A TECHNICAL REPORT

ON

STUDENT INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)

UNDERTAKEN

AT

MAIDUGURI FLOUR MILLS LIMITED

MAIDUGURI, BORNO STATE

NAFSTS PRESIDENT WORK

AQILL SAHNUN USMAN

SUBMITTED TO

FOOD SCIENCE AND TECHNOLOGY DEPARTMENT

IN PARTIAL FULFILMENT OF THE REQUIREMENTS FOR THE
COURSE FST 490
(INDUSTRIAL TRAINING II)

UNIVERSITY OF MAIDUGURI
BORNO STATE

OCTOBER 2018
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.

1.1 HISTORICAL BACKGROUND OF SIWES

The scheme was set-up under the decree 47 of 1971 constitution, precisely
on the 8Th day of October 1971, with a view to train and expose students to
working condition relevant to their respective field of study. The scheme exposes
students to industry based skills necessary for smooth transition from classroom to
the world of work. It affords students the opportunity of being familiarized and
exposed to the needed experience in the handling of equipment, machinery,
professional work methods and ways of safeguarding the work areas and workers
in industries and other organizations.

The scheme is a tripartite program involving the students, university and

industries. It is funded by the federal Government of Nigeria and jointly
coordinated by the industrial training fund (I.T.F) and the National University
Commission (N.U.C).
1.2AIMS AND OBJECTIVES OFS.I.W.E.S

The aims and objectives of the Students Industrial Work Scheme

(S.I.W.E.S) include;

 Providing an avenue for students in higher institution to acquire industrial

skill and experience in their courses of study.
 Preparing students for the industrial work situations which they are expected
to meet after graduation.
 Exposing students to work methods and techniques in handling equipment
and machinery that may not be available in their institutions.
 Making the transition from the academic institution to the world of work
easier and enhancing students contact for later job placement.
 Providing students with an opportunity to apply their knowledge in real
work situation thereby bridging the gap between theory and practice.
 Enlisting and strengthening employers’ involvement in the entire
educational process and preparing students for employment in industry and
commerce
 Correlate the knowledge obtained during the student’s stay with the actual
industrial conditions and to develop a critical and realistic approach to
problems and their solutions.
 Strengthening the cordial relationship between the industrial sector and
the educational institutions.
 Serves to introduce brilliant student train for job recommendations in
future.
 Developing the students understanding of other system of administration.
1.3 PROFILE OF PLACE OF ATTACHEMENT
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 31 st 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.
2.0 SCOPE OF WORK

The production process carried out in the plant starts from the Head House
section then to the production department which is divided into three sections;
cleaning section, Milling section and Packaging section. Other section includes the
Engineering Workshop, the Quality Control section (Laboratory), power house etc.
In this report, we will be able to get the full details of the process involved in each
section of the plant.

2.1 RAW MATERIAL USED AND ITS SOURCE:

The raw material use for the production of flour is wheat. Wheat is beside
Rice and Maize the most important staple grain in the world. It is the only grain
that can be worked into bread without restrictions due to the content of gluten
protein. The type of wheat used mostly in the Maiduguri Flour Mills is the Hard
Red Winter wheat and the soft Red winter imported from (U.S.A) and it arrived to
Lagos by ship. From Lagos it is loaded in trucks and directed to Maiduguri Flour
Mills L.T.D.

With the recent wage of insecurity and financial crisis wrecking the state and
the country at large, crop production at the Lake Chad basin came to a drastic halt
and likewise importation. These setbacks caused the flour mill to switch from
wheat to maize. The maize used is a local grains from local markets all over
Nigeria.

Maize or corn (zea mays) is a plant belonging to the family of grasses. It is

cultivated globally being one of the most important cereal crops worldwide. Maize
is not only important to human nutrient but also a basic element of animal feed and
raw material for manufacture of many industrial products. These products include
corn starch, corn oil, masavita, and products of fermentation and distillation
industries.

Maize grain can be classified into four different layers namely

i. Bran
ii. Aleuron
iii. Endosperm
iv. Germ layer

Bran: The bran layer also referred to the back or the outermost layer of the maize,
the excess of bran part in flour is ash content, hence it should be within 2 to 5
percent.

Aleuronic layer: Immediately below the bran layer, it is usually a very thin layer
which provided covering for the Endosperm.

Endosperm: The endosperm is the bulk of fleshy part of the maize reached in
carbohydrate and is usually whitish in appeareace.75 percent extraction rate is
expected.

Germ Layer: The germ layer is the innermost layer of the maize, usually smaller
compared to the size of the maize and it is found at the central middle of the maize.
The germ layer is reached in oil and protein and constitutes the major cause of
maize product particularly.

2.2 THE PRODUCTION UNIT

The processing of raw maize into the desired product (Masavita, Massa
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.

2.2. WEIGHBRIDGE

The weighbridge is located at the entrance of the industry. 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.

2.2.1 HEAD HOUSE

The Head house is the section of the factory where raw maize are 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.

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.

2.2.2 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.

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.

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

2.2.4 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. The laboratory test conducted
included, Moisture content test, Ash analysis, Visual analysis of raw materials,
Spot test, Sieve Analysis, Checking Additives, Protein test and Maltose test.
3.0 EQUIPMENTS AND METHODOLOGY

In this chapter, we will discuss extensively on the various processes

involved in the production unit, packaging unit and the various procedures
involved in each of the analysis carried out in the quality control unit. Also to be
discussed are the working principles of each of the equipment involved in these
processes.

3.1 MILLING OPERATION

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

 Cleaning and Tempering

 Milling
 Quality control
 Packaging and Storage

3.1.0 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 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 transfer 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.

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 are 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. 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:

W= 100-m x c x 100 M - n

Where:

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)

3.1.1 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 disengage when running empty.

The milling process can be classified into five system, these include:

 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.

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).

EQUIPMENTS USED DURING MILLING OPERATION

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 reduce the sizes of the grain to
its finest product.
Figure 1: 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.
 Figure 2: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 3: Diagram of rotary airlock

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

Figure 03: 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 04: 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 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 tow hitch 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 05: Diagram of bucket 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 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 6: 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.

Figure 7: De-stoner

METRIC SCALE:

The metric scale measures 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 sends29 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 8: 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.

Figure 9: 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.

Figure 10: 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).

Figure 11: 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.

Figure 12: Reciprocating air compression

3.1.2 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.

3.1.3 PAKAGING 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:

 The automated scale

 Automated sewing machine
 Entoleter
 Packing and blending bin

3.1.3a 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 intothe
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 systemdesigned 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, compactdesign with
integrated lateral bag shakers. Dust generation outside the easy-to-clean inner area
is thus prevented.

Figure 13: 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 29: single spout discharge scale

3.1.3b STORAGE:

The ware house is the storage place for pack products. Package product in
sack are conveyed from the packing floor through the 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 in to the ware house for storage and numbers of sacks dispatched out of
the ware house.
4.0 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 are noticed in flour at the final stage of production
(this hardly occur), the product are again returned for a repeated process
particularly at the sifter and entoleter.

