m3) 222.64
Volume (m3) 267.17
Factor of Safety 13%
Operation Batch
Power Consumption (kW) 1.70
Standard: American Society of Mechanical Engineers (ASME)

234
 Table 9.65. Specification Sheet No 65
Specification Sheet No. 65
Identification: ST-210
Type: Water Storage Tank
No. Required: 1
Function: To store filter aid
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1
Design Data
Diameter (m) 2.86
Radius of Hemisphere (m) 0.72
Height (m) 4.30
Capacity (m3) 30.74
Volume (m3) 36.89
Factor of Safety 13%
Operation Batch
Power Consumption (kW) 0.79
Standard: American Society of Mechanical Engineers (ASME)

235
 Table 9.66. Specification Sheet No 66
Specification Sheet No. 66
Identification: ST-211
Type: Activated Carbon Storage Tank
No. Required: 1
Function: To store filter aid
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1
Design Data
Diameter (m) 3.68
Radius of Hemisphere (m) 0.92
Height (m) 5.52
Capacity (m3) 65.07
Volume (m3) 78.08
Factor of Safety 13%
Operation Batch
Power Consumption (kW) 0.04
Standard: American Society of Mechanical Engineers (ASME)

236
 Table 9.67. Specification Sheet No 67
Specification Sheet No. 67
Identification: ST-212
Type: Activated Carbon Storage Tank
No. Required: 1
Function: To store filter aid
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1
Design Data
Diameter (m) 1.93
Radius of Hemisphere (m) 0.48
Height (m) 2.90
Capacity (m3) 9.43
Volume (m3) 11.31
Factor of Safety 13%
Operation Batch
Power Consumption (kW) 2.04
Standard: American Society of Mechanical Engineers (ASME)

237
 Table 9.68. Specification Sheet No 68
Specification Sheet No. 68
Identification: ST-301
Type: Water Storage Tank
No. Required: 1
Function: To store water
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1
Design Data
Diameter (m) 1.55
Radius of Hemisphere (m) 0.47
Height (m) 2.84
Capacity (m3) 8.85
Volume (m3) 5.79
Factor of Safety 13%
Operation Batch
Power Consumption (kW) 0.01
Standard: American Society of Mechanical Engineers (ASME)

238
 Table 9.69. Specification Sheet No 69
Specification Sheet No. 69
Identification: ST-302
Type: Phosphoric Acid Storage Tank
No. Required: 1
Function: To store phosphoric acid
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1
Design Data
Diameter (m) 1.55
Radius of Hemisphere (m) 0.39
Height (m) 2.32
Capacity (m3) 4.83
Volume (m3) 5.79
Factor of Safety 13%
Operation Batch
Power Consumption (kW) 0.001
Standard: American Society of Mechanical Engineers (ASME)

239
 Table 9.70. Specification Sheet No 70
Specification Sheet No. 70
Identification: ST-303
Type: Water Storage Tank
No. Required: 1
Function: To store water
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1
Design Data
Diameter (m) 1.95
Radius of Hemisphere (m) 0.49
Height (m) 2.93
Capacity (m3) 9.75
Volume (m3) 11.70
Factor of Safety 13%
Operation Batch
Power Consumption (kW) 0.117
Standard: American Society of Mechanical Engineers (ASME)

240
 Table 9.71. Specification Sheet No 71
Specification Sheet No. 71
Identification: ST-304
Type: NaOH Storage Tank
No. Required: 1
Function: To store NaOH
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1
Design Data
Diameter (m) 1.53
Radius of Hemisphere (m) 0.38
Height (m) 2.29
Capacity (m3) 4.64
Volume (m3) 5.57
Factor of Safety 13%
Operation Batch
Power Consumption (kW) 0.007
Standard: American Society of Mechanical Engineers (ASME)

241
 Table 9.72. Specification Sheet No 72
Specification Sheet No. 72
Identification: ST-305
Type: Bleaching Clay Storage Tank
No. Required: 1
Function: To store Bleaching Clay
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1
Design Data
Diameter (m) 1.91
Radius of Hemisphere (m) 0.48
Height (m) 2.87
Capacity (m3) 9.17
Volume (m3) 11.00
Factor of Safety 13%
Operation Batch
Power Consumption (kW) 0.01
Standard: American Society of Mechanical Engineers (ASME)

242
 Table 9.73. Specification Sheet No 73
Specification Sheet No. 73
Identification: ST-306
Type: Bleaching Clay Storage Tank
No. Required: 1
Function: To store Bleaching Clay
Material of Construction Stainless Steel
Operating Temperature 25°C
Operating Pressure 1
Design Data
Diameter (m) 2.69
Radius of Hemisphere (m) 0.67
Height (m) 4.03
Capacity (m3) 25.40
Volume (m3) 30.48
Factor of Safety 13%
Operation Batch
Power Consumption (kW) 0.005
Standard: American Society of Mechanical Engineers (ASME)

243
 Table 9.74. Pump Specification
PUMP SPECIFICATION
DESIGN DATA
NO. PUMP NO. TYPE MATERIAL OF OPERATING OPERATING STANDARD
REQUIRED CONSTRUCTION TEMPERATURE PRESSURE POWER
OPERATION EFFICIENCY
(kW)

P-101A/B A-101 to
MH-104 Centrifugal ASME PTC
1 2 Pump Stainless Steel 25°C 1 atm 11.96 Batch 80% 8.2-1990
Pump from Attrition Mill to
Hydrocyclone
P-102A/B MH-104 to
A-104 Centrifugal ASME PTC
2 2 Pump Stainless Steel 25°C 1 atm 25.84 Batch 80% 8.2-1990
Pump from Hydrocyclone to
Impact Mill
P-103A/B A-104 to
FL-103 Centrifugal ASME PTC
3 2 Pump Stainless Steel 25°C 1 atm 15.88 Batch 80% 8.2-1990
Pump from Impact Mill to Press
Dewatering Screen
P-104A/B FL-103 to
C-101
4 2 Centrifugal Stainless Steel 25°C 1 atm 11.55 Batch 80% ASME PTC
Pump from Press Dewatering Pump 8.2-1990
Screen to Disk Nozzle
Centrifuge
P-105A/B C-101 to
MH-108
5 2 Centrifugal Stainless Steel 25°C 1 atm 19.67 Batch 80% ASME PTC
Pump from Disk Nozzle Pump 8.2-1990
Centrifuge to Hydrocyclone
Washing
P-106A/B MH-108 to
C-102 Centrifugal ASME PTC
6 2 Pump Stainless Steel 25°C 1 atm 8.88 Batch 80% 8.2-1990
Pump from Hydrocyclone to
Peeler Centrifuge
P-107A/B C-102 to
TK-201 Centrifugal ASME PTC
7 2 Pump Stainless Steel 25°C 1 atm 23.59 Batch 80% 8.2-1990
Pump from Peeler Centrifuge
to Mixing Tank
P-108A/B A-102 to A-103
8 2 Centrifugal Stainless Steel 25°C 1 atm 9.27 Batch 80% ASME PTC
Pump from Drier to Horizontal Pump 8.2-1990
Rotary Cooker
P-109A/B A-103 to C-301
9 2 Centrifugal Stainless Steel 25°C 1 atm 10.02 Batch 80% ASME PTC
Pump from Expeller Press to Pump 8.2-1990
Centrifuge 1

