REPORT ON STUDENT INDUSTRIAL WORK EXPERIENCE

SCHEME (SIWES)

AT

MAIDUGURI FLOUR MILLS LIMITED (MFM), BURSARI ROAD, P.M.B. 1117,

MAIDUGURI, BORNO STATE

BY

MUSTAPHA MUHAMMAD KABIR

15/05/02/042

BEING A REPORT SUBMITTED TO THE DEPARTMENT OF CHEMICAL

ENGINEERING, UNIVERSITY OF MAIDUGURI

IN PARTIAL FULFILMENT OF THE REQUIREMENTS FOR THE COURSE,

CHE490: STUDENT INDUSTRIAL WORK EXPERIENCE SCHEME

2019

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 DECLARATION
I hereby declare that this report was written by me from my experience in the
organizations as industrial training (I.T) student

……………………. …………………….

SIGN DATE

i
 DEDICATION
I dedicate this project to my lovely parents Alh. Kabir Mustapha and Yagana Kingi for
they are the reason why I am the person I am today.

Am thankful for their continuous love and encouragement.

ii
 CERTIFICATION
This SIWES report has been read and approved by The Department of Chemical
Engineering, University of Maiduguri as meeting the requirement of the course CHE 490

………………………….. …………………………

ENGR. IBRAHIM M. IDRISS DATE

(CO-ORDINATOR)

………………………….. …………………………

ENGR. DR ABDU ZUBAIRU DATE

(HEAD OF DEPARTMENT)

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 ACKNOWLEDGEMENT

First and foremost, I wish to express my thanks and sincere gratitude to Almighty Allah
(S.W.T). May the blessing of Allah be on the prophet Muhammad ‫ﷺ‬, his family and all those

who follow him on the right path. Again, I thank my family for their love and support throughout
my life. My lovely siblings, Hajja Hafsah, Amina and Jafar deserve my wholehearted thanks as
well.

I heartily thank my coordinator and supervisor Engr. Ibrahim Maina, of The Department
of Chemical Engineering, I am indeed grateful for the support you gave me throughout this
SIWES training and the entire session. I would also like to thank my HOD Engr. Dr. Abdu
Zubairu, My able lecturers, all members of staff of Chemical Engineering department for their
moral and academic support.

I will also like to show my gratitude to my amazing friends Abdulmalik M Isah,

Abdullateef M Goni and Salahudeen Abdullateef for guiding me in many ways. I am most
grateful to you all for your support.

Lastly, I consider it a humble duty to express my deepest gratitude to Mal Umar, Quality
Control Laboratory Technician, Maiduguri Flour Mills L.T.D, for sharing pearls of wisdom with
me during the course of my training in the company.

God bless you all.

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Contents
DECLARATION..............................................................................................................................i

DEDICATION................................................................................................................................ii

CERTIFICATION..........................................................................................................................iii

ACKNOWLEDGEMENT..............................................................................................................iv

CHAPTER ONE..............................................................................................................................1

1.0 INTRODUCTION 1

1.1 AIMS AND OBJECTIVES OF SIWES 1

1.3 CONTRIBUTION OF THE SCHEME 2

1.4 FACTORS AFFECTING THE SCHEME 2

1.5 SCOPE OF REPORT 2

CHAPTER TWO.............................................................................................................................3

2.0 3

CHAPTER THREE.........................................................................................................................4

3.0 ACTIVITIES AT MAIDUGURI FLOUR MILLS 4

3.1.1 THE PRODUCTION UNIT 4

3.1.2 WEIGHBRIDGE 4

3.1.3 HEAD HOUSE 4

3.1.4 MILLING SECTION 5

CLEANING HOUSE: 5

AIR LOCK FLOOR: 6

SIFTER FLOOR: 6

SPOUT FLOOR: 6

ROLLER FLOOR: 6

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 BASEMENT 6

3.1.5 PACKAGING UNIT 6

3.1.6 QUALITY CONTROL (LABORATORY SECTION) 6

3.2 LABORATORY ANALYSIS, PROCEDURES AND DISCUSSIONS 7

3.2.1 MOISTURE ANALYSIS 7

PROCEDURE FOR MOISTURE CONTENT DETERMINATION 8

3.2.2 ASH ANALYSIS 8

PROCEDURE FOR ASH CONTENT DETERMINATION 8

3.2.3 MALTOSE ANALYSIS 9

3.2.4 SIEVE ANALYSIS 9

3.2.5 SPOT TEST OR PEKER TEST 9

3.2.6 VISUAL AND WEIGHT ANALYSIS OF RAW MATERIAL 9

CHAPTER FOUR.........................................................................................................................10

4.0 SKILLS ACQUIRED AT MAIDUGURI FLOUR MILLS 10

4.1 CLEANING AND TEMPERING 10

4.2 MILLING 12

BREAK SYSTEM 13

PURIFICATION SYSTEM 13

GRINDING AND SIFTING 14

REDUCTION SYSTEM: 14

SCRATCH SYSTEM: 14

4.2.1 EQUIPMENTS USED DURING MILLING OPERATION 14

ROLLER MILLS 14

SIFTERS 15

ROTARY AIR-LOCK 16

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 GRANUSTER (SEPARATOR): 16

CONVEYORS 17

ELEVATORS 18

ASPIRATOR: 19

DE-STONER 19

METRIC SCALE: 20

SCOURER 21

MAGNETIC SEPARETOR 21

PURIFIER 21

BLOWER 22

COMPRESSOR 23

4.3 QUALITY CONTROL 24

4.4 PACKAGING AND STORAGE 24

THE PROCESS OF PACKING FLOUR 25

STORAGE 26

CHAPTER FIVE...........................................................................................................................27

5.0 PROBLEMS ENCOUNTERED AT MFM 27

CHAPTER SIX..............................................................................................................................28

6.1 CONCLUSION 28

6.2 RECOMMENDATION 28

REFERENCES..............................................................................................................................29

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viii
 CHAPTER ONE

1.0 INTRODUCTION
With the dearth of practical skills in students of Engineering and other Technical courses
in our tertiary institutions, the federal government decided through the Industrial Training Fund
(ITF) to set up the Students Industrial Work Scheme (S.I.W.E.S) in 1971 to address this problem.
It aimed at producing graduates with knowledge of both theory and practical skills. It was to this
effect that the SIWES was introduced.