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

4.1 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. 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.

PROCEDURE FOR MOISTURE CONTENT DETERMINATION

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

 10g of the sample is added to the dish and their weight recorded as W2.
 The sample is then placed in an electronic oven at temperature of 150℃ for
30minutes.
 Sample is removed, placed into a desiccators to cool and weighted as W3

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

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.

4.2 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 600 oC for six hours.

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

 The crucible is then placed in a muffle furnace after the furnace is allowed to attain
the temperature of 600oC.
 The sample is left in the furnace for atlases six (6) hours or allowed to stay
overnight.
 The sample is them removed and allowed to cool in desiccators.
 The sample is reweight and the weight is then recorded

A−D
Ash% = S−D ×100
Where:

A = Weight of dish + ash residue

S= Weight of dish + weight of sample

D = Weight of dish

4.3 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.

PROCEDURE FOR MALTOSE ANALYSIS

 1. Weigh 5 grams of maize flour (masa flour) into a 150cm3conical flask.
2. Add 46cm3of buffer solution and digest for 1 hour at 30oC.
3. Add 2cm3of 10% H2SO4and 2cm3of sodium tungstate, shake well and filter
4. Measure 10cm3of ferricyanide solution into a separate conical flask and add
5cm3of the initial filtrate to the solution.
5. Incubate for 30 minutes at 100oC and allow cooling.
6. Add 25cm3of acetic acid solution and 2cm3of starch iodine to the solution.
7. Titrate against 0.1N sodium thiosulphate.
8. Compare titer value to thiosolphate-maltose conversion to obtain result.

4.4 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.

PROCEDURE FOR SEIVE ANALYSIS

1. 100 grams of flour sample was weighed using the weigh balance.
2. The weighed sample is then poured onto a set of sieves arranged in order of
decreasing microns 630um, 300um, 212um, 180um and 150um.
3. The set is then placed on a sieve shaker and allowed to run for 10 minutes
4. The sample on each sieve was then measured separately.

Normally the first sieve which is the 630um does not contain flour
sample, only maize offal’s remains on it. Moreover, anything that passes the
180um is flour. The final tray which contains 90% flour is then measured
and recorded.
4.5 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 help to visually assess whether
some unwanted particles have managed to escape into the product.

PROCEDURE FOR SPOT TEST

1. Flour was spread over a flat rectangular piece of glass (Peker).

2. The flour was then compacted and shaped into a flat pyramid like shape.
3. The sample was then immersed into distilled water until flour is wet.
4. Iodine solution was added in drops and left for ten minutes.
5. A dark blue colored spot was observed which indicates the presence of
ascorbic acid.

4.6 VISUAL 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.

DIAGRAMS AT THE LABORATORY SECTION:

MOISTURE CONTENT’S OVENWEIGHING SCALE

WATER BATH FOR MALTOSE TEST

 5.0 CONCLUSION

In summary, this report gives in detail the stages or unit operations involved
in the processing of maize into its various products that go on in different sections
of the Maiduguri flour Mill. It has a very detail explanation of each of these
processes which could serves as a guide for anyone who want to know how maize
is milled into flour. Indeed the importance of the student industrial training can
never be over emphasized for during my attachment period I have learned not
only knowledge beneficial to my field of study but also how to interact with
different caliber of people from different background. How to make a formidable
work force and work as a team.

5.1 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.

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.
 Moisture content being one of the major factors that determines milling
efficiency should be given due regards. On this note, I will recommend that the
quality control unit conduct moisture analysis more frequently in other to ensure
product quality is maintained at the desired standard.

I will also like to recommend to the management to give positive attention to

the welfare of their staff, give them opportunities to go for seminars and
workshops so that they can acquire more knowledge on how to effectively carry
out their duties more diligently.

Taking these few points into consideration, I strongly believe the overall
performance of the industry will improve to a greater extend, yielding more
productivity, quality product as well as high profitability.
 REFERENCES

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.

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

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

Donald Routledge Hill, Mechanical Engineering in the medieval Near East,

Scientific American, May 1991 (Donald Routledge Hill, Mechanical Engineering)

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

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

Shellenberger J.A PHD and Yeshajahu pomeran PHD. Bread Science and
technology
 UNIVERSITY OF MAIDUGURI

FACULTY OF ENGINEERING

DEPARTMENT OF FOOD SCIENCE & TECHNOLOGY

STUDENT INDUSTRIAL WORK EXPERIENCE

SCHEME
(SIWES)

Student Industrial Training (IT) Report

(FST490)

AT
MAIDUGURI FLOUR MILLS LTD
BY
SESSION 2018/2019

Brief History Of ITF and SIWES

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 programme 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 skills training programme which forms part of the
minimum academic standard in Nigerian Universities, the scheme is a participatory
programme involving Universities, Polytechnics, and Technical Colleges’ students
of various institutions in Nigeria.
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.
vi. Strengthen the relationship between educational institutions and
industrial sectors.
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.
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

Background History of Maiduguri Flour Mills

Maiduguri Flour Mills Limited is a joint venture owned by Several
Shareholders with Borno State Government, Chad Basin Development Authority
and Flour Mills of Nigeria Plc, holding the greater part of the Shares. The official
commissioning ceremony took place on 31st May, 1983. Management of the
Company was vested in Flour Mills of Nigeria Plc, Apapa. Who introduced their
brand name of “Golden Penny Products” under which the products of the
Company were marketed.
The years between the commissioning and 1986 saw a period of intense activities
and profitable operations. However, the ban on wheat imports on 1 st January, 1987
had adverse effects on the Company’s fortunes due to a drastic drop in capacity
utilization.
After careful consideration, the present Board of Directors, with the active
participation of the State Government, decided to effect conversion of the Mill to
diversify into the production of Maize products.
Maiduguri Flour Mills Limited was established as a result of the formation of Chad
Basin Development Authority (CBDA) whose mandate is to produce wheat along
the Lake Chad Basin and also to produce wheat flour to the people of the state.
The objectives are achieved in a way since the wheat flour is made available in any
part of the state and also employment opportunities created in the state.
The Mill produces the golden penny flours and semovita for making bread and
local dishes and the wheat offals which are indispensable for the Agro Feed
Industry.
The Mills have its own borehole for water supply, a power house that will take
care of the electricity requirement for the various sections of the industry.
It is a landmark on the development of the Industry in Borno State which boosted
farming, baking and Agro Allied Industries and the resultant employment
opportunities in all activities associated with the Mill.
The organization chart composed of the general manager (GM) as the head of
organization, assistant general manager (AGM) and several managers which
include: the personnel manager, Production Manager, Maintenance manager,
Electrical/Mechanical manager and Ware house manager. The company staff
strength numbered 115 employees.
The production department where I was attached comprises of the following
sections.
a. Head house
b. Mill building
c. Cleaning section
c. Packing/warehouse
e. Laboratory unit
f. Electrical unit
g. Power plant
h. Mechanical unit

