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 liters, 1 liter and 4 liters 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 Required
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.
Labor
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.
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.
Cold water starch powder
(a) Modification of raw starch methods
Dry method: Here the roller mills are heated to above 1000C. The raw starch mixed with ash is fed into the rollers. The starch gels as it rolls over the hot cylinders of the rollers. The gelled starch now in cakes or flakes are collected and grind in the pulverize. 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 rollers
Pulverize formulation: 50 kg batch
Gelled starch mixture - 50 kg
Colorant(optional) - 1 TSP
Total - 50kg
The mixture is grind
The grind starch is now packed in the required sachets and cartons for sale. This method is expensive because of the cost of the rollers.
Wet method
Here the mixture as in roller formulation above is boiled with some water to gel. The gelled starch mixture is dried in the flash dryer then pulverized as in the pulverize formulation above.
(a) 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 pulverize and grind with or without colorants and perfumes. The product is then packaged as required in the market. This is also expensive because of the dryer.
Dextrin method
This method is most suitable for micro and small scale entrepreneurs. It eliminates the use of roller mills, flash dryer and pulverizes.
(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 manually 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 Aerosol. 50 kg Batch
Dextrin or gelled starch -10 kg
Polyvinyl Acetate - 10 kg
Iso-propanol (IPA) - 2 kg
Water -28 kg
Formalin - 200 g
Total - 50 kg. Apr.
Note: Colorant and or perfume may be added as in other processing. Mix all other ingredients together except IPA. When homogeneous, add IPA and mix very well. Pack or fill into the aerosol cans with the aerosol 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.
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