The Student Industrial Work Experience Scheme (SIWES) was established by Industrial
Training Fund (ITF) in 1973 by the Federal Government under the decree 47 of 1971; the
SIWES program is implemented into the Nigerian educational sector so as to solve the problem
of lack of adequate practical skills preparatory for employment in industries by Nigerian
graduates of tertiary institutions. It is an appreciable skill training program which forms part of
the minimum academic standard in Nigerian Universities, the scheme is a participatory program
involving Universities, Polytechnics, and Technical Colleges’ students of various institutions in
Nigeria.

1.1 AIMS AND OBJECTIVES OF SIWES

i. Provide an avenue for students in Nigerian Universities to acquire industrial skills and
experience in their course of study.

ii. Prepare students for work situation they are likely to meet after graduation.

iii. Provide students with an opportunity to apply their theoretical knowledge in real
work situation thereby bridging the gap between theory and actual practice.

iv. Make the transition from school to the world of work easier, and enhance student’s
contacts for later job placement.

v. Enlist and strengthen employers’ involvement in the entire educational process and
prepare students for employment in industry and commerce.

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 vi. Strengthen the relationship between educational institutions and industrial sectors.

1.3 CONTRIBUTION OF THE SCHEME

Below is a brief summary of some of the contribution of the scheme and are as follows;

 Establishment of a closer bond between the industries and the institutions there by
improving the quality of skilled manpower in Nigeria.
 Creation of opportunity for the students to interact with workers of various facets, and
level of the industry.

1.4 FACTORS AFFECTING THE SCHEME

There are lots of issues which have created setbacks on SIWES and encumbered the growth
of the scheme. Some of these issues are;

1. Industrial Training allowances are not given to the students during the programme. And if
given, it would not be enough to solve the immediate needs (e.g. transportation, feeding
and accommodation)
2. Like warm of employers of firms, the students in some cases such as impacting
knowledge with reservations for fear of competition by students.
3. Difficulty encountered by students in getting attached to a company as a result of
financial implication.

4. Special medical care is not provided for the students during their industrial training.

5. Accommodation is not given to the students during their industrial training

1.5 SCOPE OF REPORT

This report entitles student industrial work experience scheme/ industrial training carried
out at Maiduguri flour mills (MFM).

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 CHAPTER TWO

2.0 MAIDUGURI FLOUR MILLS LIMITED (MFM)

The Maiduguri Flour Mills was first mooted in the second half of the year 1977 by the Borno
State Government in collaboration with the Federal Ministry of Industries with the objective of
utilizing the wheat produced at the Lake Chad Basin. In 1978, the first meeting was held to
consider the proposal for the formation of the company by the Borno State government in
conjunction with Chad Basin Development and the pioneer of flour milling industries in Nigeria.
The company was eventually registered in 1979 and the foundation stone was laid by Alhaji
Mohammed Goni who was then the governor of Borno State.

The official Commissioning ceremony took place on 31st May 1983.Full scale Milling
commenced immediately at the capacity of 400tonnes of wheat per day producing Flour,
Semovita and wheat offal. Management of the company was vested in Flour Mills of Nigeria
L.T.D having the largest share introduced their brand name of “Golden Penny Product” under
which the products of the company were marketed.

The organization chart composed of the General Manager (GM) as the head of the
organization, Assistant General Manager (AGM) and several Managers which include: the
Personnel Manager; Production Manager; Maintenance (Electrical and Mechanical) Manager;
and Warehouse Manager. The company staff strength numbered 149 employers with 97
Professional and 52 unprofessional employees respectively.

The production department where I was attached comprises of the following sections.

a. Head house

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b. Mill building

c. Cleaning section

c. Packing/warehouse

e. Laboratory unit

f. Electrical unit

g. Power plant

h. Mechanical unit

CHAPTER THREE

3.0 ACTIVITIES AT MAIDUGURI FLOUR MILLS

The operational activities carried out at the Maiduguri flour mills is mainly the processing
of raw maize into three products which are:

 Masaflour

 Masavita

 Maize offal

These products are achieved as a result of individual operation from each unit of the mill
which are as follows:

3.1.1 THE PRODUCTION UNIT

The processing of raw maize into the desired product (Masavita, Masa flour, Maize grid and
maize offal’s) at the Maiduguri Flour Mills involves a number of unit operations with the major
ones being separation, particle size reduction and transportation. The process starts from the
Head house unit and ends at the packaging unit.

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3.1.2 WEIGHBRIDGE

The weighbridge is located at the entrance of the industry where loaded trucks use. The maize is
received on the weighbridge, the grains and the weight of the vehicle is weighted. The vehicle
then goes to the head house to empty its contents and the vehicle alone is re- weighed again to
know the Quantity of maize received, it is then recorded by the weighbridge Clerk. The quantity
of grain received is communicated to the head house.

3.1.3 HEAD HOUSE

The Head house is the section of the factory where raw maize is received (intake) from delivery
trucks, pre-cleaned and stored in silos before later transferred to the milling building for further
processing.

