COLD WATER STARCH PRODUCTION

COLD WATER STARCH PRODUCTION

Introduction: Cold water starch is a modified starch used to stiffen textile and other related fabric. It is simply used in cold (room temperature) water or directly on the material to be treated.
Types: There are two types, namely the powder and the liquid. However, the liquid is also found in aerosol pack.

Uses:

1. Landry and dry cleaning
2. Textile finishing (cloth, bandages, rug towels) etc
3. Fishing and other nets finishing
4. Paper smoothening (in paper production)
5. Printing finishing (Anti-set-off powder)
6. Gluing and gumming (labeling, binding & gumming)

RAW MATERIALS REQUIRMENTS:

1. Cassava starch or other modified starch, dextrin, polyvinyl aalcohol, polyvinyl acetate, soda ash, borax, formalin, Isopropanol (IPA), water and soluble colourants and perfumes. The exact materials for use depends on the type to be made.


EQUIPMENT REQUIREMENTS:

1. Dryer such as flash dryer of other drying equipment. Flash dryer is the best option as it is most efficient.
2. Roller mills with heater (this is noptional)
3. Planetary or Ribbon blender
4. Filling and sealing machine. This can be powder, liquid or aerosol type.
5. Pulverisers or grinders
6. Weighing scale and other measuring devices
7. Laboratory tools. Thermometers, viscometers etc.
8. Personal protective gadgets. Coverall, mask gloves, boots, earplugs etc.

PACKAGING MATERIALS:

Cold water starch can be packaged in sachet, bottles and spray cans depending on the type. Cartons are also needed for bulk packaging. Sizes of packs should depend on market demand. However, 20g, 25g, 30g, 50g sachets are in the markets 0.5 litres, 1 litre and 4 litres packs for the liquid type can be found. The aerosol type include 250mls, 450mls, 500mls etc. The packs are well labeled with the appropriate information like maker, quantity, registration etc.



Space: The standard requirement is a minimum of four rooms excluding a cloakroom. However, a cottage scale can start with a room or two. Bigger scale will require bigger space.

Labour: A skilled hand can produce up to 1 ton of the product per day if the system is automated. Far less will be make if operation is manual. Except about 250kg of finished and package product for manual operation by one hand.

Production Process: There are three or four stages of making cold water starch depending on where you start from some of these stages can be omitted by a small scale to save cost.

1. Cold water starch powder
(a) Modification of raw starch methods

i Dry method: Here the roller mills are heated to above 1000C. The raw starch mixed with ash is fed into the rollers. The starch gells as it rolls over the hot cylinders of the rollers. The gelled starch now in cakes or flakes are collected and grinded in the pulveriser. Perfume and colorant may be added at this stage.

Roller formulation: 50kg batch
Cassava (or other) starch - 49.5kg
Soda ash (optional) - 0.5kg
Total - 50 kg

This mixture is rolled in the hot cylinder of the rolers


Pulveriser formulation: 50 kg batch

Gelled starch mixture - 50 kg
Colourant (optional) - 1 TSP
Total - 50kg

The mixture is grinded

The grinded starch is now packed in the required sachets and cartons for sale. This method is expensive because of the cost of the rollers.
ii. Wet method: Here the mixture as in roller formulation above is boiled with some water to gell. The gelled starch mixture is dried in the flash dryer then pulverized as in the pulveriser formulation above.

Boiler formulation: 50 kg batch

Cassava (or other) starch - 49.5kg
Soda Ash (optional) - 0.5 KG
Water (to form sturry) - 20 kg
Total - 70 kg
Note: while boiling, the product must be in constant mixing. The gelled starch is collected and dried in the chosen dryer. This is to remove the water used during boiling. The dried starch, now in cake form is placed in the pulveriser and grinded with or without colourants and perfumes. The product is then packaged as required in the market. This is also expensive because of the dryer.

iii. Dextrin method: This method is most suitable for micro and small scale entrepreneurs. It eliminates the use of roller mills, flash dryer and pulverisers.