HEAD HOUSE
The head house is where pre-cleaning of the wheat is being carried out or is
the section where raw wheat (unconditioned) received (intake) from delivery truck
are kept for storage into silos.
This unit carries out four major operations which include:
i. Intake of wheat
ii. Pre-cleaning of wheat
iii. Transfer of wheat
iv. Storage of wheat
These major operations are aided by the use of some machines and mechanical
devices. These include:
1. The dump bridge
2. Conveyors
3. Elevators
4. Metric scale (for intake and transfer)
5. Drum sieve
6. Fillers
7. Aspirators and
8. Silos
Procedure:
The grain received through the intake points in the head house pass through drum
sieves, to remove large admixtures e.g. wood, glasses and through series of
aspirators to remove dust, light impurities e.g. screenings etc. The dusty air passes
through filters, where the dust and screenings are received in bags. The cleaned air
is exhausted in to the atmosphere. The partially cleaned maize is then stored in the
silo (6× 900t). The maize is then transferred to the cleaning house through series of
conveyors, elevators, and scale and chain conveyor, to the cleaning house for
proper cleaning, into the raw maize bins (6 × 100t). The quantity to be cleaned
weighed over a scale that tips 100kg/tip.
Intake processes: Machine sequence of operation
Compressor

Blower

Air lock and filter

Conveyor (2 or 3 to silos)

Elevator (2 to 3)

Intake scale

Aspirations

Drum sieves

Elevator 1 (intake)

Dump Bridge Conveyor

Transfer Processes: Machine sequence of operation

Compressor

Blower

Air lock

Filter

Conveyor (2 or 3 to silos)

Elevator (2 or 3)

Transfer-scale

Elevator 1 (transfer)
Silo gate open (wheat discharge)

MACHINES USED IN HEAD HOUSE

The machines/mechanical devices used in the head house for its operation
include the following:
a. Dump Bridge: The dump bridge is located below the ground level at a
cleared space beside the building of the head house, it is a mechanical device
designed to receive delivery truck or train.
b. Conveyor: 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, belt conveyor and chain conveyor. The
chain conveyor is the type used within the head house. The intake conveyor is
located below the dump bridge while another one is located at highest point just
above the silos or raw wheat bins in the mill building.
c. Elevator: An elevator, as its name implies, is used to transport products
from a pointer level at its lowest end to another point or level at its uppermost end
for instance, the lifting of wheat discharged from the dump bridge conveyor up
into silos and from the silos through the lower or bottom conveyor via elevator 1 to
the transfer conveyor and into the mill building.
d. Metric scale: The metric scale measure and record full weight of 500kg for
each tip of wheat using the analogue system of measurement.
e. Aspirator: It’s the process where raw materials passes from the drum sieve
to aspirator to separate light weight particle such as dust.
f. Blower
g. Air lock: The air lock machine as its name implies, is used to separate (lock)
air from the product conveyed by pneumatic process.
h. 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.
i. Drum sieve: it separates heavy and large foreign matter such as stones and
metals.
j. Filters: The filters are used together with aspirator. They are used for
sucking dust and light particles, and releases clean air to the atmosphere.
SILO
The silos are located in the head house. These are made of strong aluminum,
the silos are six in numbers each with a capacity of 500 tones. The pre-cleaned
grains are stored in the silos until when the need arises for further processing. The
grain can be stored for a long period depending on the moisture content of the
grains
After a long storage of the grains in the silo the grains are turned from one silo to
another. This is to ensure that the grain does not contain moisture, also to release
humid air.
Another advantage of the use of silo is in fumigation as a result of insect
infestation by transferring from one silo to another. When the grains are to be
cleaned they are transferred from silo to the raw wheat bins in the cleaning section.

MILL BUILDING
 The main objective of the mill building as a section of the industry is the
processing of wheat by grinding (size reduction) using mechanical rollers (milling
machine) for the extraction of flour, semovita and wheat offals. After the wheat has
undergone pre-cleaning processes at the head house, cleaning,
tempering(conditioning), milling (size reduction) and packaging are all carried out
within the mill building, the quality control section (laboratory which is also an
extension of the mill building ensures that production are of the best quality
required.
Milling is commenced after the conditioned wheat are introduced to the
rollers which subjects the wheat to breaks hence the first breaks and reduction
breaks, the product are then conveyed to the sifter for separation, consequently, the
extraction of flour and other product.
This section comprises of six different floors of a story building and each
floor has a distinct role in the processing of wheat to its final products. The flow
chart below illustrates the several floors which make up the mill building is
descending order (i.e. from last floor to the ground floor) of the story building.
1. Cleaning house (leaf floor): The cleaning house which is the sixth floor of
the mill building is where the final cleaning processes takes place and the
temporary conditioning of wheat is carried out.
2. Filter floor: This is an extension of the cleaning house where large air filters,
tanks and other wheat cleaning machines and devices are operated, to clean the air
during pneumatic operation.
3. Air lock floor: The air lock is immediately above the sifter floor, it is
responsible for the separation of air of the product discharged from the rollers
(roller floor) and conveyed by a pneumatic system of conveyor pipe, the air lock
mechanism separate air from the product and channels it to free falling under
gravity to the sifters.
4. Sifter floor: This is the separation of the mill product into their constituent
particles of different sizes. So as to collect flour, wheat offals. Semovita and are
also tapped from the purifier.
5. Spout floor: The spout floor has interconnected network of conveyor pipes
which are used to convey products (truce and over fails) under gravity from the
sifters to either the packing bins (flour, semovita and bran) or back to the reduction
rolls for further breaks and further extraction of flour.
6. Roller-floor: This floor consists of mainly rollers (first breaks and reducing
rolls) which are used in the milling of wheat.
7. 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 system of belts and pulleys,
chains and sprocket to the rollers. Screw conveyor which received wheat discharge
from bins are also installed here. The elevator runs from the last floor and ends at
the basement. Also accommodated here are several conveyor pipes which are used
to transport products discharge from the rollers.
MILL OPERATION
Generally, the operations which made up the production process can be
classified into three (3) this includes:-
a. Cleaning and tempering
b. Milling
c. Packaging and storage

CLEANING AND TEMPERING:-

The main cleaning section is a very useful section. This is where the actual
cleaning of the wheat takes place: it consist of different cleaning machine pre-
cleaned wheat from silos are conveyed to the dirty wheat bins. These bins are six
in numbers and are located in the main cleaning section each bin capacity is about
124.5metric tones and 21meter in height each meter contained 5.93 tones. So
21x5.93 = 124.53 tones.
Raw wheat discharged from the raw wheat bin are collected in the screw conveyor.
The objectives of the tempering include;
I. To toughen the bran to avoid breakage into small fragment before the final
passage.
2. To mellow down the endosperm for better extraction for profit because of the
additional weight (water)
RELATIONSHIP USED TO DETERMINE THE QUALITY OF WATER
ADDED TO WHEAT FOR TEMPERING
Wheat is an agricultural product rich in vitamin and minerals and is of different
varieties. The type of wheat used mostly in Maiduguri flour mills is the hard red
wheat. Wheat can be classified into four (4) different layers namely.
1. Bran
2. Aleuron layer
3. Endosperm
4. Germ layer

BRAN
The bran layer is the outmost layer of the wheat, the excess of bran part in flour
result in each content hence it should be within 2 to 5 percent.
ALEURON LAYER
Is the layer immediately below the bran layer, it is usually a very thin layer which
provide covering for the endosperm
ENDOSPERM
The endosperm is the bulk or fleshy part of the wheat rich in carbohydrate and is
usually whitish in color.
GERM LAYER
The germ layer is the innermost layer of the wheat usually smaller compared to the
size of the wheat and it is found at the middle of the wheat.