Operations carried out at Head House are mainly intake, pre-cleaning, storage and transfer.
These operations are aided by the use of some machines and mechanical devices. These include:

 The dump bridge

 Conveyor
 Elevator
 Metric scale (for Intake and Transfer);
 Drum-Sieves
 Filters and silos

A typical Intake process commences as Maize is dumped at the dump-bridge from

delivery trucks, the dump-bridge has a receiving hopper which direct raw maize to the bottom of
the dump-bridge where a chain conveyor is used to transport the maize to elevator. The elevator
lifts the maize up and discharges it into the drum-sieve. The drum-sieve separates maize from
other large foreign matter such as metal, stones, polythene bags etc. From the drum-sieves the
grain is then elevated to the Aspirators which are four in numbers. The function of the Aspirator
is to separate light weight particles from grain products such as dust, maize bran etc. From the
aspirators, the maize is then discharge into the intake scale which measure 500Kg of maize per
tip each of its automated running, an average of three tips which equals 1500kg of maize per
minute is recorded. That is between (18-20) seconds per each tip. The weighted maize is then
channel by gravity through conveyor pipeline to elevator2 or 3, any direction (2 or 3) may be
choose at a particular time. The elevator 2 or 3 again lifts the maize and discharge it at the entry
point (inlet) of the chain conveyor2 or 3 (chosen with respect to the elevator line working)
forward transfer into silos. There are total of six silos at the Head House for raw maize storage,
each with a capacity of 1000 metric tons.

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 The impurities separated at the drum-sieves are again subjected to further separation
process whereby screens mainly chaff; dust and dead maize are removed and are collected
separately through the screen outlet for bagging.

The pre-cleaning process is further assisted by air-pressure (pneumatic) to remove dust in filters
when charged by blasting. The intake process continues until maize is completely received in
silos and dirty screens are also collected separately.

However, the processes mentioned above for the intake of maize into the silos at the
initial stage are also involved in the Transfer process. The transfer process is an extension of the
intake process, whereby the transfer scale is used to measure maize of 500kg per each tip and is
discharged into the transfer conveyor for transfer to the Mill Building to be store in bins which
are also six in number.

3.1.4 MILLING SECTION

The milling section is an important section in the flour mill industry because the section
involves processes which removes the bran layer from the endosperm and reduces the endosperm
to flour. Its main objective is the processing of maize by grinding (size reduction) using
mechanical rollers (milling machine) for the extraction flour, masavita, masa flour and maize
offal’s.

After the maize has undergone pre-cleaning process at the head-house, cleaning, tempering,
milling (size reduction) and packaging all are done within the mill building, the quality control
section (laboratory) which is also an extension of the mill building ensures that best quality
required is produced.

The milling house comprises of six different floors and each floor has a distinct role in the
processing maize to its final products. Below are the several floors which make up the mill
building in descending order (i.e. from the last floor to the ground floor);

CLEANING HOUSE: The cleaning house which is the sixth floor of the mill building is where
the final cleaning process takes place after the pre-cleaning at the head house and the tempering
(addition of water) of maize is done. Tempering is done in other to soften the grain and prevent
the shattering of endosperm and subsequent loss of the endosperm during breaking. It makes the
milling much easier.

FILTER HOUSE: This is an extension of the cleaning house, where large air-filter tanks and
other maize cleaning machines and devices are operated, to clean the air pneumatic operation.

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AIR LOCK FLOOR: The air lock is immediately above the sifter floor, it is responsible for the
separation (lock) of air off product discharged from the rollers and conveyed by pneumatic
system in a conveyor pipe, the air lock mechanism separate air from the product and channel it
free falling under gravity to the sifters.

SIFTER FLOOR: As its name implies, this floor has different types of mechanical sifters
installed for the separation of the processed maize, hence the collection of masa flour and
masavita are also trapped from the purifiers.

SPOUT FLOOR: The spout floor has interconnected network of conveyor pipes which are used
to convey products (truce and over tail) under gravity from the sifters to either the packing bins
(flour, masavita and bran) or back to the reducing rolls for further breaks and further extraction
of flour.

ROLLER FLOOR: This floor consists of mainly rollers (first break and reducing rolls) which
are used in the milling of maize. Other machines, installed on this floor includes: the flour, bran,
masavita and screen scales respectively. The control panel room is also on this floor.

BASEMENT: The basement (underground floor) serve as the engine room where several electric
motor and power transmission, mechanical devices are installed. From the basement, power is
transmitted via systems of belts and pulleys, chain and sprocket to the rollers. Screw conveyor
which received maize discharge from bins (raw maize bins and conditioning bins) is also
installed here. The elevator runs from the last floor and ends at the basement. Several conveyor
pipes are also accommodated here which are used to transport product (against gravity due to
suction effect of air- pressure) discharge from the rollers.

3.1.5 PACKAGING UNIT

The packaging unit is the last part of the production process. During the production
process at the milling section, the finished products (masa flour, masavita, and bran offal’s) are
transferred to their respective storage bins in the packaging unit. Each product has two metric
scale, a 50kg per tip scale and a 10kg per tip scale. The products stored in the storage bin are

7
collected into these scales and are bagged, sewed and transferred by gravity slides to the
warehouse.

3.1.6 QUALITY CONTROL (LABORATORY SECTION)

The quality control unit although an integral part of the production unit is not located
within the milling house but rather the administrative block. This is to provide a very conducive
and safe environment to allow and ensure efficient and reliable analysis. Quality control
department operate to ensure the quality of product meets the required standard. The Laboratory
is the focal point of the quality control unit.

The activities conducted at the quality control section include laboratory test on maize
before, during and after processing.