244
CONTINUATION OF PUMP SPECIFICATION SHEET

P-110A/B ST-101 to
TK-101 Centrifugal ASME PTC
10 2 Pump Stainless Steel 25°C 1 atm 63.57 Batch 80% 8.2-1990
Pump from Water Storage Tank
to Hopper-bottomed Tank
P-111A/B ST-102 to
TK-101 Centrifugal ASME PTC
11 2 Pump Stainless Steel 25°C 1 atm 9.56 Batch 80% 8.2-1990
Pump from SO2 Storage Tank
to Hopper-bottomed Tank
P-112A/B ST-103 to
TK-101 Centrifugal ASME PTC
12 2 Pump Stainless Steel 25°C 1 atm 8.65 Batch 80% 8.2-1990
Pump from Lactic Acid Storage
Tank to Hopper-bottomed Tank
P-113A/B ST-104 to
A-101 Centrifugal ASME PTC
13 2 Pump Stainless Steel 25°C 1 atm 17.41 Batch 80% 8.2-1990
Pump from Water Storage Tank
to Attrition Mill
P-114A/B ST-105 to
MH-108 Centrifugal ASME PTC
14 2 Pump Stainless Steel 25°C 1 atm 12.43 Batch 80% 8.2-1990
Pump from Water Tank to
Hydrocyclone Washing
P-115A/B ST-106 to
C-102 Centrifugal ASME PTC
15 2 Pump Stainless Steel 25°C 1 atm 14.80 Batch 80% 8.2-1990
Pump from Water Tank to
Peeler Centrifuge
P-116A/B F-101 to A-102
16 2 Centrifugal Stainless Steel 25°C 1 atm 11.27 Batch 80% ASME PTC
Pump from to Horizontal Pump 8.2-1990
Rotary Cooker
P-117A/B F-101 to A-103
17 2 Centrifugal Stainless Steel 25°C 1 atm 10.14 Batch 80% ASME PTC
Pump from to Horizontal Pump 8.2-1990
Rotary Cooker
P-201A/B TK-201 to
A-201 Centrifugal ASME PTC
18 2 Pump Stainless Steel 25°C 1 atm 34.35 Batch 80% 8.2-1990
Pump from Mixing Tank to Jet
Cooker
P-202A/B A-201 to E-201
19 2 Centrifugal Stainless Steel 25°C 1 atm 32.18 Batch 80% ASME PTC
Pump from Jet Cooker to Flash Pump 8.2-1990
Cooler
P-203A/B E-201 to
TK-202 Centrifugal ASME PTC
2 Pump Stainless Steel 25°C 1 atm 73.63 Batch 80% 8.2-1990
Pump from Flash Cooler to
20 Saccharification Tank

245
CONTINUATION OF PUMP SPECIFICATION SHEET
P-204A/B TK-202 to
FL-202 Centrifugal ASME PTC
21 2 Pump Stainless Steel 25°C 1 atm 19.55 Batch 80% 8.2-1990
Pump from Saccharification
Tank to Rotary Vacuum Filter
P-205A/B FL-202 to
T-201 Centrifugal ASME PTC
22 2 Pump Stainless Steel 25°C 1 atm 21.81 Batch 80% 8.2-1990
Pump from Rotary Vacuum
Filter to Decolorizing Column
P-206A/B T-201 to T-202
23 2 Centrifugal Stainless Steel 25°C 1 atm 16.82 Batch 80% ASME PTC
Pump from Decolorizing Pump 8.2-1990
Column to Demineralizing
Column
P-207A/B T-202 to E-202
24 2 Centrifugal Stainless Steel 25°C 1 atm 22.77 Batch 80% ASME PTC
Pump from Demineralizing Pump 8.2-1990
Column to Evaporator
P-208A/B E-202 to T-203
25 2 Centrifugal Stainless Steel 25°C 1 atm 16.67 Batch 80% ASME PTC
Pump from Evaporator to Pump 8.2-1990
Isomerizing Column
P-209A/B T-203 to
FL-201
26 2 Centrifugal Stainless Steel 25°C 1 atm 28.85 Batch 80% ASME PTC
Pump from Isomerizing Pump 8.2-1990
Column to Rotary Vacuum
Filter
P-210A/B FL-201 to
TK-203 Centrifugal ASME PTC
27 2 Pump Stainless Steel 25°C 1 atm 13.41 Batch 80% 8.2-1990
Pump from Rotary Vacuum
Filter to Mixing Tank
P-211A/B TK-203 to
T-204 Centrifugal ASME PTC
28 2 Pump Stainless Steel 25°C 1 atm 21.11 Batch 80% 8.2-1990
Pump from Mixing Tank to
Decolorizing Column
P-212A/B T-204 to E-203
29 2 Centrifugal Stainless Steel 25°C 1 atm 20.66 Batch 80% ASME PTC
Pump from Decolorizing Pump 8.2-1990
Column to Evaporator
P-213A/B E-203 to
TK-204 Centrifugal ASME PTC
30 2 Pump Stainless Steel 25°C 1 atm 12.15 Batch 80% 8.2-1990
Pump from Evaporator to
Mixing Tank
P-214A/B TK-204 to
E-104 Centrifugal ASME PTC
31 2 Pump Stainless Steel 25°C 1 atm 26.97 Batch 80% 8.2-1990
Pump from Storage Tank to
Mixing Tank

246
CONTINUATION OF PUMP SPECIFICATION SHEET
P-215A/B E-204 to C-203
32 2 Centrifugal Stainless Steel 25°C 1 atm 19.41 Batch 80% ASME PTC
Pump from Storage Tank to Pump 8.2-1990
Mixing Tank
P-216A/B ST-201 to
TK-201 Centrifugal ASME PTC
33 2 Pump Stainless Steel 25°C 1 atm 10.09 Batch 80% 8.2-1990
Pump from Water Storage to
Mixing Tank
P-217A/B ST-202 to
TK-201 Centrifugal ASME PTC
34 2 Pump Stainless Steel 25°C 1 atm 5.81 Batch 80% 8.2-1990
Pump from Soda Ash Storage
to Mixing Tank
P-218A/B ST-203 to
TK-201 Centrifugal ASME PTC
35 2 Pump Stainless Steel 25°C 1 atm 5.39 Batch 80% 8.2-1990
Pump from Calcium Chloride
Storage to Mixing Tank
P-219A/B ST-204 to
TK-201 Centrifugal ASME PTC
36 2 Pump Stainless Steel 25°C 1 atm 5.87 Batch 80% 8.2-1990
Pump from Alpha-amylase
Storage to Mixing Tank
P-220A/B ST-205 to
TK-202 Centrifugal ASME PTC
37 2 Pump Stainless Steel 25°C 1 atm 5.02 Batch 80% 8.2-1990
Pump from Gluco-amylase
Tank to Saccharification Tank
P-221A/B ST-206 to
FL-202 Centrifugal ASME PTC
38 2 Pump Stainless Steel 25°C 1 atm 5.50 Batch 80% 8.2-1990
Pump from Storage Tank to
Rotary Vacuum Filter
P-222A/B ST-207 to
T-201 Centrifugal ASME PTC
39 2 Pump Stainless Steel 25°C 1 atm 5.19 Batch 80% 8.2-1990
Pump from Storage Tank to
Decolorizing Column
P-223A/B ST-208 to
T-203 Centrifugal ASME PTC
40 2 Pump Stainless Steel 25°C 1 atm 5.19 Batch 80% 8.2-1990
Pump from Gluco-isomerase
Tank to Isomerizing Column
P-224A/B ST- 209 to
FL-201 Centrifugal ASME PTC
41 2 Pump Stainless Steel 25°C 1 atm 6.01 Batch 80% 8.2-1990
Pump from Storage Tank to
Rotary Vacuum Filter
P-225A/B ST-210 to
TK-203 Centrifugal ASME PTC
42 2 Pump Stainless Steel 25°C 1 atm 6.56 Batch 80% 8.2-1990
Pump from Water Storage Tank
to Mixing Tank

247
CONTINUATION OF PUMP SPECIFICATION SHEET
P-226A/B ST-211 to
T-204 Centrifugal ASME PTC
43 2 Pump Stainless Steel 25°C 1 atm 5.15 Batch 80% 8.2-1990
Pump from Storage to
Decolorizing Column
P-227A/B ST-207 to
TK-204 Centrifugal ASME PTC
44 2 Pump Stainless Steel 25°C 1 atm 11.97 Batch 80% 8.2-1990
Pump from Storage Tank to
Mixing Tank
P-228A/B B-101 to A-201
45 2 Centrifugal Stainless Steel 25°C 1 atm 5.49 Batch 80% ASME PTC
Pump 8.2-1990
Pump from Boiler to Jet Cooker
P-301A/B C-301 to C-302
46 2 Centrifugal Stainless Steel 25°C 1 atm 9.62 Batch 80% ASME PTC
Pump from Centrifuge 1 to Pump 8.2-1990
Centrifuge 2
P-302A/B C-302 to R-301
47 2 Centrifugal Stainless Steel 25°C 1 atm 7.04 Batch 80% ASME PTC
Pump from Centrifuge 2 to Pump 8.2-1990
Clarifying Reactor
P-303A/B R-301 to R-302
48 2 Centrifugal Stainless Steel 25°C 1 atm 7.09 Batch 80% ASME PTC
Pump from Clarifying Reactor Pump 8.2-1990
to Crystallizer
P-304A/B R-302 to A-301
49 2 Centrifugal Stainless Steel 25°C 1 atm 8.21 Batch 80% ASME PTC
Pump from Crystallizer to Pump 8.2-1990
Distillation Column
P-305A/B A-301 to
FL-301 Centrifugal ASME PTC
50 2 Pump Stainless Steel 25°C 1 atm 8.24 Batch 80% 8.2-1990
Pump from Distillation Column
to Polish Filter
P-306A/B FL-301 to
U-301 Centrifugal ASME PTC
51 2 Pump Stainless Steel 25°C 1 atm 7.01 Batch 80% 8.2-1990
Pump from Polish Filter to
Packaging
P-307A/B ST-301 to
C-301 Centrifugal ASME PTC
52 2 Pump Stainless Steel 25°C 1 atm 5.05 Batch 80% 8.2-1990
Pump from Storage Tank to
Centrifuge 1
P-308A/B ST-302 to
C-301
2 Centrifugal Stainless Steel 25°C 1 atm 5.01 Batch 80% ASME PTC
53 Pump 8.2-1990
Pump from Storage Tank to
Centrifuge 1

