Manufacturing of Sorbitol: The Sweetener That’s Good for Business

Categories

The manufacturing of sorbitol has become a vital process in the food, pharmaceutical, and personal care industries, thanks to the compound’s versatility and economic significance. Sorbitol, a sugar alcohol derived primarily from glucose, is widely used as a low-calorie sweetener, humectant, stabilizer, and thickener. It offers a pleasant taste and moisture-retention properties, making it highly desirable in everything from sugar-free gums to medicinal syrups and cosmetic products.

The global demand for sorbitol manufacturing continues to rise due to shifting consumer preferences toward low-sugar and diabetic-friendly products. In fact, the global sorbitol market size was valued at USD 1.7 billion in 2023, and is projected to expand at a CAGR of 6.2% through 2030. With this increasing market potential, investing in a sorbitol production unit can be a highly profitable venture when executed with proper technical know-how and strategic planning.

Visit this Page for More Information: Start a Business in Pharmaceutical sector

What is Sorbitol and Why is it in Demand?

Sorbitol, also known as glucitol, is a polyol produced by the hydrogenation of glucose. It occurs naturally in many fruits but is manufactured industrially for large-scale applications. Its non-cariogenic (tooth-friendly), water-soluble, and mild-sweet properties make it a functional ingredient in numerous consumer and industrial products.

In food products, sorbitol is used in sugar-free gums, candies, and baked items. pharmaceuticals, it is employed in vitamin C synthesis, oral solutions, and tablets. In personal care, it is used in lotions, toothpaste, and moisturizers due to its hydrating properties.

Raw Materials Required for Sorbitol Manufacturing

To initiate the manufacturing of sorbitol, the following primary raw materials are required:

Dextrose Monohydrate or Glucose Syrup – Extracted from corn or wheat starch
Hydrogen Gas – For catalytic hydrogenation
Nickel Catalyst (Raney Nickel or similar) – Facilitates the reaction
Deionized Water – As a solvent
Activated Carbon & Filter Aids – For purification processes

The quality of glucose and purity of hydrogen gas greatly influence the yield and quality of the final sorbitol product.

Read Similar Articles: PHARMACEUTICAL INDUSTRY

Step-by-Step Sorbitol Manufacturing Process

The sorbitol manufacturing process involves a series of chemical and physical steps to convert glucose into sorbitol with high purity and stability. Below is a detailed breakdown:

Preparation of Glucose Solution
Starch is hydrolyze using enzymes or acid hydrolysis to produce glucose syrup. This syrup is filtered and decolorized using activated carbon.
Hydrogenation Reaction
The purified glucose solution is pumped into a high-pressure hydrogenation reactor. In the presence of a nickel catalyst and under 150–250°C temperature and 30–80 bar pressure, glucose is converted into sorbitol.
Filtration and Catalyst Removal
The reaction mixture is cooled and filtered to remove the catalyst. This step is critical to ensure safety and product quality.
Evaporation and Concentration
The sorbitol solution is concentrated via evaporators to achieve the desire solid content of 70% or more, depending on end-use.
Purification and Polishing
The concentrated solution is further purified using ion-exchange resins and final filtration systems to remove any remaining color, odor, or impurities.
Storage and Packaging
The finished sorbitol solution is stored in stainless steel tanks and packed in HDPE drums, IBC totes, or bulk tankers based on customer demand.

Read our Books Here: Pharmaceutical, Drugs, Proteins Technology Handbooks

Equipment and Machinery Required

Setting up a sorbitol plant requires robust and corrosion-resistant machinery due to high-pressure and catalytic reactions. The main equipment includes:

Starch Hydrolysis Unit
Hydrogenation Reactor (High Pressure)
Catalyst Recovery Filter
Evaporator System
Ion-Exchange Columns
Centrifugal Pumps and Heat Exchangers
Storage Tanks and Filling Machines

For optimal performance, all systems must be automate with PLC and SCADA control to ensure precision, safety, and process consistency.

Related Feasibility Study Reports: Pharmaceutical Industry – Manufacturing Plant

Factory Layout and Space Consideration

A mid-scale sorbitol production plant typically requires 10,000 to 20,000 square feet of industrial land. Areas should be designate for:

Raw Material Handling
Reaction and Processing Zones
Filtration & Purification Sections
Quality Testing Labs
Packing and Dispatch Section
Control Rooms and Utilities

Maintaining cleanroom standards in critical sections enhances product purity and GMP compliance.

Licensing, Regulatory, and Environmental Aspects

Before commencing sorbitol manufacturing, obtain:

Factory and Pollution Control Licenses
FSSAI Registration (for food-grade sorbitol)
GMP Certification (for pharma-grade use)
Drug License (for medicinal applications)
Explosive License (for hydrogen handling)
Hazardous Waste Handling Approval

Wastewater must be treat before discharge using an Effluent Treatment Plant (ETP) with biological and chemical units.

Applications and Market Segments for Sorbitol

The sorbitol manufacturing industry caters to several diverse sectors:

Food Industry – Sugar-free gums, baked goods, candies, beverages
Pharmaceuticals – Vitamin C production, syrups, tablets, laxatives
Cosmetics and Personal Care – Moisturizers, shampoos, toothpaste
Industrial Applications – Resins, surfactants, polyurethane foams

The personal care segment alone holds over 20% market share due to the rising demand for clean-label products.

Costing, Profit Margins, and Financial Feasibility

The approximate cost for setting up a medium-scale sorbitol manufacturing plant ranges between ?8 crore to ?15 crore depending on capacity, automation, and quality standards.

Cost of Production per kg: ?30–?45
Average Selling Price per kg: ?55–?80 (depending on grade and volume)
Gross Profit Margin: 35%–50%
Breakeven Point: Within 2–3 years under efficient operations

Export potential to Middle Eastern, African, and Southeast Asian countries offers lucrative opportunities.

Challenges in Sorbitol Production and Solutions

Catalyst Deactivation? – Regular regeneration or replacement of nickel catalyst is essential.
Impurities in Product? – Enhance purification via multi-stage ion-exchange or nanofiltration.
Hydrogen Safety Risks? – Use explosion-proof reactors and hydrogen leak detectors.

Adopting continuous production models and closed-loop recycling of catalyst and water can improve sustainability.

Conclusion: Why Sorbitol Manufacturing is a Future-Ready Investment

The manufacturing of sorbitol stands as a technically advanced yet commercially rewarding venture. With growing demands across health-conscious food markets and clean-label personal care, sorbitol is pois for substantial global growth. Entrepreneurs and manufacturers who invest in modern equipment, maintain high purity standards, and align with global quality certifications will be well-position to dominate this ever-expanding market.

Click here to send your queries/Contact Us

Reasons for Buying NIIR Report:

Our research report helps you get a detailed picture of the industry by providing an overview of the industry along with the market structure and classification.
Our report provides market analysis covering major growth driving factors for the industry, the latest market trends and the regulatory framework of the industry.
Our Report provides an analysis and in-depth financial comparison of major Players / Competitors.
Our Report provides indispensable buyers’ data with their company financials as well as the contact details, which can be an important tool in identifying the target customers.
Our report provides forecasts of key parameters which help to anticipate the industry performance.
We use reliable sources of information and databases.

See More Links: