Maize processing

Types of maize processing

Maize processing refers to the method of changing the raw corn into other products. Normally, there are two main kinds of maize processing techniques: wet milling and dry milling.

• Wet maize processing: Wet milling mainly uses water and chemical solutions in the processing. This method separates the corn into various parts, such as starch, protein, oil, and fiber, by using different concentrations of acid solutions. Each of those corn parts has its specific applications. For instance, the starch can be used to produce corn syrup or sweeteners, the protein can be used in animal feed, and the oil can be used in cooking or as an ingredient in certain products. Because wet maize processing can separate the diverse parts of corn, it is usually used to produce food additives, industrial materials, and biofuel products. The machinery used for wet maize processing includes soaking tanks, crushers, separators, dryers, and more. These devices work together to separate and purify different chemical components of corn.
• Dry maize processing: Unlike the wet processing method, dry maize processing uses physical techniques to deal with corn. It mainly depends on grinding, sieving, and classifying to turn corn into corn flour, corn meal, feed, etc. The products are suitable for human consumption or animal feed. The machines involved in dry maize processing include grinders, flour sieves, and classifiers, among others. Corn grains are first crushed and then sorted according to size and weight. Finally, the flour is separated by flour sieves. The entire process is relatively simple and does not use a lot of water, which makes it suitable for small-scale production lines. Furthermore, dry maize processing usually has smaller equipment that is easier to install and use, which makes it more suitable for families or small workshops.

Specifications and maintenance of maize processing

Specifications

• Maize flour mill

  Hygienic maize processing equipment weighs 4500kg and is about 220m wide and 840m long. Its automatic pneumatic system makes it stable, especially when it is milling maize into maize flour. The maize flour mill works quickly to produce anything from 50-420D totally grist and flour. The temperature is between 55 and 60 during its milling process.

• Degerminator

  A maize processing's degerminator is usually 100-400t/24h in capacity and up to 9m in length. It has a shaft circumference with varying germination rates from 1500-1800. The motor power is 55-75Kw. The degerminator separates maize germs from the entire maize product. The degerminator has a central shaft with discs where the maize is crushed.

• Bag dumper

  An impact bag dumper helps to drop the maize dumping weight of 1 ton from around 44m x 5m in dimensions. Pneumatic conveying and floor blending are used to process maize into other by-products.

• Sifter

  Maize processing industries usually utilize a 4300axe/min maize sifter with 2.2Kw motor power. The maize sifter's capacity is approximately 20t/hr. It helps separate maize flour, endosperm, bran, and other parts of the maize into useful products.

Maintenance

• Regular inspection

  Frequent inspection is a standard practice followed for all food-grade machines. The examiner looks at the entire maize processing machine for signs of wear and tear or corrosion, especially the degerminator and the straps. The fastening points are checked as well as any frames, racks, legs and casters for any looseness. The examiners look for any defects that can be improved upon to maintain performance, efficiency and safety.

Some of the common things to be done on a more regular basis include the following: removing allergens and product residues; cleaning filters and water conveyance; inspecting hoses and their fittings; calibrating weighing scales; testing the electronic system and controls; inspecting the pneumatic system; lubricating moving parts; tightening, inspecting, and cleaning pullies and belts; and checking for leaking components.

• Urgent repairs

  When an inspection shows severe damage, trying to fix a maize processing machine again can increase the breakdown risk. Severe damage can include cracks, warp invalids or loose/lines hose or belt alignment. More extensive repairs may be needed. If parts are highly worn out, they may need replacement. Some commonly worn parts to a maize processing plant include the degerminator discs, the sifter sieves, and the mill's grinding wheels and plates.

Applications of maize processing

Maize processing is a critical component to the overall agricultural market. Approximately 950 million metric tons of maize is produced every year across the globe. Due to its versatile nature and high yield, the processed maize grain is used in various consumption products and industries.

In the food processing industry, maize grain is processed into meal, flour, grits, and sweeteners. The flour and meal are then used to make tortillas, polenta, cornbread, and other baked goods. Industrial-grade maize starch is further processed into syrups, sweeteners, alcohol, and biofuels. Starches are converted into high fructose corn syrup and used in various beverages such as sodas and other sugary drinks. Over 2000 fermenting distilleries use maize to make ethanol, which is added to gasoline to reduce the need for petrochemical products, which is one of the great uses of maize processing. Over 900 million barrels of ethanol are used annually to produce more than half of the country's fuel needs and to manufacture alcoholic beverages.

Nearly 1 billion chickens, turkeys, and farm animals consume processed maize as their primary source of protein and energy. About 40% of maize is fed directly to animals, contributing to approximately 15% of poultry processing. Corn is also a major component in assembling farm animal feed to rear cattle, cows, and livestock that contribute to the meat industry.

In the chemical industry, processed maize is transformed into biodegradable plastics, which are further used to manufacture bottles, containers, and various packaging materials.

Due to its transformative nature towards food, feed, and fuel production, maize has become an essential crop not only to the overall market but to the global economy.

How to Choose Maize Processing

When selecting corn-maze processing equipment, it's crucial to consider what type and amount of maize will be processed. Capacity must match requirements, with efficient handling of peak volumes. Evaluate the quality of end products desired, which will determine necessary machinery features and specifications. Invest in durable equipment built for constant use, and ensure maintenance and repair services are readily available.

Understand how complex or straightforward the processing line needs to be based on expertise and available resources. Lines should flow smoothly with automated controls where possible, but also have staff-friendly interfaces. Select energy-efficient machines, as grain processing uses a lot of energy, and ensure design minimizes food waste and maize waste. Consider screening, storage, transport, milling, mixing, and packing needs, and choose specialized machines based on end product requirements.

Consider whether workshop space suffices for tools like cobs shredders and silos required, and ensure the ventilation systems are adequate, which should be silent enough during operation. It is necessary to check the compatibility between machines that make up a processing line so that they work together to achieve the desired end product. Look for technical support and a reliable supply of spare parts to minimize downtime. Staff training is also crucial to ensure operators can run machines safely and correctly. Operators' health and safety should come first when handling hazardous maize, and equipment should have safeguards.

FAQ

Q1: What are the types of maize processing factories?

A1: The typical maize processing plants are divided into three types according to the products they make.

1. Maize milling plant for making flour. It processes maize into flour for baking bread, cakes, bread, biscuits, etc.

2. mD maize milling plant for producing grits and meals. It processes maize into coarse maize products, such as porridge, polenta, etc. The products are popular in North America.

3. MZT maize dry milling and Zотеr maize wet milling plants. The former processes maize to make distiller's dried grains, syrup, and ethanol. The latter is for extracting starch, glucose, and other related products.

Q2: What is maize processing?

A2: Maize processing refers to the procedure of transforming maize grains into food and feed products through a series of mechanical, physical, and chemical techniques.

Q3: What maize is used for processing?

A3: Besides the food industry, the processing of maize grains provides a valuable outlet for animal feed and industrial applications. Furthermore, the fermenting industry can yield numerous by-products suitable for animal feed.