MILLING SECTION
This is the most important part of the production department which mainly uses the
process of milling as the name implies.
After conditioning the wheat 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 is commenced when tempered wheat from the conditioning bin are
introduced to the milling machines (rollers). From the conditioning bins
harmonized wheat flow through the flow balancer attached to the screw conveyor,
the screw conveyor channel the wheat to the scourer and aspirator before it is then
lifted by the elevator (3) to the first break bin. The first break bin discharge wheat
into the wheat scale (milling scale) from where it passes through a magneto in
order to trap any ferrous metal, finally into the first break roller (B1).
The roller type machine used at any particular stage in the break system varies, for
size reduction; a fluted surface roller is used to simply break the wheat 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 the initial break and loosing
flour out of the bran layer while the shallow grooved rollers are used mainly as
reducing rolls and smooth rollers 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 (known as reducing rolls
engage and disengage automatically in response to the increasing flow of stock.
The rolls are prevented against excessive wears, since they are always disengaged
when running empty.
The milling process can be classified into five systems these includes;
1. Break system: Its mainly use for size reduction.
The objectives of the break system are to scrape progressively the endosperm
from bran. The breaks roll applies a shear force to open the wheat kernel and
we get mixture of semolina break stock middling and dust floor. The grains are
ground in the first break rolls and flour mixture passes oil, the square sifter.
2. Purification:
3. Grinding and sifting: effective grinding is achieved by the careful adjustment of
the rolls using lateral or side adjustment lever by intuition, that is testing for finest
between the fingers effective grinding is achieved.
4. Reduction system: The reduction system refers to the operation of the reducing
rolls which has relatively smoother surface finish product discharged from the
breaks are conveyed to the sifter when the overtail is return to the reducing roll
5. Scratch system: They are used mainly as purification roll
Note:
The process involve in the milling process of Maiduguri flour mill are of two
categories which are:
-CRUSHING- it’s made by the rolls, and it’s of two types which are roll and
hammer mill (not functioning)
-SIFTERS BIN- for sieving
ROLLERS are of 3 different categories which are:
-Break rolls -Reduction rolls -Smooth rolls
 The transport system of milling section is different from that of head house
and cleaning because milling section uses pneumatic system.

PACKING AND STORAGE

This is the cleanest part of the flour mill industry. It is also the part of the company
the mark the end of the production at this section all flour, bran and semovita after
appropriate procedure are controlled to this section for packaging.
The qualities packed range from 5kg - 50kg. The flour from the mill is received in
the packaging section in the flour reception bin. Where it is stored before passing it
to the hopper and then to the flour reception scale. The flour to be stored is
weighed and then the flour sighed out the small dust particles from the flour
passing through the pipes. The dust air mixture is sent to the filter and then to the
blower. The flour passes to the storage bins for flour.
The flour is stored in the bulk storage bin of flour to improve its quality. The most
economical way to do this is to let it mature in the flour storage system. The
storage bins are equipped with a discharge system which will ensure that the flour
maintains it when it is discharge and that it is fed to the feeder at specified
capacity.
The packing section has the following machine that are used for easy packaging of
bran (offal), flour and semovita.
1. The automatic flour packing scale machine:This machine is automatically set in
such a way that the rotation is slow in order to allow man power to insert the sack
in between the two arms of the gripper.
2. The shaker:- This is a machine that is used to shake the sack after injected with
the flour, this operate on vibrating principles such that the flour injected will be
more compacted for essay sewing.
3. The belt conveyor: This is a transport in a belt form which is connected to the
electric motor which control the motion in stow manner and move the bag of flour
which release from packing scale to be sewed.
4. Automatic sewing machine:- This is a sewing machine that is automatically
controlled using sensor, as it sense the presence of bags passing through the teeth,
but some time can be operated manually using leg to press the switch on for the
operation.

5. The gravity conveyor: This is a conveyor that helps in conveying any packed
product to the ware house as the name implies It operates under the action of
gravity.
6. The manual scale: This is a scale use for measuring the 10kg of flour bags and
semovita which can be manually measured before sewing.

STORAGE
The ware house is located on the ground floor on the far right end of the mill
building. It has the following staff who coordinate, execute and managed its
affairs. This includes;
PROFESSIONAL STAFFS:
- Ware house manager, Store officer and clerk (tally man)
UNPROFESSIONAL STAFFS
- The securities
- Laborers
Package product in sack are conveyed from the packing flour through the gravity
conveyor into the ware house, the scale are received by the laborers and arranged
on a raised platform made of timber in an orderly pattern. The arrangements
(pattern) help to spread the weight of the sacks evenly to the ground. The tally man
keeps counting. The number of sacks received into the warehouse for storage and
the number of sacks dispatched out of the ware house.

QUALITY CONTROL (LABORATORY SECTION):

The Laboratory is the focal point of the quality control system and receives
and analyses samples in all departments. It work load depends on:
a. The size of the Mill;
b. The number and type of flour produced;
c. The length of production runs;
d. Whether specifality flours are produced;
e. Whether a classification system is used;
f. The laboratory equipment available;
The activities conducted at the quality control section include laboratory test on
wheat before, during and after processing. The laboratory test conducted included:
1-Moisture content test.
2-Ash analysis (Ash furnace).
3-Media Preparation.
4-Sieve Analysis.
5-Checking Additives.
6- Protein test.
7- Bread making.
8- Maltose test.
QUALITY CONTROL LABOROTORY
The Quality control laboratory operates to ensure the quality of the products,
through observing the following parameters.
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.
Ensuring the moisture of the two stated above do not fall out of standard of
maximum moisture of 10.00% for the maize grits and 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.
PROCEDURE FOR MOISTURE CONTENT DETERMINATION
1. A clear standard crucible dish is weighted and it 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 150oc for
30min
4. The sample is removed and placed into a desiccator to cool and weighted as W3
Moisture % = Loss in Weight × 100 W2 - W3 × 100
Weight of Sample W2 - W1
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.
Ash Content: This is an index of the extraction rate, to determine the % of in
organic matters present in a sample. It also help in determining the correct color of
products, the physiochemical requirement of ash % (Max) in maize flour
(Masaflour) is 0.70% and that of grits (Masavita) is 0.75%

PROCEDURE FOR ASH CONTENT DETERMINATION

Ash can also 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 at least six (6) hours or allowed to stay
overnight.
4. The sample is them removed and allowed to cool in a decicator.
5. The sample is reweight and the weight is then recorded
Ash% = A -D × 100
S - D
Where:
A = Weight of dish + ash residue
S = Weight of dish + weight of sample
D = Weight of dish
 GENERATOR HOUSE
This is the division that supplies electrical power requirement where power is
not available or power doesn’t reach the required voltage supply. The plant has
four (4) generators, three works at a time to provide required power output for
every section of the plant to operate and the remaining one is a backup when
ever any of the generators got spoiled. The plant electrical power requirement is
about 6.3 MVA and 1KV voltage which is stepped up to 3.3 KV.