248
CONTINUATION OF PUMP SPECIFICATION SHEET
P-309A/B ST-303 to
C-302 Centrifugal ASME PTC
54 2 Pump Stainless Steel 25°C 1 atm 5.85 Batch 80% 8.2-1990
Pump from Water Storage Tank
to Centrifuge 2
P-310A/B ST-304 to
C-302 Centrifugal ASME PTC
55 2 Pump Stainless Steel 25°C 1 atm 5.08 Batch 80% 8.2-1990
Pump from Storage Tank to
Centrifuge 2
P-311A/B ST-305 to
R-301 Centrifugal ASME PTC
56 2 Pump Stainless Steel 25°C 1 atm 5.05 Batch 80% 8.2-1990
Pump from Storage Tank to
Clarifying Reactor
P-312A/B ST-306 to
R-302 Centrifugal ASME PTC
57 2 Pump Stainless Steel 25°C 1 atm 5.23 Batch 80% 8.2-1990
Pump from Storage to
Crystallizer
P-313A/B F-301 to A-301
58 2 Centrifugal Stainless Steel 25°C 1 atm 31.43 Batch 80% ASME PTC
Pump from Filter Aid Tank to Pump 8.2-1990
Distillation Column

249
 CHAPTER X
EQUIPMENT COST AND SUMMARY
This chapter discusses the equipment cost estimation and summary to be used by Rugi
Inc. for the production of HFCS 55 and corn oil.

I. EQUIPMENT COST
The following equipment will be used by Rugi Inc. for the production of HFCS 55 and
corn oil. The purchased equipment costs are based from the calculations using the Plant Design
and Economics for Chemical Engineering and matche.com. The table below shows the process
equipment cost to be used in the production plant of HFC S 55 and corn oil.

Table 10.1 Equipment List and Cost

Projected Unit Projected Total
Location Code Equipment Quantity Cost Cost
TK-101 STEEPING TANK 2 1,086,672.47 2,173,344.95
DEWATERING GRAVITY
FL-101 SCREEN 2 808,018.60 1,616,037.21
A-101 ATTRITION MILL 2 1,241,911.40 2,483,822.79
MH-104 HYDROCYCLONE 2 2,949,539.57 5,899,079.14
DEWATERING GRAVITY
FL-102 SCREEN 2 808,018.60 1,616,037.21
V-101 DRIER 2 4,647,077.21 9,294,154.42
HORIZONTAL ROTARY
AREA 100 A-102 COOKER 2 3,566,614.29 7,133,228.59
A-103 EXPELLER PRESS 2 1,009,053.01 2,018,106.02
A-104 IMPACT MILL 2 1,241,911.40 2,483,822.79
PRESS DEWATERING
FL-103 SCREEN 2 1,190,165.09 2,380,330.18
DISK NOZZLE
C-101 CENTRIFUGE 2 2,865,710.55 5,731,421.10
HYDROCYCLONE
MH-108 WASHING 2 1,049,415.13 2,098,830.26
C-102 PEELER CENTRIFUGE 2 2,483,615.81 4,967,231.62
TK-201 MIXING TANK 2 530,917.12 1,061,834.24
A-201 JET COOKER 2 1,203,101.67 2,406,203.33
E-201 FLASH COOLER 2 1,338,935.73 2,677,871.45
AREA 200
TK-202 SACCHARIFICATION TANK 2 3,987,311.78 7,974,623.56
FL-201 ROTARY VACUUM FILTER 2 3,642,940.10 7,285,880.20
 Continuation of Table 10.1
T-201 DECOLORIZING COLUMN 2 3,463,380.41 6,926,760.82
T-202 DEMINERALIZER COLUMN 2 3,433,885.01 6,867,770.03
E-202 EVAPORATOR 2 3,755,229.59 7,510,459.18
T-203 ISOMERIZATION COLUMN 2 2,922,372.76 5,844,745.51
FL-202 ROTARY VACUUM FILTER 2 3,472,177.28 6,944,354.56
TK-203 MIXING TANK 2 1,209,311.22 2,418,622.45
T-204 DECOLORIZING COLUMN 2 3,001,596.36 6,003,192.71
E-203 EVAPORATOR 2 2,753,835.03 5,507,670.06
TK-204 MIXING TANK 2 530,917.12 1,061,834.24
E-204 EVAPORATOR 2 2,753,835.03 5,507,670.06
C-203 ULTRAFILTRATOR 2 3,549,796.74 7,099,593.49
C-301 CENTRIFUGE 1 2 4,543,998.56 9,087,997.13
C-302 CENTRIFUGE 2 2 3,235,334.43 6,470,668.86
R-301 CLARIFYING REACTOR 2 2,451,222.62 4,902,445.24
AREA 300 R-302 CRYSTALLIZER 2 3,974,892.67 7,949,785.33
A-301 DISTILLATION COLUMN 2 3,169,357.89 6,338,715.77
FL-301 POLISH FILTER 2 4,050,804.50 8,101,609.00
U-301 PACKAGING MACHINE 2 3,579,033.41 7,158,066.82
COLLECTION 2 3,038,025.76 6,076,051.51
A-401 AERATED GRIT CHAMBER 2 973,348.06 1,946,696.12
TK-401 NEUTRALIZATION TANK 2 3,512,539.40 7,025,078.81
V-401 CENTER FEED CLARIFIER 2 2,858,724.80 5,717,449.60

AREA 400 PACKED TOWER

A-402 AERATOR 2 4,027,673.90 8,055,347.80
FL-401 MICROFILTRATION 2 1,099,091.59 2,198,183.17
ULTRAVIOLET
U-401 DISINFECTION 2 2,826,900.82 5,653,801.64
U-402 REVERSE OSMOSIS 2 4,820,686.07 9,641,372.15
Total Equipment Cost 229,317,801.13

251
 Table 10.2 Pump Cost
Projected Unit Projected Total
Location Code Equipment Quantity Cost Cost
P-101 A/B Centrifugal Pump 2 264,157.14 528,314.28
P-102 A/B Centrifugal Pump 2 229,974.46 459,948.92
P-103 A/B Centrifugal Pump 2 426,338.92 852,677.84
P-104 A/B Centrifugal Pump 2 292,642.71 585,285.42
P-105 A/B Centrifugal Pump 2 275,551.37 551,102.74
P-106 A/B Centrifugal Pump 2 269,854.25 539,708.51
P-107 A/B Centrifugal Pump 2 224,277.35 448,554.70
AREA 100 P-108 A/B Centrifugal Pump 2 269,854.25 539,708.51
P-109 A/B Centrifugal Pump 2 218,580.24 437,160.47
P-110 A/B Centrifugal Pump 2 264,157.14 528,314.28
P-111 A/B Centrifugal Pump 2 286,945.59 573,891.19
P-112 A/B Centrifugal Pump 2 269,854.25 539,708.51
P-113 A/B Centrifugal Pump 2 235,671.58 471,343.15
P-114 A/B Centrifugal Pump 2 247,065.80 494,131.60
P-115 A/B Centrifugal Pump 2 258,460.03 516,920.06
P-201 A/B Centrifugal Pump 2 229,974.46 459,948.92
P-202 A/B Centrifugal Pump 2 264,157.14 528,314.28
P-203 A/B Centrifugal Pump 2 247,065.80 494,131.60
P-204 A/B Centrifugal Pump 2 363,670.67 727,341.35
P-205 A/B Centrifugal Pump 2 244,031.29 488,062.59
P-206 A/B Centrifugal Pump 2 263,112.18 526,224.35
P-207 A/B Centrifugal Pump 2 229,974.46 459,948.92
P-208 A/B Centrifugal Pump 2 269,854.25 539,708.51
AREA 200
P-209 A/B Centrifugal Pump 2 258,460.03 516,920.06
P-210 A/B Centrifugal Pump 2 218,580.24 437,160.47
P-211 A/B Centrifugal Pump 2 218,580.24 437,160.47
P-212 A/B Centrifugal Pump 2 241,368.69 482,737.38
P-213 A/B Centrifugal Pump 2 252,762.91 505,525.83
P-214 A/B Centrifugal Pump 2 264,157.14 528,314.28
P-215 A/B Centrifugal Pump 2 229,974.46 459,948.92

