Welcome to Maizecor

Manufacturing Process

Cleaning and Conditioning

Firstly, any ferrous items are removed, using powerful magnets. The maize then falls to a grain separator which removes coarse and fine impurities, with the lighter particles being removed utilising an aspiration channel.

Sand, silica and stones are then removed by the de-stoners.

The maize is next fed into an automated moisture control unit. Here, the moisture content of the grain is automatically and continuously determined.

This, coupled together with the close observation of the throughput, allows for the accurate addition of water, to ensure that a constant level of moisture is attained.

Tempering

The conditioned maize is then allowed to stand in the tempering bins for between 6-12 hours primarily dependent on the hardness of the kernel. During this period, the water will penetrate the kernels homogeneously.

The tempered maize is next elevated to the second conditioning and de-germination process.

Secondary Conditioning/ De-germination

Water is added to soften the surface of the kernel to facilitate the removal of the husks.

This separation of the husk takes place in the de-germinators where the maize kernel is broken open and the germ loosened.

Turbo Sifting & Aspiration

Fines generated by the degerminators are removed by turbo sifters and the loosened husks are separated in aspiration channels.

Plansifters

The mixture of de-germed maize and loosened maize germs are pneumatically lifted and graded by size on plansifters.

Concentrators

A coarse separation between the maize germ and the de-germinated maize, takes place in three concentrators. This separation is achieved by exploiting the differing densities of the maize germ and the de-germinated maize.

This separation is essential to ensure low oil contents in products supplied to the food and brewing industries.

Sifting and Grinding

The maize fractions are carefully ground and sifted over a number of passages to ensure the granulation of the maize products adheres to customer specifications.

Purification

Oil contents are further reduced by purification of the maize products. The moisture of the finished products is controlled pneumatically, lifting the products in hot air by the use of thermo pneumatic lifts. On line routine samples are taken and analysed by the millers. Here the miller is looking to ensure that any deviation from optimum specifications is corrected by the appropriate mill adjustments.

Control Sifting

The finished products are passed over control sifters to ensure the removal of oversize or fine materials, prior to the transfer to the finished product bins.

Finished Products

Products A-F as detailed on our products page are then discharged into bulk vehicles, or if required by the customer, packed into 25kg multi-walled paper sacks.

Packaging Line

Finished products to be supplied in sacks are fed onto a fully automated packaging line. Sacks are accurately weighed and filled at a rate of 600 sacks per hour. Each sack is coded with date of manufacture, use by date, sequential tally number and product code if required, prior to metal detection of the filled sacks.

The sacks are then automatically palletised and wrapped in plastic, prior to storage in the warehouse.

View Flash movie of the process (opens in new window)