3.2 LABORATORY ANALYSIS, PROCEDURES AND DISCUSSIONS

Quality control department operate to ensure the quality of products are at the required
standard. Another responsibility of the quality control section is the addition of additives to
improve flour quality. The quantity of additive to be added to flour is usually given in milligram
per each kilogram. It is advice that maltose level should not exceed 350ml/g as it affects the
baking quality of flour.

The quality control also checks for insect infestation in flour and other products such as
the masavita and maize offal’s. The major insect which attack maize and maize products is
weevil and their eggs. Eggs are destroyed primarily during production process at the entoleter
machine. The entoleter is designed to destroyed weevil, their eggs and other insect which
survived the operations at the different stage of production such as the rollers process and sifting
process. It consists of a high speed rotating blade which continuously beat the flour as it passes
through it.

When insect is noticed in flour at the final stage of production (this hardly occur), the
product is again returned for a repeated process particularly at the sifter and entoleter.

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 Below is the analysis carried out by the quality control unit to achieve the o
aforementioned objectives.

3.2.1 MOISTURE ANALYSIS

Determination of the moisture level of the raw material, maize and the finished products
maize flour, as well as that of maize grits is very vital for quality control and it is expressed in
percentage. Ensuring the moisture of the two stated above due not fall out of standard maximum
moisture of 10.00% for the maize grits ad 12.50% for maize flour. This information from
moisture analysis helps the millers to know the right quantity of water to be added to the raw
material during tempering to achieve the required moisture level. It also helps in making milling
process easy and the extraction done efficiently.

Profit maximization is achieved when moisture analysis is performed adequately and

standard are implemented in all production process. Therefore, outmost importance must be
given to this analysis and professional most be hired to conduct it. Moisture analysis apparatus
should be upgraded regularly to avoid error in result.

PROCEDURE FOR MOISTURE CONTENT DETERMINATION

1. A clear standard crucible dish is weighted and its weight recorded as W1

2. 10g of the sample is added to the dish and their weight recorded as W2.

3. The sample is then placed in an electronic oven at temperature of 150℃ for 30minutes.

4. Sample is removed, placed into a desiccator to cool and weighted as W3

loss∈weight W 2−W 3
Moisture% = ×100= ×100
weight of sample W 2−W 1

WHERE:

W1= Initial weight of empty crucible

W2 = Weight of crucible + weight of sample before drying.

W3 = Weight of sample + weight of crucible after drying.

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3.2.2 ASH ANALYSIS

This is an index of the extraction rate, to determine the percentage of inorganic matters
present in a sample. It also helps in determining the correct color of a product. The maximum
physiochemical requirement percentage of ash in maize flour (Masa flour) is 0.70% and that of
grits (Masavita) is 0.75.

PROCEDURE FOR ASH CONTENT DETERMINATION

Ash can be said to be the part of a sample which remain after combustion at a set
temperature of not less than 600oC for six hours.

1. 5grams of flour sample is weight and put in a standard crucible.

2. The crucible is then placed in a muffle furnace after the furnace is allowed to attain the
temperature of 600oC.

3. The sample is left in the furnace for atlases six (6) hours or allowed to stay overnight.

4. The sample is them removed and allowed to cool in desiccators.

5. The sample is reweight and the weight is then recorded

A−D
Ash% = ×100
S−D

Where:

A = Weight of dish + ash residue

S= Weight of dish + weight of sample

D = Weight of dish

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3.2.3 MALTOSE ANALYSIS

Determined the activities of the natural enzymes present in a sample, maltose analysis
help to know the sprouting level of a raw material and also to know whether the natural enzymes
are active or not, a standard maltose is measured in mg/10g which start from 250 – 334 mg/10kg.

3.2.4 SIEVE ANALYSIS

This test is carried out to analyze milling efficiency, four extraction rate, and the amount
of bran particles present in the flour. This analysis is very important to the milling house because
it determines the efficiency of the entire mill especially the roller mills. Sieve analysis is done
once daily to ensure effective milling. Sieve analysis is the basic analysis conducted since time
millennium; traditionally people perform sieve analysis to know quantity of maize and process of
separating the maize grain from other impurities. So often there for rural communities engage in
sieving before grinding to remove impurities.

3.2.5 SPOT TEST OR PEKER TEST

This test is done to determine the presence of ascorbic acid in the flour and to visually
asses the color index of a product. It also helps to visually assess whether some unwanted
particles have managed to escape into the product.

3.2.6 VISUAL AND WEIGHT ANALYSIS OF RAW MATERIAL

This is a test conducted on raw materials to determine whether the raw material is up to
the required standard in terms of physical features e.g. Grain size, color, impurities etc. When
grain is bought they are physically analyzing visually to see its features and quantity of
impurities in it, they are also weight in samples to check the standard content of the raw
materials.

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 CHAPTER FOUR

4.0 SKILLS ACQUIRED AT MAIDUGURI FLOUR MILLS

Generally, the operations which made up the production process can be classified into
three. These include:

1. Cleaning and Tempering (PARTICLES SEPERATION)

2. Milling (SIZE REDUCTION)
3. Quality control
4. Packaging and Storage

4.1 CLEANING AND TEMPERING

The cleaning section plays a major role in the cleaning of maize such that when there is a
break down at any stage of its operation, the production process is impaired. The importance of
the cleaning section is obvious, that is the cleaning of maize as well as tempering by the addition
of water. Pre-cleaned maize from Silo are transported to the Cleaning section and subjected to

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further cleaning using several machines: granuster (separator), de -stoner, magnetic plate,
scourer, elevators and conveyor. The raw maize bin (1-6) within the Mill building each with a
capacity of 124 metric tons each serve as a temporary storage for the pre-cleaned and
unconditioned maize while the conditioning bin (7-12) each with a capacity of 114 metric tons
are used for temporary storage of tempered maize and all these bins are constructed of concrete.