A TECHNICAL REPORT

ON

STUDENT INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)

UNDERTAKEN

AT

MAIDUGURI FLOUR MILLS LIMITED

 MAIDUGURI, BORNO STATE

BY

MUHAMMAD SHETTIMA MUSTI

13/05/02/016

SUBMITTED TO

CHEMICAL ENGINEERING DEPARTMENT

IN PARTIAL FULFILMENT OF THE REQUIREMENTS FOR THE
COURSE CHE 409
(INDUSTRIAL TRAINING II)

UNIVERSITY OF MAIDUGURI
BORNO STATE

OCTOBER 2017
 DEDICATION

I dedicate this project to God Almighty my creator, my strong pillar, my source of

inspiration, wisdom, knowledge and understanding. He has been the source of my
strength throughout this program. I also dedicate this work to my parents for all
their years of love and encouragement. It is because of their guidance and
example that I am the person I am today. I am extremely grateful and thankful for
all they provided me in the past and continue to provide me today.
 ACKNOWLEGMENT

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
‫ ﷺ‬his family and all those who follow him on the right path. I thank
my parents for their love and support throughout my life. Thank you for giving me
strength to reach for the stars and chase my dreams. My uncles, aunties,
brothers, sisters, cousins and friends deserve my wholehearted thanks as well.

I would like to sincerely thank my coordinator, Engr. Maina, for his

guidance throughout this SIWES training. I would also like to thank my HOD Engr.
Dr. Murtala, my able lecturers, all members of staff of Chemical engineering
department and the faculty of engineering at large for their moral and academic
support. Sir, I am grateful. My University education would have been a wishful
thinking but for the unflinching support you gave me, I owe you all a great deal.

I consider it a humble duty to express my deepest gratitude to all staff of

the Maiduguri Flour Mills L.T.D, for understanding and guiding me in many ways
and for making my stay a worthwhile. I am most grateful to you all for support.
God bless you all.
 ABSTRACT

This report is on the student industrial work experience scheme (S.I.W.E.S)

undertaken at Maiduguri Flour Mill LTD. It explains in details the various activities
carried out at the various units of the industry. It also explains the many
processes involved in the production process which includes transportation,
storage, separation, tempering, size reduction, packaging etc. Procedures of all
the analysis carried out at the quality control (Laboratory) unit was also discussed.
The analysis carried out at the quality control unit include Moisture content
analysis, maltose analysis, sieve analysis, and spot test.
 TABLE OF CONTENTS
Title Page ...................................................................................................................i
Dedication..................................................................................................................ii
Acknowledgments......................................................................................................iii
Abstract………………………………………………………………………..………………………………………….iv
Table of content…………………………………………………………….………………………………………...v
Chapter I: Introduction......................................................................................1
1.1 Historical background of SIWES.........................................................................1
1.2 Aims and objectives of SIWES ...........................................................................2
1.3 Profile of place of attachment...........................................................................3
Chapter II: Literature Review.............................................................................4
2.0 Scope of work....................................................................................................4
2.1 Raw material used and its source......................................................................4
2.2 The production unit...........................................................................................6
2.2.0 Weighbridge...................................................................................................6
2.2.1 Head house.....................................................................................................6
2.2.2 Milling section................................................................................................8
2.2.3 Packaging unit................................................................................................10
2.2.4 Quality control unit........................................................................................10
Chapter III: Methodology and
Equipment’s ................................................................12
3.1 Milling operation..............................................................................................12
3.1.0 Cleaning and tempering................................................................................12
3.1.1 Milling............................................................................................................16
3.1.2 Quality control...............................................................................................30
3.1.3 Packaging and storage ..................................................................................31
Chapter IV: Laboratory analysis, procedures and discussions............................34
4.1 Moisture Analysis.............................................................................................35
4.2 Ash analysis......................................................................................................36
4.3 Maltose analysis...............................................................................................37
4.4 Sieve analysis ..................................................................................................37
4.5 Spot test..........................................................................................................38
4.6 Visual analysis of raw materials......................................................................39
Chapter IV: Conclusions and Recommendations ...........................................…40
5.0 Conclusion.......................................................................................................40
5.1 Recommendation............................................................................................ 40
References ......................................................................................................42

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.

1.1 HISTORICAL BACKGROUND OF SIWES

The scheme was set-up under the decree 47 of 1971 constitution, precisely
on the 8Th day of October 1971, with a view to train and expose students to
working condition relevant to their respective field of study. The scheme exposes
students to industry based skills necessary for smooth transition from classroom to
the world of work. It affords students the opportunity of being familiarized and
exposed to the needed experience in the handling of equipment, machinery,
professional work methods and ways of safeguarding the work areas and workers
in industries and other organizations.

The scheme is a tripartite program involving the students, university and

industries. It is funded by the federal Government of Nigeria and jointly
coordinated by the industrial training fund (I.T.F) and the National University
Commission (N.U.C).
1.2 AIMS AND OBJECTIVES OF S.I.W.E.S

The aims and objectives of the Students Industrial Work Scheme

(S.I.W.E.S) include;

 Providing an avenue for students in higher institution to acquire industrial

skill and experience in their courses of study.
 Preparing students for the industrial work situations which they are expected
to meet after graduation.
 Exposing students to work methods and techniques in handling equipment
and machinery that may not be available in their institutions.
 Making the transition from the academic institution to the world of work
easier and enhancing students contact for later job placement.
 Providing students with an opportunity to apply their knowledge in real
work situation thereby bridging the gap between theory and practice.
 Enlisting and strengthening employers’ involvement in the entire
educational process and preparing students for employment in industry and
commerce
 Correlate the knowledge obtained during the student’s stay with the actual
industrial conditions and to develop a critical and realistic approach to
problems and their solutions.
 Strengthening the cordial relationship between the industrial sector and
the educational institutions.
 Serves to introduce brilliant student train for job recommendations in
future.
 Developing the students understanding of other system of administration.
1.3 PROFILE OF PLACE OF ATTACHEMENT
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 31 st 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.
 CHAPTER TWO

2.0 SCOPE OF WORK

The production process carried out in the plant starts from the Head House
section then to the production department which is divided into three sections;
cleaning section, Milling section and Packaging section. Other section includes the
Engineering Workshop, the Quality Control section (Laboratory), power house etc.
In this report, we will be able to get the full details of the process involved in each
section of the plant.

