Maize processing equipment. Corn processing equipment. Market for manufactured products

The grain contains approximately 77% starch, 2% sugar, 9% protein, 5% oil, 5% pentosan and 2% ash on a dry matter basis.

Ash grain contains salts of calcium, magnesium, phosphorus, aluminum, iron, sodium, potassium and chlorine. The structure, composition and quality of grain were considered by Inglett.

In most parts of the world, corn is used primarily as food, while in the United States about 85% of the crop is fed to livestock. A relatively large proportion of corn in northern Europe is used as forage or green fodder. Corn as a fodder crop includes roughage, straw and silage. Roughage consists of whole fresh or dried plants; straw includes dry stalks of corn, excluding cobs. In many areas, whole green plants are mowed down and fed to livestock, or dried in shocks as roughage. A properly mowed, shredded and stored corn plant is ideal for ensiling. In some countries, the leaves or tops of the plants are separated and used for food.

Directly or indirectly, corn provides the United States with more food than any other grain. It provides animals with more food in both grain and roughage than any other cereal. Maize also produces more industrial products than any other grain. The industrial processing of corn in the United States can be divided into four categories: feed, milling, starch, alcohol, and fermentation.

The Organization for the Scientific Industrial Use of Corn lists over 500 major and by-products of corn, as well as their uses. This multiple use of corn is distributed among three main consumption groups: livestock, industry and humans. Inglett has published an excellent description of the uses of corn for food throughout the world.

Corn is used for livestock feed in a variety of ways. It can be used as grain, silage, pasture, roughage and for grazing. In the US, most of the crop is used for grain feed. Pigs are fed 40% of the harvest and somewhat less for cattle (29%) and poultry (19%). The feed industry is the largest consumer of threshed corn. By-products of processing are gluten feed, gluten meal, cake meal, germ meal, vinasse and spent grains.

About 3/4 of compound feed is produced for poultry and dairy cattle.

For American industry, the starchy part of the corn grain is of great interest. Corn is probably the cheapest and cleanest organic American agricultural raw material available for widespread industrial use. The wet milling process produces starch, corn feed, molasses, corn sugar, oil, and dextrins from corn. In this case, yellow dent corn is mainly used. A bushel (25.4 kg) of medium quality corn at a moisture content of 16% contains about 15.9 kg of starch, 0.73 kg of oil, while the rest is feed. About 18.2 kg of molasses or 12.5 kg of refined sugar can be obtained from a bushel of corn.

The milling industry also uses large quantities of corn. The main food products of the flour-grinding industry are corn flour, grits, oil, corn flakes. The groats consist of roughly ground grain endosperm, from which most of the bran and germ have been separated. Corn flakes are made by crushing preflavored crushed kernels.

The alcohol and fermentation industry in the United States ranks fourth in terms of corn consumption. They produce ethyl and butyl alcohol, acetone and whiskey.

The average volume of world trade in corn is approaching 25 million tons per year. The US exports about 59% of this amount. Other exporting countries are Argentina, Thailand, France; and Mexico. Italy is the main importing country. Japan, Great Britain, Germany, the Netherlands and Spain.

Inglett published a comprehensive book entitled Corn: Culture, Processing, Products. The compilers of this book were 21 authors who know corn well.

Additional sources on the use and sale of corn are the works of Palmby, Jones, and Klosterman.

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Processing of grain crops

The company "VITAL PRODUCT" uses the most modern European technologies in the field of processing corn grain using the equipment of the companies "SOVOKRIM" and "MILLERAL".

Products are manufactured in accordance with international requirements in the field of food safety - FSSC 22000.

Productive capacity
- 300 tons per day
- Modern European technologies in the field of processing
- Equipment of SOVOKRIM and MILLERAL companies
Logistics
- Own logistics network for auto and rail shipments
- Railway tracks at the Ryzdvyanny station, Stavropol Territory
- Fleet of trucks for the transportation of bulk and packed cargo in the amount of 25 units
Quality
- Manufacture of products in accordance with international requirements in the field of food safety - FSSC 22000
- Certification was carried out by the Swiss company SGS in 2016
- Own laboratory for testing the physical and chemical parameters of corn grain and products of its processing
- Processing quality control at every stage
- Projection of the operation of each production unit on the control panel
- Multilinear production of different fractions

Corn is one of the activities of our country. As an agricultural crop, it occupies one of the highest places in Russia in terms of production.