252
 Continuation of Table 10.2
P-216 A/B Centrifugal Pump 2 426,338.92 852,677.84
P-217 A/B Centrifugal Pump 2 292,642.71 585,285.42
P-218 A/B Centrifugal Pump 2 275,551.37 551,102.74
P-219 A/B Centrifugal Pump 2 269,854.25 539,708.51
P-220 A/B Centrifugal Pump 2 224,277.35 448,554.70
P-221 A/B Centrifugal Pump 2 269,854.25 539,708.51
P-222 A/B Centrifugal Pump 2 218,580.24 437,160.47
P-223 A/B Centrifugal Pump 2 264,157.14 528,314.28
P-224 A/B Centrifugal Pump 2 286,945.59 573,891.19
P-225 A/B Centrifugal Pump 2 269,854.25 539,708.51
P-226 A/B Centrifugal Pump 2 235,671.58 471,343.15
P-227 A/B Centrifugal Pump 2 247,065.80 494,131.60
P-228 A/B Centrifugal Pump 2 258,460.03 516,920.06
P-301 A/B Centrifugal Pump 2 247,065.80 494,131.60
P-302 A/B Centrifugal Pump 2 312,396.65 624,793.31
P-303 A/B Centrifugal Pump 2 241,368.69 482,737.38
P-304 A/B Centrifugal Pump 2 437,733.15 875,466.29
P-305 A/B Centrifugal Pump 2 251,717.95 503,435.90
P-306 A/B Centrifugal Pump 2 392,156.24 784,312.48
AREA 300 P-307 A/B Centrifugal Pump 2 357,973.56 715,947.12
P-308 A/B Centrifugal Pump 2 392,156.24 784,312.48
P-309 A/B Centrifugal Pump 2 235,671.58 471,343.15
P-310 A/B Centrifugal Pump 2 218,580.24 437,160.47
P-311 A/B Centrifugal Pump 2 264,157.14 528,314.28
P-312 A/B Centrifugal Pump 2 286,945.59 573,891.19
P-313 A/B Centrifugal Pump 2 269,854.25 539,708.51
Total Pump Cost 30,552,279.26

253
 Table 10.3 Conveyor Cost
Location Code Equipment Quantity Projected Unit Cost
MH-101 Conveyer 1 498,947.03
MH-102 Conveyor 1 432,631.66
MH-103 Conveyer 1 329,139.05
AREA 100
MH-105 Conveyer 1 384,832.35
MH-106 Conveyer 1 517,608.18
MH-107 Conveyer 1 233,685.50

Table 10.4 Summary of Equipment Cost

SUMMARY OF EQUIPMENT COST (Php)

Equipments 229,317,801.13
Pumps 30,552,279.26
Conveyors 2,396,843.77
Storage Tanks 7,033,885.15
Boilers 2,067,200.80
TOTAL 271,368,010.10

254
 CHAPTER XI
EQUIPMENT LAYOUT
This chapter presents the equipment layout to be used by Rugi Inc. for the production of
HFCS 55 and corn oil. The equipment layout is the plan of each area of the plant. Equipment
layout is one of the most important deliverables of a piping department. It shows location and
placement of all equipment in a particular process or utility area along with various types of
displays, access, controls, and maintenance areas. It is done as per general industry practice as
well as piping design basis, process flow, gravity requirements, structure philosophy.

The Rugi Inc.has three major areas in manufacturing HFCS 55 and corn oil and a
separate area for wastewater treatment. Furthermore, the manufacturing plant provided backup
for all of the equipment to ensure that the processing would not be interrupted in case of
emergency. The table below shows the area descriptions where major and minor equipment will
be located.

Table 11.1. Area Description

AREA DESCRIPTION
100 Corn Milling
200 HFCS 55 Production
300 Corn Oil Production
400 Wastewater Treatment
256
257
258
259
260
 CHAPTER XII
PLANT SITE SELECTION AND PLANT LAYOUT
This chapter presents the equipment list and specification sheet to be used by Rugi Inc.
for the production of HFCS 55 and corn oil.

I. Plant Site Selection

A. Raw Material Availability
Corn Kernels are primarily obtained from the corn plantations and other corn
processing industries in the province of Isabela is considered to be one of the main
producers of corn in the country with a production level of 1.1 million metric tons.
Specifically, Reina Mercedes Corn Processing Center located at Isabela Province which
is one of the direct nearest locations where the raw material could possibly be obtained.
The processing center which processed about 200,000 metric tons of corn, annually.
with a distance of about 12 kilometers away from the plant. Other possible sources of
raw materials will be sourced from neighboring provinces: Nueva Vizcaya and Quirino
with their approximate respective annual production of 218,446 MT and 73,423 MT,
respectively.

B. Market Availability
Market availability is of utmost importance in a manufacturing plant. One of the
significant benefits of understanding market availability is that it enables manufacturing
plants to optimize production processes. This optimization helps Rugi Inc. produce
products more efficiently and meet customer demand more effectively, improving the
overall performance of the business. Additionally, plant production is based on customer
demand. The site of the facility should be convenient, efficient, and easily accessible.
The location of the target market impacts the cost and methods of product distribution,
as well as the shipping time.
In addition to reducing shipping costs, the proximity of demand for finished
products can expedite service to consumers. A thorough analysis of the primary market
is performed in order to reduce the manufacturing site's transportation expenses.
Furthermore, the increasing number of market consumers from various city regions and
adjacent municipalities led the researchers to consider the site for an industrial plant.
Moreover, understanding market availability helps manufacturing plants make informed
decisions about investing in new equipment, technology, and expanding operations. With
 a good understanding of market availability, Rugi Inc. can make data-driven decisions
about investing in new equipment or technology to increase production capacity.

C. Energy Availability
The availability of energy is crucial to the success of any production plant. In
order to power the production processes, manufacturing plants require a substantial
amount of energy, making energy availability a significant aspect of their operations. The
production processes at Rugi Inc. require a constant and reliable energy supply. With a
reliable energy source, manufacturing facilities can avoid production downtime, ensure
uninterrupted production, and meet customer demand more effectively.
In connection, this project will get its energy from the Cagayan Electric
Cooperative (CAGELCO). In 2019, CAGELCO supplied electricity to 33 industrial
companies in the CAGAYAN VALLEY. For industry consumers, the company uses coal,
geothermal, and hydroelectric fuel. For 15 years, the company has offered 20 Megawatts
(MW) of contracted capacity. CAGELCO continuously improved the energy source
system by sourcing additional long-term competitive selection processes. The
cooperative also intends to use renewable energy. The manufacturing plant is also able
to acquire energy from Isabela Electric Cooperative (ISELCO), Quirino Electric
Cooperative (QUIRELCO), and Nueva Vizcaya Electric Cooperative (NUVELCO).
Additionally, generators are another potential source of power for the proposed
facility. The plant will be powered by natural gas using diesel generators at their core.
This backup power is supplied by generators, which also contribute to the plant and
employees' safety. Renewable energy sources, such as solar panels, will be installed at
the facility as a backup energy source.

D. Water Supply
Water is a vital resource for the success of any manufacturing plant. It is utilized
in a variety of ways, including cleaning, cooling, and processing raw materials. Thus, the
availability of a reliable water supply is essential for ensuring the smooth operation of a
manufacturing plant. In addition, the location of the manufacturing plant is thoroughly
determined by the accessibility and sustainability of the water supply. Chemical and
physical processes also require substantial quantities of water for washing and general

262
 process use. With this, Isabela Water District will provide the water supply for the Rugí
Inc. manufacturing plant. The water system facility is located in Barangay Menzi in
Isabela Province. It can operate an average water production of 10,000 CMD, providing
services for about 71% of the city's entire population.
Moreover, the district manages three water treatment plant facilities, nine
reservoirs with a total storage capacity of 2,500 cubic meters, four pumping systems,
and six gravity-fed systems. On the other hand, Ilagan Water District is the second
source of water for Rugí Inc. Manufacturing Plant. Its pumping station is equipped with a
5 LPS, 7.5 HP pump motor. The depth of the pipelines, which were constructed in 2012,
is 80 meters below the ground. The district is entirely contained within the administrative
boundaries of the province of Ilagan. Furthermore, a reliable water supply also enables
manufacturing facilities to reduce water consumption and conserve water, which is a
crucial advantage. Water conservation is a critical component of sustainability, and
numerous manufacturing facilities have implemented water conservation measures to
reduce their water usage. By conserving water, Rugí Inc. can reduce operational costs,
enhance sustainability, and meet regulatory requirements.