2.1 RAW MATERIAL USED AND ITS SOURCE:

The raw material use for the production of flour is wheat. Wheat is beside
Rice and Maize the most important staple grain in the world. It is the only grain
that can be worked into bread without restrictions due to the content of gluten
protein. The type of wheat used mostly in the Maiduguri Flour Mills is the Hard
Red Winter wheat and the soft Red winter imported from (U.S.A) and it arrived to
Lagos by ship. From Lagos it is loaded in trucks and directed to Maiduguri Flour
Mills L.T.D.

With the recent wage of insecurity and financial crisis wrecking the state and
the country at large, crop production at the Lake Chad basin came to a drastic halt
and likewise importation. These setbacks caused the flour mill to switch from
wheat to maize. The maize used are local grains from local markets all over
Nigeria.
 Maize or corn (zea mays) is a plant belonging to the family of grasses. It is
cultivated globally being one of the most important cereal crops worldwide. Maize
is not only important to human nutrient but also a basic element of animal feed and
raw material for manufacture of many industrial products. These products include
corn starch, corn oil, masavita, and products of fermentation and distillation
industries.

Maize grain can be classified into four different layers namely

v. Bran
vi. Aleuron
vii. Endosperm
viii. Germ layer

Bran: The bran layer also referred to the back or the outermost layer of the maize,
the excess of bran part in flour in ash content, hence it should be within 2 to 5
percent.

Aleuronic layer: Immediately below the bran layer, it is usually a very thin layer
which provided covering for the Endosperm.

Endosperm: The endosperm is the bulk of fleshy part of the maize reached in
carbohydrate and is usually whitish in appeareace.75 percent extraction rate is
expected.

Germ Layer: The germ layer is the innermost layer of the maize, usually smaller
compared to the size of the maize and it is found at the central middle of the maize.
The germ layer is reached in oil and protein and constitutes the major cause of
maize product particularly.

2.2 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.

2.2. WEIGHBRIDGE

The weighbridge is located at the entrance of the industry. 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.

2.2.1 HEAD HOUSE

The Head house is the section of the factory where raw maize are 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.

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.

2.2.2 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.

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.

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

2.2.4 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. The laboratory test conducted
included, Moisture content test, Ash analysis, Visual analysis of raw materials,
Spot test, Sieve Analysis, Checking Additives, Protein test and Maltose test.
 CHAPTER THREE

3.0 EQUIPMENTS AND METHODOLOGY

In this chapter, we will discuss extensively on the various processes

involved in the production unit, packaging unit and the various procedures
involved in each of the analysis carried out in the quality control unit. Also to be
discussed are the working principles of each of the equipment involved in these
processes.

3.1 MILLING OPERATION

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

 Cleaning and Tempering

 Milling
 Quality control
 Packaging and Storage

3.1.0 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 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 transfer 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.

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 are 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:

W= 100-m x c x 100 M - n

Where:

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)

3.1.1 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 disengage when running empty.

The milling process can be classified into five system, these include:

 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.

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).

EQUIPMENTS USED DURING MILLING OPERATION

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 1: 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.
 Figure 2: 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 3: Diagram of rotary airlock

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

Figure 03: 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 04: 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 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 05: Diagram of bucket 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 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 6: 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 consist 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.

Figure 7: 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 8: 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.

Figure 9: 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.

Figure 10: 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).

Figure 11: 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.

Figure 12: Reciprocating air compression

3.1.2 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.

3.1.3 PAKAGING 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:

 The automated scale

 Automated sewing machine
 Entoleter
 Packing and blending bin

3.1.3a 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.

Figure 13: 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 29: single spout discharge scale

3.1.3b STORAGE:

The ware house is the storage place for pack products. Package product in
sack are conveyed from the packing floor through the 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 in to the ware house for storage and numbers of sacks dispatched out of
the ware house.
 CHAPTER FOUR

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

Below are the analysis carried out by the quality control unit to achieve the
aforementioned objectives.
4.1 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. 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.

PROCEDURE FOR MOISTURE CONTENT DETERMINATION

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

 10g of the sample is added to the dish and their weight recorded as W2.
 The sample is then placed in an electronic oven at temperature of 150 ℃ for
30minutes.
 Sample is removed, placed into a desiccator to cool and weighted as W3

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

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.

 4.2 ASH ANALYSIS

This is an index of the extraction rate, to determine the percentage of

inorganic matters present in a sample. It also help in determining the correct color
of a products. 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 600 oC for six hours.

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

 The crucible is then placed in a muffle furnace after the furnace is allowed to attain
the temperature of 600oC.
 The sample is left in the furnace for atlases six (6) hours or allowed to stay
overnight.
 The sample is them removed and allowed to cool in a desiccator.
 The sample is reweight and the weight is then recorded

A−D
Ash% = S−D
×100

Where:

A = Weight of dish + ash residue

S= Weight of dish + weight of sample

D = Weight of dish

4.3 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.

PROCEDURE FOR MALTOSE ANALYSIS

9. Weigh 5 grams of maize flour (masa flour) into a 150cm3conical flask.

10.Add 46cm3of buffer solution and digest for 1 hour at 30oC.
11.Add 2cm3of 10% H2SO4and 2cm3of sodium tungstate, shake well and filter
12.Measure 10cm3of ferricyanide solution into a separate conical flask and add
5cm3of the initial filtrate to the solution.
13.Incubate for 30 minutes at 100oC and allow to cool.
14.Add 25cm3of acetic acid solution and 2cm3of starch iodine to the solution.
15.Titrate against 0.1N sodium thiosulphate.
16.Compare titer value to thiosolphate-maltose conversion to obtain result.

4.4 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.

PROCEDURE FOR SEIVE ANALYSIS

5. 100 grams of flour sample was weighed using the weigh balance.
6. The weighed sample is then poured onto a set of sieves arranged in order of
decreasing microns 630um, 300um, 212um, 180um and 150um.
7. The set is then placed on a sieve shaker and allowed to run for 10 minutes
 8. The sample on each sieve was then measured separately.

Normally the first sieve which is the 630um does not contain flour
sample, only maize offal’s remains on it. Moreover, anything that passes the
180um is flour. The final tray which contains 90% flour is then measured
and recorded.

4.5 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 help to visually assess whether
some unwanted particles have managed to escape into the product.

PROCEDURE FOR SPOT TEST

6. Flour was spread over a flat rectangular piece of glass (Peker).

7. The flour was then compacted and shaped into a flat pyramid like shape.
8. The sample was then immersed into distilled water until flour is wet.
9. Iodine solution was added in drops and left for ten minutes.
10.A dark blue colored spot was observed which indicates the presence of
ascorbic acid.