Raw maize discharged, from the raw maize bin (1-6) are collected in the screw conveyor
and passes through the flow balancer. The flow balancer (Mechanical device) attached to the
screw conveyor, regulates the flow of maize discharged from the bins to avoid chocking, it then
transfers the maize to the elevator 1 which lifts the maize into the metric scale which measures
the quantity of maize per trip. Each trip is 100 kg and it is then discharged by gravity through
conveyor pipe to granuster (separator) which separates relatively larger particles with respect to
maize size by throwing it off the mesh. As the granuster oscillates, relatively smaller particles
with respect to maize size are sieved through the top and middle layers respectively. While
particles of maize size only are trapped and collected at the middle layer and are conveyed to the
aspirator. The granuster can simply be described as a machine with three layers of mesh inclined
horizontally within a metal panel with an opening at the top to receive maize.

During operation, it oscillates (to-from) about a fixed axis thereby throwing off particles
trapped on the top of the mesh. The granuster is powered by an electric motor, which transmit
power through a belt and pulley system. Maize channeled through the aspirator are subjected to
suction effect which remove relatively lighter particles from the maize before it is then conveyed
to another machine called de-stoner.

The de-stoner also a mesh with openings smaller than the maize size and inclined
horizontally, but rather than to and fro, it vibrates up and down causing relatively heavier
particles such as stones to moves backward progressively until it falls off the mesh to be
collected through an outlet inclined, higher end side of the mesh while relatively smaller
particles mainly maize are collected on the lower end side through another outlet point. The
maize is again passed through the aspirator and after this stage it is assumed clean free of other
foreign matter.

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 The scourer machine is used to polish the maize to remove any sticking dirty and hairy
layers on the maize before and after the maize has undergone conditioning. The scourer can be
described as a wire mesh weaved into an opened ended cylindrical shaped which is rough from
its interior side, the mesh is fixed at both ends to a circular plate transmitting power which
rotates the mesh and also serving as a cover with single inlet and outlet point. Maize are
introduced into the mesh from one end to exit from the other end after it has been scrubbed, the
whole system is assembled within a rectangular shaped metal box and is powered by an electric
motor transmitted through a system of belt conveyor pipe to elevator 2, from which it is lifted
and discharged into the dampener.

The dampener is a machine or mechanical device, which facilitate the proper mixing of
water added to the maize for conditioning. The dampener also operate like the screw conveyor
but it is relatively bigger than the screw conveyor, instead of a continuous thread-like metal
formed around the rotating shaft, it has a slightly twisted metal bars fixed at interval on rotating
shaft, the dampener has only one opening for maize inlet attached with a flow balancer to
harmonize the rate of maize flow into the dampener and a single exit point for maize out of the
dampener, where the tempered maize is then conveyed to the conditioning bin (7-12).

As the harmonized maize flow continuously into the dampener, a water metering device
released stream of water into the dampener to moist the maize and after mixing by the action of
screw conveyor, the maize is conveyed to the conditioning bin (7-12) where it is left for the
period of 12 to 24 hours as the length of conditioning. A well-conditioned maize is expected to
have a toughened outer layer and soften endosperm which aid in the success of the milling
process, that is the bran will be easily separated off and not mill with the endosperm which will
result in more ash content in flour. Consequently, this affects the standard extraction rate and
quality of flour.

The relationship used to determine the quantity of water to maize is given by

M −n
W=
100−m× c × 100 ¿
¿

Where:

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W=Total volume of water needed for conditioning;

M=Moisture content required before milling;

m =initial moisture content of raw maize

C= Running capacity of maize (adjusted using the flow balancer)

4.2 MILLING

After conditioning the maize, it is expected to have a toughened outer-layer and a soften
endosperm, this is to facilitate an easy separation of the endosperm from the bran layer during
milling.

Milling process commences when tempered maize from the conditioning bin is
introduced to the rollers. From the conditioning bins, clean maize flow through the flow balancer
attached to the screw conveyor channel to elevator 3 or 4 then lifted to scourer then Aspirator
and then to the First break bin. The First break bin discharge maize into the maize scale (milling
scale) from where it passes through a magneto in order to trapped any ferrous metal, finally into
the first break roller (B1).

The roller type milling machine used at any particular stage in the break system varies,
for size reduction a fluted surface roller is used to simply break the maize into half. Fluted rollers
also varies from one another according to the size of the groove of the roller surface, deep
grooved rollers are used for initial break and loosing flour out of the bran layer (separation)
while the shallow grooved roller are mainly used as reducing rolls and small roller are used to
reduce the endosperm layer to finer size. Smooth surface rollers are used for finishing (grinding)
into flour while fluted surface rollers are used for breaks and purification. The grinding rolls
contribute only to the automation of the mill; the aspiratory rolls (also known as reducing roll)
engaged and disengage automatically in response to the increasing flow of stock. The rolls are
prevented against excessive wear; since they are always disengaging when running empty.

The milling process can be classified into five systems; these include:

15
  Break System
 Purification
 Grinding and sifting
 Reduction System
 Scratch System

BREAK SYSTEM

These are various degree of break system in the milling process, the first break include
B1; B2; B3; and B4 used mainly for size reduction while the reducing breaks ranges from M1 to
M9, with M1 having higher flour extraction rate compared to M9, other break system are 3BK
and 7BK, each are used to achieved different result. The latter is a large break system used when
enough Masavita is required. The objective of the break system is to scrape progressively the
endosperm from the bran.