E. Land Adequacy
Municipality of Naguilian, Province of Isabela has a total land area of
approximately 1,166 km2. A significant percentage of the land area – 24.99% is not
being fully utilized leaving them idle and under utilized. The manufacturing plant location
is headed beside the Cagayan river with a total land area of 65,000 m2. The plant
location, Naguilian, has a sufficient land area for the establishment of the plant. The
coordinates for Naguilian on the island of Luzon are roughly 17.1478 and 121.8937.
These coordinates are approximately 50.6 meters (166.0 feet) above mean sea level
(Isabela Profile – PhilAtlas, 2013). The site is near Cagayan river which is readily
available for industrial and commercial use. The land is generally accessible for
transportation. It is suitable for the establishment of the processing, storage, and
transportation of the incorporation. There is also a spare space that is suitable for future
expansions and development of the site. The total area for the manufacturing plant
establishment is 16,500 m2.

263
F. Transportation Facilities
The Rugi Manufacturing Plant will be built near the corn plantation and other food
processing plants that utilize corn products such as Coca Cola which is located at Ilagan
City. The main raw materials will be transported from the supplier using enclosed trucks
and the others such as enzymes will use tanker trucks. Furthermore, the location is
surrounded by airports of the neighboring cities and provinces such as Cauayan City,
Isabela Airport which can be used for product distribution.

G. Water Disposal
The waste generated during the production of HFCS 55 and corn oil will be
properly disposed of. The factory will provide a comprehensive variety of operations for
treating wastewater generated during the manufacturing of HFCS 55 and corn oil,
thereby preventing economic loss and environmental degradation. Environmental impact
assessments should be performed for each new project or in addition to the present
phase. Environmental rules and regulations shall be followed, and environmental audits
will be appropriately regulated and monitored.

H. Labor Supply and Site Topography

The location of the plant can provide enough labor supply needed. This is
because the population of the region is composed of skilled and unskilled workers with
different expertise that can be prospective workers for manufacturing plants. Specifically,
the labor force and employment rate of the region are 64.8% and 97.7%, respectively.
The Rugi Manufacturing Plant will hire experienced, productive and proficient
staff such as plant operators, engineers, maintenance technicians and management or
administration experts. During hiring, specific requirements for the different positions will
be considered by the hiring personnel. Training will also be provided before the staff
operate any unit or equipment. Furthermore, safety training, drills and safety talks will be
provided to the employees in order to ensure a safe working environment. The salary
rates of the workers will be based on the existing rate in the province.
In terms of topography, the climate in Cagayan Valley is warm, humid, and sunny.
The average temperature in the region is 79°F to 89°F and is rarely below 76°F or above

264
 92°F. This temperature is suitable for the growth of corn as its temperature requirement
for growth is 75°F to 86 which will also be beneficial for the manufacturing plant.

I. Climate
One of the key elements that might affect a manufacturing facility's capacity to
adapt is the climate, which the facility has to be tropical in nature. High annual
temperatures and a lot of rain are characteristics of the climate of Davao. Isabela
experiences a 29° average annual temperature and receives around 1902 mm of
precipitation annually. While the hottest months are from March to May, the coldest
months are from November through February. The location is regarded as a
typhoon-prone one that frequently experiences significant damage. The municipality of
Naguilian, nevertheless, has the fewest storms near the commercial fields and the
CAGAYAN River. As a result, the Naguilian environment will be suited for the
manufacturing plant.

J. Community Factors
Rugi Incorporation will use its most productive strategy to serve the local
community. The factory will adhere to the local government's environmental and
community safety norms and regulations, and it will be given significant importance and
attention. Hazard mitigation and safety actions will be implemented. The plant is located
far enough away from residential areas to assure the community's safety and
convenience. To ensure a peaceful relationship within the sector and the society, the
well-being of each worker must also be considered. Outreach programs and leisure
activities can be used to achieve the friendly relationship indicated in the preceding
statement. Rugi Incorporation will also ensure that all necessary safety regulations and
waste disposal are met and completed.

II. Plant Layout

Plant layout may be summed up as a method of positioning equipment,
processes, and plant services inside the factory to produce the most products of the
highest quality at the lowest feasible manufacturing costs. Accordingly, RUGI Inc.
Manufacturing Plant created isometric, top, and front images of the layout of its factory,

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showing where all the operations and other potential processes will be. The following are
major structures: processing facilities, administrative buildings, dormitories, small fire
station, canteen, clinic, Q.A building, maintenance building and warehouse..

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 CHAPTER XIII
FINANCIAL ANALYSIS
This chapter presents the financial assumptions, cost estimation, and financial analysis
of the Rugi Manufacturing Plant. It will determine the feasibility of the plant in terms of financial
aspects.
A. Financial Assumptions
Listed below are the major assumptions that will serve as the basis for estimating the
proposed plant's economic and financial data. This will serve as the basis for calculating the
project's future costs, expenses, and income.
1. Rugi Manufacturing Plant will operate within a twenty-five (25) year period, 90 days
annually with monthly, or quarterly preventive maintenance.
2. The financial projections will be based on a twenty-five-year period and the start of
normal operation will be in 2028.
3. An exchange rate of 1 USD = Php 54.31 (April 2023) is used.
4. The salvage value of all depreciable assets is 10% of the original cost as grounded on
Plant Design and Economics for Chemical Engineers by Timmerhaus, 5th Edition.
5. The total capital investment of the plant will be Php 1,372,123,474.32.
6. Thirty (30) percent of the capital investment will be loaned from the bank and the
remaining seventy (70) percent will come from the stockholder’s equity.
7. Based on the banking information, the interest rate on the borrowed capital is ten (10)
percent. The bank loan is amortized for 10 years.
8. Depreciation charges are based on the straight-line method of computation.
9. The water consumption is not included in the computation of the raw materials cost as it
is already accounted as a cost in the utilities.
10. From the material balance, the annual raw materials consumption is based on the
following table:
Table 13.1. Total Annual Consumption per Year

Raw Materials Annual Consumption (kg/yr)

Yellow Corn Kernels 6,300,000.00
SO2 189,000.00
Lactic Acid 47,250.00
Soda Ash 440,727.89
Calcium Chloride 21,249.38
 Alpha-amylase 787.01
Gluco-amylase 3,652.11
Gluco-isomerase 481.92
Filter Aid 241,304.95
Granular Carbon 13,762.45
Mono Anion Exchange Resin 5,314.46
Mono Cation Exchange Resin 6,643.07
Polishing Resin 3,321.54
Phosphoric Acid 1,593.78
Sodium Hydroxide 12,289.42
Bleaching Clay 11,884.55
Oxygen 19,842,348.50

11. The following are the basic assumptions used for the annual increase in n in expenses:
Table 13.2. Total Annual Growth Projection
Annual Growth Projection Rate
Raw Materials 5%
Operating Labor 10%

Supervisory and Clerical Labor 10%

Operating Supplies 5%
Plant Overhead 5%

Research and Development 10%

Utilities 5%

Maintenance and Repair 5%

Laboratory Charges 10%

Distribution and Selling Cost 5%

Administrative Cost 10%

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 12. The selling price of the products will be based on the computed values at the break-even
analysis. The selling price increases at a rate of 5% annually. From the financial
analysis, the market price, non-VAT price, and unit price are presented in the following
table:
Table 13.3. Selling Price of HFCS 55 and Corn Oil
Market Price Projected Price Unit Selling
Products (Php/kg) by 2028 Price Non-VAT Price Non-VAT
HFCS 55 516.59 627.92 560.64 558.19
Corn Oil 216.23 262.83 234.67 63.72

13. The Social Security System (SSS) and PhilHealth contributions of employees,
deductions were based on wage range from the SSS and PhilHealth contribution table,
respectively. As for the Pag-IBIG, contributions were deducted according to the
employees’ monthly salaries.
14. Income tax is 35% of the gross sales, based on Plant Design and Economics for
Chemical Engineers by Peters and Timmerhaus, 5th edition.
15. It is assumed that the plant will be operating at 90% of its capacity in its first year since it
is still introducing itself to the market; 95% in its second year; 100% in its third year and
increasing by 1% from the fourth year onwards.

