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    Corn Milling

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    Noshaba Fiaz
    The document discusses the processing of corn through dry milling and wet milling. In dry milling, the corn is ground to remove the germ and produce grits, meals, and flours. In wet milling, the corn is soaked, ground, and separated using water to produce starch, germ, and feed. The key steps in wet milling include cleaning, soaking, germ separation, grinding, and separating starch from gluten using hydroclones or centrifuges.

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    Corn Milling

    Uploaded by

    Noshaba Fiaz
    56 views22 pages
    The document discusses the processing of corn through dry milling and wet milling. In dry milling, the corn is ground to remove the germ and produce grits, meals, and flours. In wet milling, the corn is soaked, ground, and separated using water to produce starch, germ, and feed. The key steps in wet milling include cleaning, soaking, germ separation, grinding, and separating starch from gluten using hydroclones or centrifuges.

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    Corn Milling (1)

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    The document discusses the processing of corn through dry milling and wet milling. In dry milling, the corn is ground to remove the germ and produce grits, meals, and flours. In wet milling, the corn is soaked, ground, and separated using water to produce starch, germ, and feed. The key steps in wet milling include cleaning, soaking, germ separation, grinding, and separating starch from gluten using hydroclones or centrifuges.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    56 views22 pages

    Corn Milling

    Uploaded by

    Noshaba Fiaz
    The document discusses the processing of corn through dry milling and wet milling. In dry milling, the corn is ground to remove the germ and produce grits, meals, and flours. In wet milling, the corn is soaked, ground, and separated using water to produce starch, germ, and feed. The key steps in wet milling include cleaning, soaking, germ separation, grinding, and separating starch from gluten using hydroclones or centrifuges.

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    of 22

    PROCESSING

    TECHNOLOGY OF CEREALS
    ASFE 2201

    SUDIPTA BEHERA
    ASSISTANT PROFESSOR, SoABE
    CORN MILLING
    INTRODUCTION
     Corn is one of the world's most versatile seed crops. Its botanical
    name is Zea mays. Corn is used as food and feed.
     Corn can be processed into various food and feed ingredients,
    industrial products and alcoholic beverages.
     There are two modern methods of milling of corns, dry milling and
    wet milling.
     Besides germ for corn oil extraction and husk and deoiled germ,
    etc.., for feed, grits (mainly used for the breakfast cereals) are the
    main products of corn dry milling whereas pure starch, germ and feed
    are the major products of wet milling.
    CORN DRY MILLING
     Corn dry milling system can be divided into two groups : the
    traditional non: degerming system and modern degerming system.
     In the non degerming system, the whole corn is ground into meal of
    high fibre as well as high protein contents by a stone grinder without
    removing germ. After grinding certain amount of germ and hull can
    be removed from the meal by sifting.
     In the degerming system the corn is moistened with a little amount of
    water and tempered for moisture equilibration. After degerming the
    stock is dried, milled and classified into different products.
     The purpose of all dry degerming corn milling methods is to remove
    hull, germ and tip cap from the corn kernel as far as practicable and
    primarily produce corn grits with some meals and flours.
     The germ is then used for oil extraction and deoiled germ, hull, etc.,
    are used as feed.
     The yield of endosperm products are about 70 per cent.
    TEMPERING-DEGERMING (T.D.) METHOD OF
    DRY MILLING:
    The major objectives of this method are :
    (a) to remove essentially all germ and hull so that endosperm contains
    as low fat and fibre as possible,
    (b) to recover a maximum amount of the endosperm as large clean
    grits without any dark speck, and
    (c) to recover a maximum amount of germ as large and pure particles.
    DESCRIPTION OF THE T.D SYSTEM
    1) Cleaning of the corn
    2) Conditioning of the corn by addition of control amount of
    moisture
    3) Releasing hull, germ, and tip cap from the endosperm in a
    degermer.
    4) Drying and cooling the degermer products obtained from the
    degermer.
    5) Fractionating degermer stock by multistep milling through a series
    of machines namely roller mills, sifters, aspirators, gravity table
    separators, and purifiers to separate and recover the various products.
    6) Drying of the products
    7) Blending and packaging of products.
    1. Cleaning of corn
     Thorough cleaning of corn is essential for the subsequent milling
    operations. Pieces of iron, etc., are removed by magnetic
    separators.
     Dry cleaners consisting of sieves and aspirators and sometimes a
    wet cleaner consisting of a washing destoning unit and a
    mechanical type dewatering unit, known as whizzer, are used for
    cleaning of corn.
    2. Hydrothermal treatment / conditioning