The full cycle of an enterprise begins with research. The main indicators on which the future corn harvest will depend are being studied. After that, cultivation takes place directly - the most responsible process. Although without human influence this type of crop can grow without much problem, supervisory control is necessary. Proper care requires certain skills and abilities. Constant watering is one of the main parameters due to which corn will grow in quality and healthy. During the active stage of growth, the removal of lateral processes is necessary.

Active control of diseases and pests is also carried out. It is advisable to stop them in the initial stages, because the quantity and quality of the crop directly depend on this.

Our country has about 3,000 thousand hectares devoted to corn. This fact confirms that corn is one of the main directions in agricultural activity.

Harvesting is no less responsible process. Due to the fact that many companies have modern and high-quality equipment, harvesting and transportation of corn takes place very quickly and, which is no less important, with high quality. The main goal is to minimize losses, as well as reduce damage to the corn grain. There are certain requirements for the technological process, following which leads to maximum results.

Grain storage conditions must provide the necessary temperature control, as well as a moisture system that provides the most favorable conditions for long-term storage.

Corn processing should be carried out according to modern European technologies, subject to certain standards. The figure of 300 tons per day gives any enterprise an advantage over competitors. Also, any company should have two or three lines that will not depend on each other. Thanks to this, it is possible to produce products of different granulometry, which will be a great advantage.

Thanks to the company's own logistics network, corn products such as flour, oil, feed are usually delivered quickly and safely. At the moment, the enterprises of our country have a great potential for productivity, which is proof of the constant growth and quality of products.

Corn is one of the highest yielding crops in our country. The sown area in Russia is 21.9 million hectares. This figure once again confirms the importance of this type of culture. Corn by-products increase in variety over time. If earlier it was possible to isolate only corn flakes, then today corn porridge, corn sticks and other derivatives of corn are used as food.

In recent years, corn products have become more and more important in human life. Their usefulness has been proven by many scientists and researchers. Therefore, many people refuse wheat products in favor of corn. The presence of beneficial nutrients, along with the fact that products from corn products are dietary, gives even more superiority over other types of this kind. Athletes are increasingly beginning to pay attention to this type of cereal. After all, the minerals that are contained in corn grits give them the strength to recover, as well as the proteins that are so necessary for the growth of muscle mass.

Maize processing is carried out at specialized enterprises. The equipment must comply with all norms and rules, since obtaining corn processed products is a difficult and responsible process. Previously, when technological schemes were far from today's ideal, corn processing technology was integrated. This created difficulties with the availability of free space. One small workshop could not cope with the entire flow. During the production of corn groats in the corn flakes production workshop, requirements were voiced to increase the output of large groats. Thus, the production of flakes increased, since corn grits were often used as feed and waste. However, these requirements led to the fact that flint corn became scarce, and the need for large volumes became more urgent. The thing is that flint corn is too low-yielding, so it was impossible to provide such volumes that would give the required yield of processed products. Now the trend is such that most of them go to flour, cereals, butter and livestock feed. It reaches about 80%. The remaining 20% comes from the production of corn flakes. However, this has its own plus. Due to this, it turns out to achieve better quality cereals for flakes.

At the moment, it is customary to divide corn processing technology into stages, thereby ensuring high-quality work, as well as convenience.

Since corn products are produced at fairly large flour and cereal enterprises, this creates excellent conditions for additional jobs. Thanks to the fact that corn processing is gaining more and more momentum, favorable conditions are being created for improving automation processes and improving working conditions.

Corn processing technology is an interesting and rather complicated process. Like all such procedures, it has its own individual characteristics and nuances. Currently, centralized processing and processing of corn is often used. This is done in order to more rationally use all the products of corn processing. Different types of cereals can be used for various purposes and directions. Some for cereal, some for corn oil, and some for corn sticks.