4.6 VISUAL 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.

DIAGRAMS AT THE LABORATORY SECTION:

MOISTURE CONTENT’S OVEN WEIGHING SCALE

WATER BATH FOR MALTOSE TEST

CHAPTER FIVE
 5.0 CONCLUSION

In summary, this report gives in detail the stages or unit operations involved
in the processing of maize into its various products that go on in different sections
of the Maiduguri flour Mill. It has a very detail explanation of each of these
processes which could serves as a guide for anyone who want to know how maize
is milled into flour. Indeed the importance of the student industrial training can
never be over emphasized for during my attachment period I have learned not
only knowledge beneficial to my field of study but also how to interact with
different caliber of people from different background. How to make a formidable
work force and work as a team.

10.1RECOMMENDATION

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.

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.
 Moisture content being one of the major factors that determines milling
efficiency should be given due regards. On this note, I will recommend that the
quality control unit conduct moisture analysis more frequently in other to ensure
product quality is maintained at the desired standard.

I will also like to recommend to the management to give positive attention to

the welfare of their staff, give them opportunities to go for seminars and
workshops so that they can acquire more knowledge on how to effectively carry
out their duties more diligently.

Taking these few points into consideration, I strongly believe the overall
performance of the industry will improve to a greater extend, yielding more
productivity, quality product as well as high profitability.

REFERENCES
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.

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

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

Donald Routledge Hill, Mechanical Engineering in the medieval Near East,

Scientific American, May 1991 (Donald Routledge Hill, Mechanical Engineering)

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

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

Shellenberger J.A PHD and Yeshajahu pomeran PHD. Bread Science and
technology
 CHAPTER ONE

1.0 INTRODUCTION

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 programme 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 skills training programme which forms part of the minimum academic standard in
Nigerian Universities, the scheme is a participatory programme 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 students 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.

vi. Strengthen the relationship between educational institutions and industrial sectors

1.2 PROSPECTS OF SIWES

The Student Industrial Work Experience Scheme (SIWES) offers a lot to the students and labour
employers; it forms a bridge between the theories and practical field skills required by the labour
employers after graduation. It also encourages students to work hard and excel in their areas of
specialties. Therefore, students are interested in the program and looking forward for it. Also employers
and most industries have appreciated the relevance of the programme.
1.3CONTRIBUTION OF THE SCHEME

The enormous impact that the students industrial work experience scheme is making on the economic,
technological and industrial sector of the country as well as human resources development cannot be
over emphasized. Below is a brief summary of some of the contribution of the scheme 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.

Practical industrial experience now forms part of the assessment of the award of certificates and
degrees in specific discipline in institutions and industries.

1.5 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

1.6 Back ground History of Maiduguri Flour Mills

Maiduguri Flour Mills Limited is a joint venture owned by Several Shareholders with Borno State
Government, Chad Basin Development Authority and Flour Mills of Nigeria Plc, holding the greater part
of the Shares.

Plans for setting up the Mill were drawn up between 1977 and May 1981 when the foundation stone
was laid.
The official commissioning ceremony took place on 31 st May, 1983. Full scale milling commenced
immediately at the capacity of 400 tonnes of wheat per day. Management of the Company was vested
in Flour Mills of Nigeria Plc, Apapa who introduced their brand name of “Golden Penny Products” under
which the products of the Company were marketed.

The years between the commissioning and 1986 saw a period of intense activities and profitable
operations. However, the ban on wheat imports on 1 st January, 1987 had adverse effects on the
Company’s fortunes due to a drastic drop in capacity utilization.

After careful consideration, the present Board of Directors, with the active participation of the State
Government, decided to effect conversion of the Mill to diversify into the production of Maize products.

Maiduguri Flour Mills Limited was established as a result of the formation of Chad Basin Development
Authority (CBDA) whose mandate is to produce wheat along the Lake Chad Basin and also to produce
wheat flour to the populace of the state.

The objectives are achieved in a way since the wheat flour is made available in any part of the state and
also employment opportunities created in the state.
 1.6.1

ORGANIZATIONAL CHART

GENERAL MANAGER

FINANCE ADMINISTRATION
COMMERCIAL
PRODUCTION
MAIN CASH COMPUTER PERSONNEL INTERNAL
OFFICE ROOM MANAGER AUDIT WARE PURCHASING SALES
ACCOUN
HOUS
MECHANICAL
ELECTRICAL

SECURITY CANTEEN CLINIC TRANSPORT

MILLING
STOREPOWER PLANT

QUALITY
CONTROL LAB.

CHAPTER TWO

2.0 LITERATURE REVIEW

Flour are Finely ground purified material from the wheat kernel, maize or any other cereal crops
Purification of process depends up on source Usually remove the outer fibrous coating through a gradual
milling process Increased palatability but reduced nutritional value maize Flour Pass through 10 XX sieve
Flour particle size range from 1µ to 200µ .
2.1 SOURCES OF FLOUR

Generally flour are ground purified material from cereal crops, cereal grains are fruits of cultivated grasses
members of the monocotyledons family graminea(Kent,1983). They are the seed of domesticated grasses.
Stable civilizations have arisen only when primitive hunting communities have learned how to raise
successive cereal crops unsettled nomadic life.

Cereal crops provide the world most population with most of its food calories and about half of its
protein (Norman, 1978).they is the staple food of the people of the tropics providing them with
about75per of their total caloric intake and 67per of their total protein intake.

TABLE1: Chemical composition of cereal crops (%)

Cereal grain moisture protein fat fibre Ash CHO

Wheat 13.0 14.0 2.5 2.3 1.6 66.6

Maize 12.0 9.5 4.0 1.4 1.3 78

Sorghum 11.0 9.7 3.3 1.5 1.8 72.7

Millet 8.4 8.4 4.0 1.2 1.6 76.2

2.2 PROCESSING MAIZE FLOUR

Corn is the cereal with the highest production worldwide and is used for human consumption, livestock
feed, and fuel. Various food technologies are currently used for processing industrially produced maize
flours and maize grid(masaflour,masavita), also corn meals in different parts of the world to obtain
precooked refined maize flour, dehydrated nixtamalized flour, fermented maize flours, and other maize
products. These products have different intrinsic vitamin and mineral contents, and their processing
follows different pathways from raw grain to the consumer final product, which entail changes in nutrient
composition. Dry maize mechanical processing creates whole or fractionated products, separated by
anatomical features such as bran, germ, and endosperm. Wet maize processing separates by chemical
compound classification such as starch and protein.

2.2.1 MAIZE KERNEL ANATOMY

The maize kernel is composed of four primary structures from a processing perspective. They are
endosperm, germ, pericarp, and tip cap, making up 83%, 11%, 5%, and 1% of the maize kernel,
respectively (Fig. 1). The endosperm is primarily starch surrounded by a protein matrix. Two main types of
starch include hard or vitreous, and soft or opaque. Vitreous endosperm is negatively related to starch
degradability and in vivo starch digestibility in ruminants. The germ or embryo of the maize kernel is high
in fat (33.3%) in addition to enzymes and nutrients for new maize plant growth and development.