B. Equipment Cost
The estimated cost of equipment for the Rugi Manufacturing Plant was from
www.matche.com and www.alibaba.com. The costs were based on design specifications such
as dimensions, materials of construction, and the structure of the equipment. Furthermore, the
“Estimation of fixed-capital investment by the percentage of delivered-equipment cost” method
from Plant Design and Economics for Chemical Engineers by Peters and Timmerhaus, 5th
edition was used to estimate capital investment as well as the certain estimates and
percentages of the components for the computation of the capital investment are summarized in
the said method. And the estimate for the total production cost was attained using the
percentage ranges provided by Peters and Timmerhaus in the Plant Design and Economics for
Chemical Engineers while other expenses were computed on the actual basis.

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 C. Capital Investment
The total capital will be acquired from 30% and 70% of the total capital investment from
bank loans and stockholder’s equity, respectively. The estimated total capital investment is Php
1,372,123,474.32. From the estimation of the total capital investment, the bank loan amounts to
Php 411,637,042.30 while the investment from the owner’s equity amounts to Php 960,486,432.03.
The table 13.4 below presents the total capital investment of the company.

Table 13.4. Total Capital Investment of RUGI Inc. Manufacturing Plant

TOTAL CAPITAL INVESTMENT
DIRECT PLANT COSTS Cost (Php) % of Delivered Equipment Cost
Purchase of Equipment 271,368,010.10 Actual
Installation 105,833,523.94 39% Purchased Equipment
Instrumentation and Controls 70,555,682.63 26% Purchased Equipment
Piping 84,124,083.13 31% Purchased Equipment
Electrical Systems 27,136,801.01 10% Purchased Equipment
Buildings (including services) 78,696,722.93 29% Purchased Equipment
Yard Improvements 32,564,161.21 12% Purchased Equipment
Service Facilities 149,252,405.56 55% Purchased Equipment
Land 4,849,869.94 Actual
TOTAL DIRECT COST 824,381,260.45
INDIRECT PLANT COSTS Cost (Php) % of Delivered Equipment Cost
Engineering and Supervision 86,837,763.23 32% Purchased Equipment
Construction Expenses 92,265,123.43 34% Purchased Equipment
TOTAL INDIRECT PLANT COST 179,102,886.67
FIXED CAPITAL INVESTMENT Cost (Php) % of Delivered Equipment Cost
Total Direct and Indirect Plant
1,003,484,147.11
Cost
Legal Expenses 10,854,720.40 4% Purchased Equipment
Contractor's Fee 51,559,921.92 19% Purchased Equipment
Contingency 100,406,163.74 37% Purchased Equipment
TOTAL FIXED CAPITAL
1,166,304,953.17
INVESTMENT
TOTAL CAPITAL INVESTMENT Cost (Php)
Fixed Capital Investment 1,166,304,953.17
Working Capital 205,818,521.15
TOTAL 1,372,123,474.32

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CAPITALIZATION SCHEDULE Cost (Php) % of Delivered Equipment Cost
Bank Loans 411,637,042.30 30% Total Capital Investment
Owner's Equity 960,486,432.03 70% Total Capital Investment

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 D. Production Cost
Production cost is the cost incurred by the company combining manufacturing costs and
general expenses. The summary of computation for the production cost of the designed plant is
Php 1,791,513,683.06. The table 13.5 below shows the costs and actual values of the Rugi
Manufacturing Plant.

Table 13.5. Total Production Cost of RUGI Inc. Manufacturing Plant

TOTAL PRODUCTION COST
DIRECT PRODUCTION COST Cost (Php) % of Delivered Equipment Cost
Raw Materials 1,395,646,045.45 Actual
Operating Labor 15,577,315.80 Actual
Direct Supervisory and Clerical
Labor 8,880,320.40 Actual
Utilities 116,630,495.32 10% Actual
Maintenance and Repairs 23,326,099.06 2% Fixed Capital Investment
Operating Supplies 2,332,609.91 10% Maintenance and Repairs
Laboratory Charges 1,557,731.58 10% Operating Labor
Patent and Royalties 11,663,049.53 1% Fixed Capital Investment
TOTAL DIRECT
PRODUCTION COST 1,575,613,667.05
FIXED CHARGES Cost (Php) % of Delivered Equipment Cost
Depreciation 24,716,198.36 Actual
Local Taxes 11,663,049.53 1%
Property Insurance 11,663,049.53 1%
TOTAL FIXED CHARGES 48,042,297.42
MANUFACTURING COST Cost (Php) % of Delivered Equipment Cost
Direct Production Cost 1,575,613,667.05
Fixed Charges 48,042,297.42
OL, DSCL, Maintenance &
Plant Overhead Cost 23,891,867.63 50% Repairs
TOTAL MANUFACTURING
COST 1,647,547,832.11
GENERAL EXPENSES Cost (Php) % of Delivered Equipment Cost
Administrative Cost 21,160,800.00 Actual

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Distribution and Marketing Cost 23,326,099.06 2% Fixed Capital Investment
Research and Development
Cost 58,315,247.66 5% Fixed Capital Investment
Financing 41,163,704.23 Actual
TOTAL EXPENSES 143,965,850.95
PRODUCTION COST Cost (Php)
Manufacturing Cost 1,647,547,832.11
General Expenses 143,965,850.95
TOTAL PRODUCTION COST 1,791,513,683.06

E. Amortization Schedule
The bank loan will be amortized for 10 years with an interest rate of 10% annually.
Based on the financial analysis of the plant, the periodic payment amount is Php
223,306,776.66. The table below presents the summary of computation for the amortization
schedule of the Rugi Manufacturing Plant.

Table 13.6. Amortization Schedule of RUGI Inc. Manufacturing Plant

AMORTIZATION SCHEDULE
PRINCIPAL AT PERIODIC
PERIODIC PRINCIPAL
PERIOD THE BEGINNING INTEREST PAYMENTS TO
PAYMENTS ENDING
OF PERIOD THE PRINCIPAL
1 411,637,042.30 41,163,704.23 66,992,033.00 25,828,328.77 385,808,713.53
2 385,808,713.53 38,580,871.35 66,992,033.00 28,411,161.64 357,397,551.89
3 357,397,551.89 35,739,755.19 66,992,033.00 31,252,277.81 326,145,274.08
4 326,145,274.08 32,614,527.41 66,992,033.00 34,377,505.59 291,767,768.49
5 291,767,768.49 29,176,776.85 66,992,033.00 37,815,256.15 253,952,512.34
6 253,952,512.34 25,395,251.23 66,992,033.00 41,596,781.76 212,355,730.58
7 212,355,730.58 21,235,573.06 66,992,033.00 45,756,459.94 166,599,270.64
8 166,599,270.64 16,659,927.06 66,992,033.00 50,332,105.93 116,267,164.71
9 116,267,164.71 11,626,716.47 66,992,033.00 55,365,316.53 60,901,848.18
10 60,901,848.18 6,090,184.82 66,992,033.00 60,901,848.18 0.00
TOTAL 258,283,287.67 669,920,329.97 411,637,042.30

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 Total Bank Loan Php 411,637,042.30
Period (years) 10
Rate 10%
Periodic Rate Php 66,992,033.00

F. Payback Period
Payback period or the pay-out period, refers to the period of time required to return the
funds expended in an investment. It is the time in which an initial cash outflow of an investment
is expected to be recovered from the cash inflows generated by investment. The payback period
can be computed by using the following formula:
𝑇𝑜𝑡𝑎𝑙 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡
𝑃𝑎𝑦𝑏𝑎𝑐𝑘 𝑃𝑒𝑟𝑖𝑜𝑑 = (𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑃𝑟𝑜𝑓𝑖𝑡 𝑎𝑛𝑑 𝑇𝑎𝑥𝑒𝑠−𝑇𝑎𝑥)
× 100%
𝑃ℎ𝑝 1,372,123,474.32
𝑃𝑎𝑦𝑏𝑎𝑐𝑘 𝑃𝑒𝑟𝑖𝑜𝑑 = 𝑃ℎ𝑝 316,830,732.41
× 100%