The technological scheme of processing has one important feature. It must ensure the separation of the germ, which, in turn, is fundamental to corn oil. At large plants, several technological schemes are used at once, in which corn processing takes on different directions. According to one of the schemes, polished cereals are obtained, according to the other - cereals for sticks and cereals.

Thus, several types of corn processing products are obtained. Each of them has already occupied a certain niche in the world of products. And every year the volumes only increase. Maize processing technologies are also reaching a new level of development, which provides a more powerful way to bring the necessary products to the market.

At present, the production of corn products is beginning to occupy an increasingly significant place in our country. The number of corn processing plants has been gradually increasing over the past 20 years. But compared to the US, Russia is still lower. However, the rapid growth of this type of production allows in the coming years to catch up with the country of North America. In our country, in addition to the construction of new ones, the reconstruction of old, idle corn processing enterprises is also taking place, since this requires somewhat smaller investments.

At the moment in Russia, more than ten projects are at the design stage. All these projects relate specifically to the creation of new corn processing plants. This growth occurs for several reasons. One of them is the economy. With increased productivity, this area can become not only a vehicle for investment, but also a source of income. This also improves the transport infrastructure.

The climate in Russia is very favorable for the growth of corn. If we turn to the analytics of past years, we can see that, despite the drought that was in our country in 2010, the yield was still higher than in the nineties. This confirms the fact that investing in a corn processing plant is bearing fruit.

If we analyze the three directions in which the market develops and increases, namely export, processing and feed, then significant growth is possible only in processing. That is why there is such a rapid, in contrast to previous years, construction of large corn processing plants. If we consider and analyze the possible development in the other two directions, we can come to certain conclusions. In order to actively develop exports, it is necessary to develop many factors. First of all, it is transport infrastructure and logistics. It will be much more profitable to build a corn processing plant. And a large number of competitors in the world market will not allow to fight for large volumes of exports.

As far as feed is concerned, the livestock industry will likewise not be able to increase domestic use of processed crops. And the thing is that the so-called "feed conversion" is significantly reduced every year. Therefore, the construction of corn processing plants is the only correct and developing solution.

Large corn processing plants in Russia are of several types. Each differs from each other in the resulting products. One is engaged in the production of cereals, flakes and flour. Another corn processing plant is responsible for the production of molasses and starch products. Each of them has its own processes, thanks to which the necessary product is obtained.

The construction of corn processing plants is carried out through investments and financial support from various companies, very often state-owned. These investments not only pay for themselves, but also give a powerful boost to the economy of the Russian Federation. Due to the geographical location, as well as the diverse climatic conditions, our country has excellent opportunities to become the best producer of corn products. Large corn processing plants have been built not only in the south of the country, but also in central Russia. Thus, the number of jobs in the regions increases, workers undergo special training and, thereby, improve their professional skills.

The corn processing plant also has several negative impacts. First of all, these are sewage treatment plants. They can be in a very bad state, so after the corn processing plant is built, it is necessary to invest heavily in the aforementioned infrastructure as well. Otherwise, rivers and agricultural lands will become infected, thereby causing total harm to the ecology of the environment.

Three main types of induction are produced from corn: polished five-dimensional grits; large groats for pg: - production of flakes; fine grits for the production of corn ticks.

Polished corn grits are crushed particles of corn kernels of various shapes, obtained by separating the fruit shells and the germ, polished, with rounded edges.

Corn grits coarse for the production of flakes and air grains is crushed particles of the kernel of various shapes, obtained as a result of "separation of the shells and the germ. The size of the cereal is characterized by the passage of a sieve with holes of 0 7 mm and the descent of the sieve with holes of 0 5 mm. The evenness of the cereal is 80%.

Small corn grits for the production of corn sticks are crushed particles of the kernel of various shapes, obtained by separating the fruit shells, the germ and crushing the kernel. The size of the groats is characterized by the passage of a metal-woven sieve No. 1, 2 and the descent of the same sieve No. 067. The evenness of the groats is at least 80%.

Characteristics of corn grain. The grain is large, the embryo is well developed, its mass is up to 15% of the grain mass, the content of shells is 4...5%, endosperm is 80...83%. As a rule, the vitreous part of the endosperm occupies the peripheral layer, the central part of the grain consists of mealy endosperm.