PURIFICATION SYSTEM

Product discharged from the rollers are conveyed to the airlock floor by suction air in
conveyor pipe line, the airlock machine separates air from product by locking the air within the
cyclone and is released through another conveyor pipe to the air filter. The product thus, falls
under gravity into sifters which subject it (product) to different sizing and finally flour is
extracted or collected as the truce. The over tail from each sifter are again directed back into the
rollers for purification.

Dust (flour trapped in air) which escape the airlock mechanism are channel to the filter
where flour is again trapped and collected as screens. Cleaned air is released to the atmosphere.
The centrifugal sifter is also used for sieving of very fine flour.

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GRINDING AND SIFTING

Grinding rolls consists of M1 to M9; effective grinding is achieved by the careful

adjustment of the rolls using the lateral or side adjustment lever, by intuition, which is testing for
fines between the finger effective grinding, is achieved. When optimum condition of roller
operation is reached, extraction rate of flour is expected to be 75%.

REDUCTION SYSTEM:

The reduction system refers to the operation of the reduction rolls which has relatively
smoother surface finish. Product discharged from the breaks are conveyed to the sifter then the
over tail is returned to the reducing roll. The reducing rolls constituted the 3BK; 7BK; and M1 to
M9.

The reducing rolls further grind the product until flour extraction is satisfied. Thus, the
remains are channel to pass through all series of roll and finally it is discharged into the scratch
roll for purification.

SCRATCH SYSTEM:

The scratch system consists of rollers with relatively large groove of fluted rolls. They
are used mainly as purification roll and are arranged in a sequential manner such that product are
made to pass through the entire scratch roll. The scratch system signifies the end of the milling
process where flour can be extracted and the after sieving are collected as maize offal’s (bran).

4.2.1 EQUIPMENTS USED DURING MILLING OPERATION

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ROLLER MILLS

Rollers are machines used within the milling section for particle size reduction. It is used
in grinding feeds in to different sizes depending on the type of product desired. The rollers are of
different types. We have the crushing roller which crushes the maize grain and separates bran,
endosperm and some flour and the reducing rollers which are the finest rollers that reduces the
sizes of the grain to its finest product.

Figure 4.0: Roller mill

SIFTERS

Plan sifters are used for classifying the grinded products. Products, which enter from
passage top inlet to finish through six outlets, move along case length and passage height. Sieved
and separated materials are directed to outlet through thirty six channels. Sifter circular
movement is supplied by means of centrifugal force. Sieving is achieved by this circular
movement.

Sifters are used for high capacity sieving and designed according to their sieving
capacities. Different types and heights of sieve case and space laths are used in the plan sifters.
Sieve bottom and top ways (channels) could be adjusted any time.

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 Figure 4.1: Plan sifters

ROTARY AIR-LOCK

Rotary air locks are primarily used for discharge of bulk solid materials from
hoppers/bins, receivers, and cyclones into a pressure or vacuum-driven pneumatic conveying
system. Rotary airlocks separate air from the product needed to be conveyed, which is
discharged from a cyclone separator into pneumatic systems. They are installed underneath the
cyclone separators and filters. They work with the negative pressure as well as an air seal against
leakage.

Figure 4.3: Diagram of rotary airlock

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GRANUSTER (SEPARATOR):

This machine is preliminarily used for grain cleaning in the milling, as well as storage
elevators. It separates coarse and fine impurities from grain via screening and classifies a broad
range of materials according to size.

With two sieve-decks, the separator classifier removes coarse impurities like large kernels,
string, straw, wood, stones, as well as sand and breakage from the grain. In this way, it provides
efficient grain cleaning. In order to optimize the cleaning effect, air recycling aspirator is
employed along, through which low-density particles such as dust, full fragments or husks can
also be separated. A Broad range of materials according to size are separated by the granuster.

Figure 4.4: Diagram of a Granuster separator

CONVEYORS

The conveyor is used to transport (transfer) product from one point to another along a horizontal
surface. There are three types of conveyors used within the factory namely: screw conveyor;
chain conveyor and belt conveyor.

CHAIN CONVEYOR: The Chain conveyor is the only type used within the Head house. The
intake conveyor is located below the dump bridge it forms the integral part of the dump bridge,
while the transfer conveyor is located at height just above the Silos or raw maize bins in the Mill
building. The chain conveyor comprises of the assembly of chain like metal-links attached with
a dragline and supported on a rail track. An electric motor transmits power to the system of chain
and sprocket assembly for its circulatory motion about a fixed axis. At inlet point of conveyor,

20
maize is subjected to a continuous dragging effect along the direction of travel of the chain until
it reaches the discharge point

Figure 4.5: chain conveyor

SCREW CONVEYOR: A screw conveyor or auger conveyor is a mechanism that uses a rotating
helical screw blade, usually within a tube, to move liquid or granular materials. Screw conveyors
usually consist of a trough or tube containing either a spiral blade coiled around a shaft, driven at
one end and held at the other, or a shaft -less spiral, driven at one end and free at the other. The
rate of volume of transfer is proportional to the rotation of the shaft. Screw conveyors are very
cost effective and require minimal maintenance to operate.

Figure 4.6: Diagram of screw conveyor

Belt conveyor: a conveyor belt is the carrying medium of a belt conveyor system. The system
consists of two or more pulleys, with an endless loop of carrying medium-the conveyor belt -that
rotates about them. One or both pulleys are powered, moving the belt and the material on the belt

21
forward. The powered pulley is called the drive pulley while the unpowered pulley is called the
idler pulley. The belt conveyors used at the industry are general material handling pulley
conveyors.