𝑃𝑎𝑦𝑏𝑎𝑐𝑘 𝑃𝑒𝑟𝑖𝑜𝑑 = 4. 33 𝑦𝑒𝑎𝑟𝑠

Table 13.7. Payback Period of RUGI Inc. Manufacturing Plant

PAYBACK PERIOD

Year Operating Profit and Taxes Tax Net Cash Inflows

2028 375,816,316.44 131,535,710.75 244,280,605.68

2029 398,138,235.61 139,348,382.46 258,789,853.15
2030 421,354,189.43 147,473,966.30 273,880,223.13
2031 445,486,673.49 155,920,335.72 289,566,337.77
2032 470,557,087.56 164,694,980.65 305,862,106.92
2033 496,585,458.73 173,804,910.55 322,780,548.17
2034 523,590,128.47 183,256,544.97 340,333,583.51
2035 551,587,399.74 193,055,589.91 358,531,809.83
2036 580,591,139.39 203,206,898.79 377,384,240.61
2037 610,612,331.35 213,714,315.97 396,898,015.38
Average 487,431,896.02 170,601,163.61

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 G. Return on Investment
Return on investment is a performance measure used to evaluate the efficiency of an
investment or to compare the efficiency of a number of different investments. It measures the
gain or loss on an investment relative to the amount of money invested. The Rugi manufacturing
plant has an average percentage ROI of 17.46%. The average ROI can be computed by using
the following formula:
𝑁𝑒𝑡 𝐼𝑛𝑐𝑜𝑚𝑒 𝑇𝑎𝑥
𝑅𝑒𝑡𝑢𝑟𝑛 𝑜𝑛 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 (𝑅𝑂𝐼) = 𝑇𝑜𝑡𝑎𝑙 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡
× 100%
𝑃ℎ𝑝 316,830,732.41
𝑅𝑒𝑡𝑢𝑟𝑛 𝑜𝑛 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 (𝑅𝑂𝐼) = 𝑃ℎ𝑝 1,372,123,474.32
× 100%

𝑅𝑒𝑡𝑢𝑟𝑛 𝑜𝑛 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 (𝑅𝑂𝐼) = 23. 09%

The table 13.8 below presents the summary of return on investment of the Rugi
manufacturing plant.
Table 13.8. Return on Investment (ROI) of RUGI Inc. Manufacturing Plant
RETURN OF INVESTMENT
Year Total Capital Investment Net Income Investment % ROI
2028 1,372,123,474.32 244,280,605.68 17.80%
2029 1,372,123,474.32 258,789,853.15 18.86%
2030 1,372,123,474.32 273,880,223.13 19.96%
2031 1,372,123,474.32 289,566,337.77 21.10%
2032 1,372,123,474.32 305,862,106.92 22.29%
2033 1,372,123,474.32 322,780,548.17 23.52%
2034 1,372,123,474.32 340,333,583.51 24.80%
2035 1,372,123,474.32 358,531,809.83 26.13%
2036 1,372,123,474.32 377,384,240.61 27.50%
2037 1,372,123,474.32 396,898,015.38 28.93%
Average 1,372,123,474.32 316,830,732.41 23.09%

H. Return on Owner’s Investments

Return on Owner’s Investment (ROOI) is the amount of net income returned as a
percentage of stockholder’s equity. It measures a corporation’s profitability by disclosing how
much profit a company generates with the money the stockholders have invested. The

287
proposed plant has an average percentage ROOI of 24.94% and can calculated by using the
following formula:
𝑁𝑒𝑡 𝐼𝑛𝑐𝑜𝑚𝑒 𝑇𝑎𝑥
𝑅𝑒𝑡𝑢𝑟𝑛 𝑜𝑛 𝑂𝑤𝑛𝑒𝑟'𝑠 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 (𝑅𝑂𝑂𝐼) = 𝑇𝑜𝑡𝑎𝑙 𝑆𝑡𝑜𝑐𝑘ℎ𝑜𝑙𝑑𝑒𝑟𝑠' 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡
× 100%
𝑃ℎ𝑝 316,830,732.41
𝑅𝑒𝑡𝑢𝑟𝑛 𝑜𝑛 𝑂𝑤𝑛𝑒𝑟'𝑠 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 (𝑅𝑂𝑂𝐼) = 𝑃ℎ𝑝960,486,432.03
× 100%

𝑅𝑒𝑡𝑢𝑟𝑛 𝑜𝑛 𝑂𝑤𝑛𝑒𝑟'𝑠 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 (𝑅𝑂𝑂𝐼) = 32. 99%

The table 13.9 below presents the summary of return on owner’s investment of the Rugi
manufacturing plant.

Table 13.9. Return on Owner’s Investment (ROOI) of RUGI Inc. Manufacturing Plant
RETURN OF OWNER'S INVESTMENT
Year Total Stockholders Investment Net Income Investment % ROOI
2028 960,486,432.03 244,280,605.68 25.43%
2029 960,486,432.03 258,789,853.15 26.94%
2030 960,486,432.03 273,880,223.13 28.51%
2031 960,486,432.03 289,566,337.77 30.15%
2032 960,486,432.03 305,862,106.92 31.84%
2033 960,486,432.03 322,780,548.17 33.61%
2034 960,486,432.03 340,333,583.51 35.43%
2035 960,486,432.03 358,531,809.83 37.33%
2036 960,486,432.03 377,384,240.61 39.29%
2037 960,486,432.03 396,898,015.38 41.32%
Average 960,486,432.03 316,830,732.41 32.99%

I. Break-Even Analysis
A break-even analysis is a financial calculation used to determine a company’s
break-even point (BEP) wherein revenue received equals the costs associated with receiving
the revenue. It calculates the margin of safety, the amount that revenues can fall while still
staying above the breakeven point. The summarized break-even analysis of the whole plant is
presented on Appendix I.

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 1. Break-Even Volume
The break-even volume indicates the minimum volume of products required to maximize
the utilization of the fixed costs while simultaneously meeting the market sales demand. It also
represents the volume of production wherein the total amount of the cost of production is equal
to sales or the sales is less than the production cost and interest is equal to zero. The
break-even volume of the proposed plant for HFCS 55 and corn oil is presented on Appendix I.

2. Break-Even Selling Price

The break-even selling price is the minimum price a product can be sold and with which
the costs can still be covered. It also represents the selling price per unit of product based on
the total cost of production. The summary of computation for the break-even selling price of the
products of the Rugi manufacturing plant is shown on Appendix I.

J. Net Profit Margin

The net profit indicates the percentage of revenue after all operating expenses, interest,
taxes, and preferred stock dividends have been deducted from a company’s total revenue. The
Rugi manufacturing plant has an average percentage ROS 11.55% and can be calculated by
using the following formula:
𝑁𝑒𝑡 𝐼𝑛𝑐𝑜𝑚𝑒 𝐴𝑓𝑡𝑒𝑟 𝑇𝑎𝑥
𝑅𝑒𝑡𝑢𝑟𝑛 𝑜𝑛 𝑆𝑎𝑙𝑒𝑠 (𝑅𝑂𝑆) = 𝑁𝑒𝑡 𝑆𝑎𝑙𝑒𝑠
× 100%
𝑃ℎ𝑝 316,830,732.41
𝑅𝑒𝑡𝑢𝑟𝑛 𝑜𝑛 𝑆𝑎𝑙𝑒𝑠 (𝑅𝑂𝑆) = 𝑃ℎ𝑝 2,737,887,009.41
× 100%

𝑅𝑒𝑡𝑢𝑟𝑛 𝑜𝑛 𝑆𝑎𝑙𝑒𝑠 (𝑅𝑂𝑆) = 11. 55%

The table 13.10 below presents the Return on Sales (ROS) of the Rugi manufacturing
plant.
Table 13.10. Return on Sales (ROS) of RUGI Inc. Manufacturing Plant
RETURN ON SALES
Year Net Sales Net Income After Tax ROS
2028 2,167,329,999.49 244,280,605.68 11.27%
2029 2,277,459,040.64 258,789,853.15 11.36%
2030 2,393,270,787.95 273,880,223.13 11.44%
2031 2,515,067,002.16 289,566,337.77 11.51%
2032 2,643,166,294.56 305,862,106.92 11.57%
2033 2,777,905,145.81 322,780,548.17 11.62%

289
 2034 2,919,638,993.28 340,333,583.51 11.66%
2035 3,068,743,392.14 358,531,809.83 11.68%
2036 3,225,615,255.85 377,384,240.61 11.70%
2037 3,390,674,182.17 396,898,015.38 11.71%
Average 2,737,887,009.41 316,830,732.41 11.55%

K. Gross Profit Margin

The gross profit margin represents the return on sales after accounting for the number of
products sold. The average gross profit margin can be calculated by:
𝐺𝑟𝑜𝑠𝑠 𝑃𝑟𝑜𝑓𝑖𝑡
𝐺𝑟𝑜𝑠𝑠 𝑃𝑟𝑜𝑓𝑖𝑡 𝑀𝑎𝑟𝑔𝑖𝑛 = 𝑁𝑒𝑡 𝑆𝑎𝑙𝑒𝑠
× 100%
𝑃ℎ𝑝 669,263,893.23
𝐺𝑟𝑜𝑠𝑠 𝑃𝑟𝑜𝑓𝑖𝑡 𝑀𝑎𝑟𝑔𝑖𝑛 = 𝑃ℎ𝑝 2,737,887,009.41
× 100%

𝐺𝑟𝑜𝑠𝑠 𝑃𝑟𝑜𝑓𝑖𝑡 𝑀𝑎𝑟𝑔𝑖𝑛 = 24. 41%

The table below presents the Gross Profit Margin of the Rugi manufacturing plant.