     Predetermined amount of moisture is added to the corn in the


    form of cold or hot water or steam in one, two or three stages
    with appropriate tempering times after each stage.
     The tempering times (rest periods) vary according to the
    hydration methods. So also tempering temperatures vary from
    room temperature to about 50ᵒC accordingly.
     The optimum moisture content for degerming in the Beall
    Degermer is 2l-25%.
     Either cold or hot water is used for the addition of moisture. A
    little heat in the form of open steam is added as and when
    necessary.
    3. Degerming
     The purpose of degerming is to remove hull, tip cap, and germ as
    far as practicable and leave the endosperm into large grits.
     However, the products from degermer consists of a mixture of
    kernel components, freed from each other to varying degrees, with
    the endosperm particles varying in sizes from grits to flour.
     The Beall Degermer consists of a rotating cast iron conical roller
    mounted on a horizontal shaft in a conical cage.
     Part of the cage is fitted with perforated screens and the remainder
    with plates having conical projections on its inner surface.
     The rotating cone has similar projections over most of its surface.
     The feed end of the cone has spiral corrugations to move the corn
    forward whereas the large end has corrugations in an opposite
    direction to retard the flow.
     The product leaves the unit in two streams.
     The major portions of the released germ, husk and fines as well as
    some of the grits are discharged through the perforated screens.
     Tail stock containing large amount of grits, escapes through an
    opening fitted with the large end of the cone. A hinged gate with
    an adjustable weight adjusts pressure inside the chamber and
    controls the flow of the stock.
    4. Drying and cooling of degermer stock
     The degermer products are to be dried to 15 to 18 per cent moisture
    content for proper grinding and sifting.
     Generally rotary steam tube dryers are used for drying the product.
     The stock is heated to about 50ᵒC.
     Counter flow or cross-flow rotary, vertical gravity or fluidized bed
    types of cooler can be used for cooling the dried products.
    5. Rolling and Grading
     Recovery of various primary products is the next step. Further
    release of germ and husk from the endosperm products occurs
    during their gradual size reduction roller mills.
     The germ, husk and endosperm fragments are then separated by
    means of sifters, aspirators, specific gravity table separators or
    purifiers.
     Sifting is an important operation and is variously referred to as
    scalping, grading, classifying, or bolting depending upon the
    means used and purpose.
     Sifting is actually a size separation operation on sieves.
     Scalping is the coarse separation made on the product leaving a
    roller mill or degermer. Grading or classifying is the separation
    of a single stock (usually endosperm particles) into two or more
    groups according to particle size.
     Bolting is the removal of hull fragments from a corn meal or
    flour.
    CORN WET MILLING
     Pure starch, pure germ and feed are the basic products of corn wet
    milling.
     But a few hundreds of byproducts can be produced from these
    three main products. A list of these byproducts with their uses is
    given in Table.
     The raw corn for wet milling should contain 15-16 per cent
    moisture and it should be physically sound.
     Insect and pest infested, cracked and heat damaged corns (treated
    at temperature around 75ᵒC during drying) are unsuitable for wet
    milling.
     The heat damaged corn affects the quality of oil extracted from its
    germ.
     Sufficient amount of moisture is added to the corn during steeping
    in the wet milling process in order to prepare the corn for
    subsequent degerming, grinding and separation operations.
    The flow diagram of corn wet milling process
    The wet milling process consists of the following steps :
    (a) Cleaning, (b) soaking, (c). germ separation and recovery, (d)
    grinding and hull recovery, and (e) separation of starch and gluten.

    a. Cleaning
     All impurities such as dust; chaff, cobs, stones; insect-infested
    grain and broken grain, and other foreign materials are removed
    from corn by screening and aspirating. The clean grains are
    conveyed to the storage bins.
    b. Steeping
    The major objectives of steeping are
    1) To soften the kernel for grinding,
    2) To facilitate separation of germ,
    3) To facilitate seperation of gluten from the starch granules,
    4) To remove solubles, mainly from the germ.
     Water impregnated with SO2 (i.e, acidulated water with H2SO3)
    is used for steeping.
     It helps in arresting certain fermentation during long steeping
    process.
     The steeping is carried out at about 50ᵒC for a period varying
    from 28 to 48 hours in different plants.
     The steeped corn attains a moisture content of about 45 per cent.
    c. Germ Recovery

     The wet and softened corn kernels containing about 45 per cent
    moisture are conveyed to the degerminating unit.
     This machine consisting of a metallic stationary plate and a
    rotating plate with projecting teeth is employed only for tearing
    the soft kernels apart and freeing the germs without grinding them.
     The pulpy mixture containing germs, husk, starch and gluten is
    passed through hydroclones, where the germ being lighter is
    separated from other heavier ingredients, by centrifugal force.
     Only modern starch plants employ hydroclones for germ
    separation.
     Otherwise the floatation method of germ separation is still in use
    in old types of mills.
    d. Milling and Fibre Recovery
     After separation of germ and screening of the coarse particles, the
    mixture contains starch, gluten and hulls.
     Mainly endosperm and hull are then generally ground by either
    traditional Burstone mill or modern entoletor impact mills to
    release the rest of the starch.
     Material to be ground enters the machine through a spinning
    rotor and is thrown out with great force against the impactors at
    the periphery of the rotor and also against a stationary impactor
    resulting in considerable reduction in particle size.
     Here only the starch is readily released, with a very little size
    reduction of hulls.
     The milled slurry, containing the ground starch, gluten, and hulls,
    is passed through a series of hexagonal reels where the coarser
    hulls and fibres are removed.
    e. Starch- Gluten separation
     In the modern process, the slurry containing starch and gluten is
    concentrated and then the lighter gluten particles are separated
    from the relatively heavier starch particles by the centrifugal
    force in high speed centrifuges.
     The centrifuging of starch is carried out in two stages.
     In many modern plants, the second stage of centrifugation is
    performed by a number of hydroclone type of equipments.
     The starch obtained from the second stage of separation is filtered
    and then dried to produce dry starches.
    PRODUCTS OF CORN MILLING
    1. Degerminated flour:
     This represents about 70 per cent extraction.
     The degerminated flour consists mostly of the endosperm and has
    low content of B-vitamins.
     It is used by brewers as a starch medium for the action of barley
    malt in the preparation of wort for the production of beer.

    2. Germ:
     Corn-germ contains about 21 .0 per cent proteins and 32 per cent
    fat. Since the germ constitutes about 13 per cent of the grain, it is
    an important source of proteins and fat.
     The oil can be extracted by solvent extraction and the residual
    protein-rich (about 30 per cent protein) corn germ flour can be
    incorporated in weaning foods.

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