(b) Cold water starch powder: 50 kg Batch
Dextrin - 49.5 kg
Soda ash light - 0.5 kg
Perfume (optional) - TSP
Colourant (powder) - 1 tsp (optional or blue)
Total - 50 kg

Note: TSP means tablespoonful. Tsp means teaspoonful.

PROCESSING: The materials as above simply measured out and mixed manuallym if batch is below 100kg or in ribbon mixer for bigger batches. When homogeneous, it is packed as required.


(c) Cold water starch powder: 50 kg Batch
Dextrin or gelled starch - 20kg
Polyvinyl Acetate (PVA) - 10kg
Water - 20kg
Formalin - 200 g
Perfume (optional) - 1 TSP
Total - 50 kg Apr.


PROCESSING:

(1) Gel local cassava starch with hot water: This can ba done by mixing the raw starch with equal amount of cold (ordinary) water. The mixture is the mixed with about 4 to 5 times quantity of boiling water (1000C) and properly mixed till homogeneous.

(2) The gelled starch or dextrin is mixed with the water in the formulation above. When smooth, the other ingredients (PVA, formalin etc) are then added and mixed well for feeling into the appropriate bottles for sale.


Note: The use of cassava starch here instead of dextrin ensures very good profit without changing the desired quality.


(3) Cold water starch Aeroslo. 50 kg Batch

Dextrin or gelled starch -10 kg

Polyvinyl Acetate - 10 kg

Isopropanol (IPA) - 2 kg

Water -28 kg

Formalin - 200 g

Total - 50 kg. Apr.

Note: Colourant and or perfume may be added as in other processing. Mix all other ingredients together except IPA. When homogenenous, add IPA and mix very well. Pack or fill into the aerosol cans with theaerosol filling machine. The IPA guarantees the spray ability of the product and its fast drying. For better spraying IPA can be increased if desired.

QUALITY PARAMETERS:

1. Product should stiffen cotton fabric well compare with accepted brands in its market.
2. Odour must be well controlled. Use good fragrance.
3. Spoilage. This is especially for the liquid type. However if the powder type is not well dried, it can also decay. Use good preservative (formalin) to avoid bad odour in the liquid types.
Consult a good chemical consultant or a public analyst for detailed quality control tests and analysis.

TOILET CLEARNERS FORMULATONS:

(A) Toilet Cleaner Batch 20 litres

Rose perfume (or others) - 1/10 litres

Empicol (or Liquid Detergent) - 1 litre

Soda Ash (or STPP) - ½ KG

Natrosol - 5 TSP

Colourant (e.g. Blue) - 2 tsp

Water - 13-15 litres

Total - 20 litres

Note:

1. Any good perfume can be used
2. Two perfume can be equally mixed
3. STPP is sodium Tripolyphosphate
4. TSP is Tablespoonful. Tsp is teaspoonful.

(b) 20 litres Batch Toilet Cleaner
Jasmine perfume - 1/10 litres (100ml)
Sulphonic Acid - ½ litre
Hydrochloric Acid - ¼ litres
Soda Ash - 1 kg
Natrosol - 5 TSP
Colourant (green) - 2 tsp
Water - 18 litres
Total - 20 litres

Note:
1. A good liquid detergent can be used to replaced Sulphonic Acid.
2. Hydrochloric Acid is a germ killer and stain remover
3. Natrosol is a thicker
4. Use only soluble colourants
5. Empicol is a foaming agent and emulsifier to help the ingredients to mix well.
PROCESSING METHOD:
1. Measure out the ingredients in separate containers.
2. Place the water in the mixer (bowl or tank) and add the soda ash (or STPP) and mix till fully dissolved. (about 20 minutes)
3. Add the empicol, detergent or sulphonic acid and mix slowly to avoid excessive foaming.
4. Add the perfume and mix till well blended (if not well blended , add ¼ litre empicol or others to blend well). (About 10 minutes)
5. Into a ½ litre cup of water, put the 5 TSP natrosol and mix well (about 10 second) and immediately add this mixture into the main product and continue mixing till the product becomes thick (about 5 minutes)
6. Add the Hydrochloric acid or cetrmidie and mix well (about 5 minutes)
7. If colourant is needed, add as the last item and mix to blend (about 3 minutes)
8. Pack product as needed in the market.