Table 13.11. Gross Profit Margin of RUGI Inc. Manufacturing Plant

Gross Profit Margin

Year Gross Profit on Sales Sales Gross Profit Margin

2025 519,782,167.39 2,167,329,999.49 23.98%
2026 548,635,163.41 2,277,459,040.64 24.09%
2027 578,976,986.50 2,393,270,787.95 24.19%
2028 610,886,695.76 2,515,067,002.16 24.29%
2029 644,447,764.99 2,643,166,294.56 24.38%
2030 679,748,349.63 2,777,905,145.81 24.47%
2031 716,881,571.66 2,919,638,993.28 24.55%
2032 755,945,823.76 3,068,743,392.14 24.63%
2033 797,045,094.33 3,225,615,255.85 24.71%
2034 840,289,314.88 3,390,674,182.17 24.78%
Average 669,263,893.23 2,737,887,009.41 24.41%

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 L. Operating Profit Margin
The operating profit margin represents the return on sales if the income before the taxes
was used instead of the net income after tax. The average operating profit margin can be
calculated by:
𝑃𝑟𝑜𝑓𝑖𝑡 𝐵𝑒𝑓𝑜𝑟𝑒 𝐼𝑛𝑡𝑒𝑟𝑒𝑠𝑡 𝑎𝑛𝑑 𝑇𝑎𝑥𝑒𝑠
𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑃𝑟𝑜𝑓𝑖𝑡 𝑀𝑎𝑟𝑔𝑖𝑛 = 𝑁𝑒𝑡 𝑆𝑎𝑙𝑒𝑠
× 100%
𝑃ℎ𝑝 487,431,896.02
𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑃𝑟𝑜𝑓𝑖𝑡 𝑀𝑎𝑟𝑔𝑖𝑛 = 𝑃ℎ𝑝 2,737,887,009.41
× 100%

𝑂𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑃𝑟𝑜𝑓𝑖𝑡 𝑀𝑎𝑟𝑔𝑖𝑛 = 17. 77%

The table below presents the Operating Profit Margin of the Rugi manufacturing plant.

Table 13.12. Operating Profit Margin of RUGI Inc. Manufacturing Plant

OPERATING MARGIN
Gross Profit Before Interest on Operating
Year Taxes Sales Profit Margin
2028 375,816,316.44 2,167,329,999.49 17.34%
2029 398,138,235.61 2,277,459,040.64 17.48%
2030 421,354,189.43 2,393,270,787.95 17.61%
2031 445,486,673.49 2,515,067,002.16 17.71%
2032 470,557,087.56 2,643,166,294.56 17.80%
2033 496,585,458.73 2,777,905,145.81 17.88%
2034 523,590,128.47 2,919,638,993.28 17.93%
2035 551,587,399.74 3,068,743,392.14 17.97%
2036 580,591,139.39 3,225,615,255.85 18.00%
2037 610,612,331.35 3,390,674,182.17 18.01%
Average 487,431,896.02 2,737,887,009.41 17.77%

M. Cash Flow
Cash flow is the company’s prediction or assessment of their income and expenditure
over a period of time. It is the presentation of the cash receipts and disbursements incurred by
the company. Furthermore, it shows the pattern of inflows and outflows of cash and which
determines future loans and financing needs. And determines the maximum profitability by
efficient cash utilization. The measure of cash flow of Rugi Inc. is presented on Appendix I.

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 N. Income Statement
The income statement measures a company’s financial performance over a specific
accounting period. Financial performance is evaluated by giving a rundown of how the business
acquires its revenues and expenditures through operating and non-operating activities.Tthe
income state of Rugi Manufacturing Plant is presented on Appendix I.

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 CHAPTER XIV
SUMMARY, CONCLUSIONS AND RECOMMENDATIONS

This chapter presents the summary and conclusion drawn and the recommendations for
further research.

SUMMARY
The food shortages claimed loss in revenues because of lack of resources. In 2022, the
food industry faced problems with sugar shortage that affected different food manufacturing
companies. Corn is one of the main crops in the Philippines that produces tons of products
annually. It is used in many industries as raw materials for foods, pharmaceutical and chemical
products. Accordingly, RUGÍ Inc. designed a manufacturing plant that catered the needs for
sweeteners and sugar products. Specifically, the manufacturing plant wanted to produce HFCS
55, a sweetener used for beverage companies as the main sweeteners for their products.
Moreover, corn oil is the byproduct of the production's process. This product will be the first local
HFCS 55 produced in the country. Thus, it will promote innovation, and responsible production
for the industry.
The CAGAYAN Region, which is regarded as the top producer of corn in the Philippines,
would provide RUGI Inc. Manufacturing Plant with 70 metric tons corn from the local farmers
around the Region per batch. The following processes will be used in the production of HFCS
55 and Corn Oil: Corn Milling, HFCS 55 production, Corn Oil Production and Refinery.
Batch operation will be used, requiring advanced process engineering approaches. To
guarantee effective management of the products, compliance with the relevant rules and
regulations shall be monitored.
In this regard, Municipailty ofNaguillian, Isabela Province is where the production facility
is located where 6.5 hectares of property will be purchased. The space is large enough to
maintain a safe distance from the residential area and to allow for future growth and
development. The Cagayan Electric Cooperative (CAGELCO) and Isabela Water District,
respectively, will be the main source of supply in the industrial plant with enough energy and
water to operate.
The HFCS 55, will have a market share of 2.46% locally and 0.01% internationally for
the planned production facility. Corn Oil, a by-product, with local and global percentage market
shares of 1.86% and 0.02%, respectively.
 RUGI Inc. Manufacturing Plant will begin operations in the year 2028 and has a total
capital investment of Php 1,372,123,474.32. Thirty (30%) percent of the capital investment will
be funded by a bank loan with a 10-year amortization period and a 10% interest rate. The
selling price of the products was based on the breakeven analysis of each product, while the
pricing of the raw materials was based on the current market. The plant’s financial studies have
an estimated payback period which is 4.30 years with a percentage of 23.28% Return on
Investment (ROI). The project is feasible, beneficial and profitable based on the examination of
the engineering, socioeconomic, technological, and financial components of the design.

CONCLUSION
Based from the conducted research design, the proponents gathered the following
conclusions:
1. Based on technical considerations, the Rugi Manufacturing Plant is feasible for the
production of HFCS 55 and corn oil.
2. The introduction of noble refining processes such as demineralization after
decolorization greatly influenced the purity of HFCS 55 compared to traditional
technologies.
3. The Philippines’ first HFCS 55 manufacturing plant is technical and market feasible.
4. The Rugi manufacturing plant is relatively eco-friendly and considers socio-economic
impact which conforms to implemented laws and regulations.
5. The financial aspects of produUtiliction are feasible making it more profitable for the
manufacturing plant.

RECOMMENDATION
Based from the conducted research design, the proponents developed the following
recommendations:
1. Utilization of corn into other main food-based products or materials aside from HFCS 55
and corn oil which are feasible and ecologically friendly.
2. Utilization and development of other by-products (e.g. fiber, gluten, steepwater)
produced during the production of HFCS 55 and also convert them into other food-based
products.

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3. Future expansion should be taken into consideration to meet the increasing demand for
HFCS 55 and corn oil, consequently, increasing the income of the plant.
4. Consideration and analysis of relative sweetener plant design studies with regards to
process and unit operation selection to ensure the sustainability among the following:
production yield, efficiency, energy consumption and safety consideration.
5. Conduct further research and analysis on how other parameters (e.g. temperature,
reaction time or process time) can affect the production of HFCS 55 and corn oil.

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