ELEVATORS

It is a conveying system for carrying bulk materials in a vertical or inclined path. Bucket
elevators used for the mechanical, vertical transportations of materials have become a crucial
link in the production process in many industrial sectors. Typical elevator consists of: an endless
belt, a chain or chains to which buckets are attached, necessary loading and discharging terminal
machinery, drive arrangement, supporting frame or casing. Material is fed into an inlet hopper;
buckets or cups dig into the material, and convey it up over the head sprocket, then throwing the
material out the discharge throat.

Figure 4.7: elevator

ASPIRATOR:

Aspirators are designed to produce suction pressure (negative air flow) which sucks (lift)
relatively lighter particles with respect to wheat. The lighter particles lifted include: screens,
dead wheat and dust.

Aspirator consist of an opened sided panel made from metal and covered with glass, which also
serves as observatory, to observe the rise of screens suck out from wheat. The panel is installed
erect on its end, wheat in-flow enters through the lower part of the panel and suction pressure

22
introduced from the upper end, consequently sucks out other particles (foreign matter) from the
maize as it is channel away. The particles are directed into the airlock to separate air from
product and air is directed to the air-filter which trapped the dust leaving cleaned air to escape to
the atmosphere.

Figure 4.8: Air aspirator

DE-STONER

De-stoner is a machine used to separate stones from the maize grain during processing. It
utilizes the characteristics of some impurities that are of lighter specific gravity than that of the
maize grain. It consists of a vibrating unit. The whole structure is inclined such that there are side
slopes. During the vibration of the structure, the feed is spread out with maize grains sliding
down to the sloppy side of the structure with the aid of an air current. Other impurities mostly
stones which are not affected by the air current are collected at the other end of the machine.

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Figure 4.9: De-stoner

METRIC SCALE:

The metric scale measure and record full weight of 500kg for each tip of maize using the
analogue system of measurement. The component which make up the integral part of the unit
are, the basin (hardened plastic box), electromotive sensor, weighted system balance, analogue
metering device and dial gauge which displays the maize measured. The electromotive sensor
sends 29 signal to the shutter or close lid which opens to allow maize fall under gravity into the
basin and when the basin is of full weight measure, a signal is again sent to the terminal to stop
maize flow by closing the shutter and the basin tip-off its content as signal tip.

Figure 4.10: Metric scale

SCOURER

These are machines that eliminate the dust, bran, and other particles attached on the
kernel from the kernels. During the scouring process, the grain is intensively rubbed and pressed
between the screen and itself by using a horizontal motor. In the meantime, the following
processes occur because of intense friction is generated; The grain is pressed and rubbed against
each other. The grain is pressed and rubbed by rotor -fitted wings. The grain is rubbed by an
abrasive screen.

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Figure 4.11: Scourer

MAGNETIC SEPARETOR

They are employed for the removal of metal particles, e.g. nails, wire and screws, etc.
They are applied in the cleaning house. During operation, the material stream is distributed
evenly over the entire width of the separator and flows over a permanent magnet with a high
magnetizing force. This allows for optical removal of all metal particles at high throughout
capacities.

PURIFIER

These machines are widely applied in modern flourmills for high quality flour. They comprise
two independent sieve-decks, each with three ranges of double superimposed sieves. The two
sieve-decks are based on four rubber spring shrubby on the steel frame and vibrated by two
vibration motors which are installed in the machines. Independent aspiration is connected on top
of the device. The mix flows into sieve-decks and it is indexed by the interaction of vibration and
suction. The types of materials then are separated to pure endosperm semolina, endosperm with
bran fraction, pure bran fraction after which it is delivered to different next passages.

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Figure 4.11: purifier

BLOWER

The Blower can simply be described as a mechanical device (high speed fan) which directs
streams of air through a pipe network at a very high pressure. It is used to transport products
from one place to another. The major components which make up the blower are: the fan blade
(made from lighter material such as aluminum) and electric motor which provide power for the
high speed rotation of the fan blade. During operation the design of the chain reached the
discharge point (outlet), attached to the dragline at interval is leather (sweeper) which provide
the clearing action to sweep off the remaining maize out of the conveyor box or metal casing.
Fan blade (bringing out produced spray of air forward which are directed through conveyor pipe
network for pneumatic operation).

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 Figure 4.12: Blower

COMPRESSOR:

The compressor is used to pump stream-jet of air at a very high pressure required to work
some of the machines and mechanical devices used in the production process. The main
component which makes up the compressor machine include: the engine system (piston-cylinder
or rotary type), reservoir (tank), safety valve and unloaded valve. Atmospheric air drawn by the
compressor engine via the air filter from the atmospheric are subjected to the compression which
increased the air pressure as it is stored temporarily in the reservoir and then discharges it
through a hose or pipe network at a much higher pressure as it required. The reservoir also helps
in the compression of air as it prevent the compressed of air from escaping when the loader value
and safety value are still engage. A pressure gauge dial indicate the pressure of the air
compressed, interconnected pipes or hose are used to direct the air to the point of usage. The
compressor engine is itself driven by an electric motor and power is transmitted by a system of
gears and sprocket or pulley and belt, both are available. Pneumatic air system is important in
running some of the machines such as the sewing machine, product transfer in conveyor pipe.

