CORN DRY MILLING PLANT

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Maize/corn dry milling process is a less versatile, less capital intensive process that focuses primarily on the production of grain ethanol. In this process, the corn kernel are hammer milled into a medium to fine grind meal for introduction to the ethanol production process. The products of a traditional dry grind ethanol facility and dried distillers grain (DDG) a low value animal feed product.

Dry milling technology has been standardized by Central Food Technological Research Institute (CFTRI) Mysore. The grits is the main product of dry milling process, which is used as porridge by boiling domestically. The processing units, use grits for manufacture of products like ready to eat snacks (Corn flakes), manufacture of glucose by direct hydrolysis etc.

Maize is one of the staple foods in India. The annual maize production in India is around 21 million tons with the highest maize cultivation in Karnataka, Andhra Pradesh and Rajasthan.

India is one of the largest cultivators of maize in the world, and it is a crop suitable for all the growing seasons in nearly every agro-climatic zone within the country’s borders. India has seen a dramatic increase in maize cultivation over the past few years, which explains its pre-eminence as a starch source among processors.

Traditionally, the grain is converted into flour in mill for making bread immature cobs are roasted and eater all over the country. It is an important material for animal and poultry feed, corn flakes etc.

The quantity of maize utilized by this unit, is limited as the existing units are of small scale nature. They make only a few products having limited demand where as a large scale unit can process a large quantity of maize to different value added products.

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Description

INTRODUCTION
USES AND APPLICATION
GRITS/CONES
FLOUR
GERM
MAIZE KERNEL ANATOMY AND COMPOSITION
MAIZE KERNEL COMPOSITION
MAIZE OUTLOOK IN INDIA
INTERNATIONAL GRAIN COUNCIL’S WORLD CORN PROJECTIONS (IN MILLION METRIC TONNES)
INTERNATIONAL GRAIN COUNCIL’S INDIAN CORNPROJECTIONS (IN MILLION METRIC TONNES)
MONTH-WISE AVERAGE PRICES OF MAIZE AT VARIOUS MARKETS
MAIZE ARRIVALS AND PRICES IN WARANGAL MARKET FOR THE MONTH OF JUNE 2020
MAIZE PRICE OUTLOOK
MARKET OVERVIEW OF MAIZE DRY MILLING
PRESENT MANUFACTURERS/SUPPLIERS
COMPOSITION OF YELLOW DENT CORN
SAMPLING PROBE
CORN TESTING
GRAIN STORAGE
CLEANING
TEMPERING CONVEYOR
DEGERMINATOR
DRY MILLING OF GRAIN
PROCESS OVERVIEW OF CORN DRY MILLING
TEMPERING
DEGERMINATION
ASPIRATION
GRAVITY SEPARATION
ROLLER MILLING AND SIFTING
MILLING SYSTEM OF MAIZE
PROCESSING OF MAIZE
DESTONING
CONDITIONING
TEMPERING
CONDITIONING
DEBRANNING AND DEGERMING
HORIZONTAL ABRASIVE POLISHER
HORIZONTAL FRICTION POLISHER
SIFTING
SPECIFIC GRAVITY SEPARATOR
DRYING
DETAILS OF MAIZE DRY MILLING
COMPARISON OF PRODUCT YIELD FOR LABORATORY DRY-MILLED MEDIUM-HARD ENDOSPERM AND MEDIUM SOFT ENDOSPERM DENT MAIZE DRIED AT TWO TEMPERATURES
INDUSTRIAL MAIZE PROCESSES
TYPES OF DRY GRINDERS
THREE METHODS USED FOR CORN DRY MILLING
PROCESS OVERVIEW
TEMPERING
DEGERMINATION
ASPIRATION
GRAVITY SEPARATION
ROLLER MILLING AND SIFTING
MANUFACTURING PROCESS
CLEANING
CONDITIONING
DEGERMINATION
DRYING
COOLING
GRADING
MILLING
PROCESS FLOW DIAGRAM
TEMPERING DEGERMING PROCESS
TECHNOLOGICAL PROCESS OF CORN GRITS AND FLOUR PRODUCTION LINE
CORN GRITS AND FLOUR PRODUCTION LINE WITH DRY METHOD
TECHNOLOGY INTRODUCTION OF CORN GRITS AND FLOUR PRODUCTION LINE
DETAILS OF DRY MILLING PROCESS OF MAIZE
EXPERIMENTAL DRY MILLING OF CORN
MATERIALS AND METHODS
MATERIALS
EXPERIMENTAL METHODS
ANALYTICAL METHODS
RAW MATERIALS & FINISHED PRODUCTS
PRINCIPLES OF PLANT LAYOUT
STORAGE LAYOUT
EQUIPMENT LAYOUT
SAFETY
PLANT EXPANSION
FLOOR SPACE
UTILITIES SERVICING
BUILDING
MATERIAL-HANDLING EQUIPMENT
RAILROADS AND ROADS
PLANT LOCATION FACTORS
PRIMARY FACTORS
SPECIFIC FACTORS
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
PROJECT IMPLEMENTATION SCHEDULES
INTRODUCTION
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
PLANT LAYOUT
SUPPLIERS OF RAW MATERIALS
HDPE WOVEN BAGS
SUPPLIERS OF PLANT AND MACHINERY
BUCKET ELEVATOR
CYCLONE
SCREW CONVEYORS

APPENDIX – A:

1. COST OF PLANT ECONOMICS
2. LAND & BUILDING
3. PLANT AND MACHINERY
4. FIXED CAPITAL INVESTMENT
5. RAW MATERIAL
6. SALARY AND WAGES
7. UTILITIES AND OVERHEADS
8. TOTAL WORKING CAPITAL
9. COST OF PRODUCTION
10. PROFITABILITY ANALYSIS
11. BREAK EVEN POINT
12. RESOURCES OF FINANCE
13. INTEREST CHART
14. DEPRECIATION CHART
15. CASH FLOW STATEMENT
16. PROJECTED BALANCE SHEET

Additional information

Plant Capacity

100 MT/Day
Land & Building

(12,000 sq.mt.)
Plant & Machinery

US$ 285714
Rate of Return

28%
Break Even Point

59%

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