The amount of protein in corn grain is about the same as in the grain of other cereal crops, but its biological value is lower due to the lack of lysine. Currently, varieties of corn with a high content of lysine have been bred, and their technological properties are being studied.

For the cereal industry, flint, semi-tooth and dent corn are used, and from flint and semi-tooth corn they produce polished grits and large grits for flakes. Small grits for sticks are produced from grains of dent and semi-dent corn.

Preparation of grain for processing. When preparing grain for processing, it is cleaned of impurities and subjected to hydrothermal treatment (XXVII-29). Regardless of the range of manufactured products, the grain preparation scheme is almost the same, only the modes of hydrothermal treatment are different.

Impurities are isolated in two successively installed air-sieve separators: large - on sieves with holes 0 12 mm; fine-passage sieves with holes.0 5 mm and 2.7x20 mm. Small impurities include underdeveloped, feeble corn grains, broken, corroded. Mineral impurities are isolated in stone-separating machines.

Hydrothermal treatment is carried out to facilitate the separation of the shells and especially the embryo. The embryo is attached to the endosperm with the help of a cementing layer that does not have a cellular structure and consists of protein and pentosans. As a result of moisture, this layer softens and the connection between it and the endosperm weakens. -

The grain is moistened with water at a temperature of about 40 ° C or steamed at a steam pressure of 0.07 ... ... 0.10 MPa for 3 ... 5 minutes. Depending on the range of manufactured products, the final moisture content of the grain is adjusted to 15...16 or 20...22% (when producing large cereals for flakes, when the germ is separated in germ separators).

Bringing the grain to high humidity contributes to less crushability of the kernel, obtaining large parts of the grain. The duration of softening after moisturizing or steaming is 2-3 hours.

Processing of corn into cereals. One of the most important operations in the production of all types of cereals is the removal of the germ. It is separated in germ separators or as a result of grain crushing in roller mills. This operation is necessary, since the presence of an embryo in the croup leads to its rapid deterioration. In addition, the embryo, which contains a large amount of fat, is an excellent raw material for obtaining edible vegetable oil, which contains a lot of unsaturated fatty acids, phospholipids, tocopherols and other biologically active substances. Therefore, the germ must be separated from the grain as completely as possible, and the content of endosperm in the isolated product must be minimal.

Production of polished corn grits. Prepared grain is crushed in special grinders (degerminators). where the embryo also separates (XXVII-30). As a result of hydrothermal treatment, the embryo becomes elastic and separates without significant crushing. Instead of shredders, you can use roller machines with rollers with mutually perpendicular cutting.

Corn is one of the most popular crops. It is boiled, canned, frozen, dried.

In Russia, corn is grown not so long ago, but even now the country can boast of the name of one of the largest exporters and importers of such grain. That's just the quality of raw materials sometimes lame. Indeed, not every landowner has primary equipment for processing raw materials, which allows further processing enterprises to lose almost a third of the volume of purchased corn.

The own organization of the business for processing and growing crops will allow minimizing the risks. Thus, although the business will entail large investments, it will allow minimizing risks and creating a successful business.

Lease of land for growing corn.

It is most favorable to grow a solar crop in the Krasnodar Territory, the Rostov Region, the Stavropol Territory, the Belgorod and Voronezh Regions. After all, the plant is not only thermophilic, but also requires a twelve-hour sunny day. Chernozem is suitable for cultivation.

The best lands for rent are the predecessors of legumes, pumpkin, nightshade. The cost of renting land in different regions can vary significantly and depend on the soil, roads, availability of irrigation, proximity to settlements. So, rent can cost from $25 to $250 per hectare. Plus, it will be necessary to pay for plowing the field separately. This is another $30-50 for each hectare. In total, the rental cost of the season of 5-7 hectares of the field will be estimated at $350 to $4.35 thousand.

Item for grain processing.

The best option for organizing a point is an elevator. Almost every city has one, and the cost of renting it is very low. Such a room most often requires repair and in most cases it must be capital. But, corn processing belongs to the food industry and it is important to create sanitary conditions, fire safety, cleanliness and order.