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Figure 4.13: Reciprocating air compression

4.3 QUALITY CONTROL

This unit works hand in hand with the production unit of the factory. It ensures the
quality of product is maintained at the desired standard by making laboratory analysis from time
to time. The results of the analysis made are then compared with standard results to see whether
a change is required in the production process or not. These outcomes are then issued to the
production manager’s office for due consideration and necessary actions. In the next chapter, the
procedures and results of each analysis carried out at the quality control department will be
discussed extensively. One of the most significant analysis carried out by the quality control is
the sieve analysis

4.4 PACKAGING AND STORAGE

The packing section is where all the products (flour, semolina and maize offal’s) are packed
inside sack. The sacks are made from polyethene and are of different sizes (10 and 50kg). The
packing section consists of several machines and mechanical devices used for its operation, these
include:

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  The automated scale
 Automated sewing machine
 Entoleter
 Packing and blending bin

THE PROCESS OF PACKING FLOUR

Flour packaging process starts when flour is discharged from the flour bulk storage bins
i.e. (bin17-20) received and stored temporarily, flour conveyed from the flour scale at milling
section. From bulk storage bin, flour is transferred into the mixing bin where at least two
different bulk storage bins (fast and slow) are blended together. The purpose of blending is to
harmonize the variety of flour extracted at different stages so that package flour remained
uniform when packed in sacks.

After blending, it is transferred into the packing bin. The packing bin is linked to the
automatic scales (scale1 and 2) when flour is measured to specified weight on the scale and
finally packed into sacks using the automatic packing machine after which they are being sewed
and transported by gravity slides to the warehouse unit for storage.

At the flour mills Maiduguri, two types of bagging machines are used, namely; Carousel bagging
machine and single-spout bagging machine.

Carousel Bagging Machine; this machine is a multi -spout system designed for high-speed
bagging of flour and other powdered products that need to be densified or compacted. It places,
fills and compacts at the same time, which enables achieving production capacities of up to 12
bags per minutes. The machine used at the industry includes four filling spouts and a bag placer
equipped with a high volume blower and suction cup, capable of handling open mouth bags.

The machine is also characterized by its enclosed, compact design with integrated lateral bag
shakers. Dust generation outside the easy-to-clean inner area is thus prevented.

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Figure 4.14: Carousel bagging machine

Single-spout Bagging Machine: The single spout bagger is also suitable for packing open-mouth
bags, with a filling weight ranging from 10kg to 50kg and a bagging capacity of 6-10 bags per
minute. The spout is dust -tight – a precondition for clean machine surroundings. The machine is
made with robust structure, based on the following equipment: storage hopper, feeding system,
weighing hopper, and heavy duty bag closer machine on height adjustable column.

Figure 4.15: single spout discharge scale

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STORAGE

The ware house is the storage place for packed products. Packaged products in sack are
conveyed from the packing floor through gravity conveyor in to the ware house, the sacks are
received by the laborers and arranged on a raised platform made of timber in an order pattern.
The arrangement helps to spread the weight of the sacks to the ground. The tally man keep count
of the number of sacks receives into the ware house for storage and numbers of sacks dispatched
out of the ware house.

CHAPTER FIVE

5.0 PROBLEMS ENCOUNTERED AT MFM

Maiduguri flour mills is an industry build for full scale daily production of their products
but due to mismanagement, lack of fund and improper utilization of resources and manpower the
mill operates only upon request of goods by customers which has drastically affected industrial
training of students attached to the mills by not being opportune to attend daily where they might

31
gain more experience and have great insight on how the milling activities carried out on wheat.
Hence, students on IT are limited only to the milling process of maize.

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 CHAPTER SIX

6.1 CONCLUSION

Student Industrial Work Experience Scheme (SIWES) provides a forum where students
are trained and practically exposed to what they were taught theoretically in the school. SIWES
provides a means of bridging the gap between theory usually taught in the school and practical
carried out in the industrial industries

My industrial attachment has been one of the most interesting and productive experience in my
life. Though I have gained new insight and more comprehensive understanding about the real
industrial working condition and practice, it also improved my ability to relate theoretical and
practical skills. This experience has helped to broaden my understanding of certain concepts
learnt in class (transport phenomena, financial management, heat transfer and chemistry), thus
allowing me to appreciate what I learnt before embarking on the SIWES training.

All these valuable experiences and knowledge that I have gained were not only acquired
through the direct involvement in task but also through other aspects of the training such as work
observation, interaction with colleagues, superior and other people related to the field. These also
made me to take in good workplace ethics, and improved my inter-personal and communication
skills. It has also exposed me to some of the modern equipment used in analysis. As a result of
this Industrial training program I am now more confident about chemical engineering related
topics and I have been able to determine without doubt my future line of profession.

6.2 RECOMMENDATION

As important as the SIWES can be to the success of students’ academic career, there are
certain setbacks which hinders the success of the program. One of these setbacks is wrong choice
of place of attachments by student.

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 I will recommend that the I T F itself help the students by posting them to different
organizations that would suit their course because many students suffer to get a place of
attachment.

With regards to my place of attachment, I will like to recommend that the Maiduguri Flour Mill
Ltd. should try as much as possible to replace some of the machines used in the production
department with new ones as most of the available machines are old and dilapidated. This has a
negative impact on the overall efficiency of the milling operation and thus reduces productivity
and profitability. Major stakeholders should partake and enhance the financial difficulties of the
mills so that it will be able to operate on full production.

REFERENCES

I. American Association of cereal chemists 2000 Approved methods of the AACC,

10th edition method 55-10 test weight bushel, method 56-81B, Association, St. Paul
MN.

II. Arthur N. Hibbs and Eliezer’s (2006) filling hopper maize flour milling, second
edition.

III. Butcher J. and stenvert N.L. 1972, an entoleter for the Buhler laboratory mill.
Milling 154 (July), 27.

IV. Donald Routledge Hill, Mechanical Engineering in the medieval Near East,
Scientific American, May 1991 (Donald Routledge Hill, Mechanical Engineering)

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V. Refai, M.K.F (1979) food and agriculture organization of the united Nation.
Manuals of food quality control 4. microbiological analysis. Rome Italy.

VI. Richardson, J.F and Harker. J.H (1999) Coulson and Richardson Chemical
Engineering. Vol 2 New York.

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