It is important that the room is subjected to sufficient lighting, ventilation, all communications are present. Renting such an elevator can cost as little as $100, depending on its condition and the further investment required. Additionally, do not forget about monthly utilities. A room of 300-400 square meters will cost the entrepreneur in the amount of $ 800-1 thousand. Moreover, the lion's share of monthly investments will be drawn by utilities.

Equipment.

For growing corn, they buy the following equipment:

1. Corn seeder - from $10,000 to $30,000;
2. Multi-cultivator - about $ 1 thousand;
3. Furrow device - about $1.5 thousand;
4. Spraying machine - $800.

To process corn, you need to buy a batch of the following equipment:

1. Stationary sectional dryer (with a capacity of at least 40 tons of culture per day of work) - from $ 20 thousand;
2. Machine for preliminary cleaning of grain (40-50 tons per hour) - from $10 thousand;
3. Secondary grain cleaning machine (16-20 tons per hour) - from $20,000;
4. Pneumatic separator for cleaning seeds of major crops from hard-to-separate impurities (3-10 tons per hour) - $5-15 thousand;
5. Grain conditioner (3-7 tons per hour) - $5-7 thousand;
6. A device with a fan and a dust removal system - $ 4 thousand.

Equipment for growing corn can also be rented for the season or you can invite personnel with equipment to work in order to save on initial investment. So, the purchase of a full cycle of equipment for creating a business for processing and growing corn will cost $ 97-120 thousand.

Raw material.

To create a silo conveyor system, early-ripening and mid-ripening hybrids are grown, which are sown in two or three terms, according to the principle of 40 to 60, in order to achieve a continuous harvest throughout the season. About 52 thousand plants can grow on one hectare of land. This is 4 grains per linear meter.

In general, 20 kg of seeds are bought for sowing one hectare, the total cost is about $1,000. It is necessary to fertilize the land for planting corn in the fall; for this, superphosphate compost and manure are bought. Potash and nitrogen fertilizers are suitable for spring fertilizer. It is possible to increase corn resistance to drought by using raw materials based on zinc and molybdenum as a microfertilizer. In case of a high probability of weed contamination, the following herbicides are used: Frontier Optima (0.8-1.2 l/ha), Merlin (0.1-0.16 kg/ha), Stomp (3-6 l/ha). In total, at least $10,000 is being prepared for the purchase of all fertilizers and corn seeds themselves.

Staff.

Separately, you will have to recruit staff for the corn growing season. This is a group of 15-20 people, part of the cob pickers and 2-3 drivers for agricultural machinery. One worker can pick about 2.5 thousand cobs per day. Separately, a staff will be created for the corn processing zone. In addition to operators, loaders, handymen, drivers, a quality technologist, an accountant, and an administrator are also needed. In total, about $8,000 will need to be invested to pay workers.

Marketing.

A special business requires publicity in a narrow circle. And it is better to start with the Internet and specialized literature. This is how a website is created in the network and a number of offers are formed on other available resources. An agricultural company may give the right to place an advertisement about its enterprise. Also, meetings and personal agreements will not be superfluous. You can hire sales managers. You can create word of mouth about your company by participating in agricultural exhibitions, seminars, and gatherings.

List of costs.

The main costs of the corn growing and processing business will include:

1. Land rent - $350-4.35 thousand;
2. Rent of premises - 800-1 thousand $;
3. Equipment - 97-120 thousand $;
4. Raw materials - 10 thousand $;
5. Staff - about $8 thousand;
6. Marketing - $400.

In total, to start a business, you need an amount from $120,000 to $130,000.

Profit and payback.

The business of growing and processing corn gives a profitability of 800%. So, when sowing 50 thousand seeds per hectare of the field, about 56 centners of corn and more than 200 centners of green mass are obtained. Accordingly, the income per hectare will be from $20,000. If corn is sown in stages, different types of varieties, then 1 hectare can be obtained three times more. At the end of the season, you can get your hands on about $420,000. Payback will come in the first season.

Consumers and development.

The next stage in the route of processed corn will be the food industry, wholesale depots, livestock and poultry farms. And it is they who need to offer raw materials. An option for development may be the opening of our own complex for the further processing of corn.