The germ also contains vitamins from B complex and antioxidants such as vitamin E. Maize germ oil is
particularly high in polyunsaturated fatty acids (54.7%), which are subject to oxidative and other forms of
rancidity resulting in off or objectionable flavors from full-fat maize products. Pericarp is a high-fiber
(8.8%crude) semi permeable barrier surrounding the endosperm and germ, covering all but the tip cap.
The tip cap is the structure through which all moisture and nutrients pass through during development
and kernel drydown. The black or hilar layer on the tip cap acts as a seal. The term bran is also used to
refer to the fiberrich outer layer (pericarp) that contains B vitamins and minerals and the tip cap.

2.2.2 MAIZE KERNEL COMPOSITION

Table 2 provide the vitamin and mineral analysis of corn, crude bran, and corn starch. As can be observed,
the corn bran is a significant contributor to maize vitamin and mineral content. The wet milling of maize
separates much of its nutrient content away from the starch component. In addition to chemical
composition, physical characteristics of maize in the commercial market place influence the value of the
grain or the final product.

2.3 Milling method

Different types of milling and variations in operating conditions will produce a wide range of particle sizes
in animal feed and human food. These mills include but are not limited to the hammer mill, roller mill, pin
mill, stone mill, disc mill and plate mill. Because the optimum particle size of most farm animals feed
material is greater than 400 μm and due to the need for high milling production capacity, roller and
hammer milling will be the primary focus for this review. Roller-milling has been reported to be more
efficient as it requires less energy for particle size reduction than hammer-milling (Good band et al., 2002)
and the shape of ground particle looks more cubic (Amerah et al., 2007). The extent of energy saving is
dependent on the target particle size: for example the advantage for corn relative to other grains is <5% at
sizes smaller than 500 μm, which increases to 25-30% at 800 μm, and up to 80% at a size of 3000 μm (Kim,
2008). Hammer- mills are more widely used in feed mills because they are easier to operate and maintain
and produce particles spherical in shape (Kim et al., 2002; Amerah et al., 2007). To increase production
capacity of hammer mills, they are equipped with an air-assist system that draws air into the hammer mill
with the product to be ground, thus allowing particles to exit through screen holes (Kim et al., 2002).
Hammer mills have been reported to produce a wide range of particle sizes compared to roller mills
(Seerley et al., 1988; Douglas et al., 1990; Audet, 1995). During roller milling each grain passes through the
mill independently of surrounding grains (Campbell et al., 2001). For that reason, the breakage patterns
for each grain depends mainly on the interaction between the grain, the roller mill design and operation
conditions (Campbell and Webb, 2000). Roller mills have at least two pairs of rollers, often accompanied
by two or three additional pairs that usually crush the grains as it passes between rollers (Laurinen et al.,
2000). Reducing geometric standard deviation along with particle size has been achieved by using mills
employing three high-rollers mills (Healy et al., 1994a). Alternatively, further reduction of geometric
standard deviation has been reported when corn grains are firstly ground by roller mill and then milled
using a hammer mill (Healy et al., 1994a; Wondra et al., 1995a). Adjustment of operating conditions within
a mill can affect particle size distribution. In a milling trial with corn, reducing the hammer mill screen size
from 9.6 mm to 1.2 mm resulted in a linear reduction in geometric standard deviation (Wondra et al.,
1995b; Wondra et al., 1995d). When hammer mill screen size was plotted against geometric standard
deviation, each 1 mm reduction in milling screen size resulted in a 0.09 reduction in geometric standard
deviation (R2=0.82, n=7). Use of multiple stages of grinding using a roller mill has been reported to reduce
geometric standard deviation. However a series of test grindings is required using a double pair roller mill
to establish the optimal distance between the rollers to obtain the required particle size.(Svihus et al.,
2004). Pin milling is of great interest as it has applications in macronutrient enrichment in fractionated
particles although this technique does tend to produce fine particles (Mathew et al., 1999). It is generally
used in nutrient fractionation by separating less dense protein particles from the denser starch particles
(Drew et al., 2007). Pin milling is used mainly in grinding of legumes as this method is capable of producing
a fine grind which facilitates better separation between protein and starch granules without damaging
starch granules (Jones et al., 1959). During pin milling, the number of particles increases greatly and thus
the number of contacts required for further size reduction also increases (Mani and Tabil, 2002).
Therefore, production output of the mill decreases and energy consumption of the infrastructure
increases. After pin milling, air classification is used to produce legume flour and a protein concentrate
fraction (Tyler, 1984; Han and Khan, 1990). To achieve nutrient enrichment/fractionation objectives, a pin
mill must produce a narrow distribution of particle size to facilitate fraction by air classification (Mani and
Tabil, 2002). Multi-stage milling processes have been shown to reduce the total energy required for milling
(Dziki, 2011). In a study of wheat milling, initially grinding of the grains through a roller mill before hammer
milling reduced the total energy required from 32.6-79.0 kJ/kg (hammer milling only) to 23.1-44.4 kJ/kg
(roller milling and hammer milling). The change in particle size distribution in multi-stage milling processes
is also of importance (Dziki, 2008). Soft wheat grains crushed before milling had a lower particle size and a
higher proportion of material that was smaller than 200 μm than samples milled without crushing.
Depending on the moisture content, some hard wheat samples also had a lower particle size and higher
proportion of material smaller than 200 μm.
2.3.1 GRAIN TREATMENT BEFORE AND AFTER MILLING

Several attempts have been used to optimize the grinding process of grains. Tempering grain before
rolling has been reported to reduce mechanical wear on processing equipment (Mathison et al., 1997) and
causes the germ to swell and increase endosperm friability (Bradbury et al., 1960). Tempering has been
reported to be achieved by raising the moisture content of the barley to 200–250 g/kg by adding water,
mixing, and storing for 12–24 h prior to rolling (Dehghan-banadaky et al., 2007). Tempering helps maintain
the integrity of the kernels and reduces shattering when grains pass between the rollers (Yang et al.,
1996). Altering the moisture content also affected the milling of field peas processed through a combined
mill and air classifier. As the moisture content increased, the energy required to create new surface area
through the fracturing of grain particles also increased (Dijkink and Langelaan, 2002a; Dijkink and
Langelaan, 2002b). A comparison of legume seeds showed that their mechanical properties during
crushing depends on a combination of moisture content, type of legume and the characteristic being
studied (force required for deformation through different physical transitions) (Laskowski and Lysiak,
1999). For that reason, tempering increases the proportion of particles retained on the coarsest screens
while decreasing the particles on the finer screens when compared to dry rolling (Combs and Hinman,
1989; Wang et al., 2003; Dehghan-banadaky et al., 2007). Alternatively, moisture can be added as steam
instead of water (liquid phase) as an efficient method to decrease presence of fines after rolling (Hironaka
et al., 1992). In an in vitro study evaluating field peas, roller or hammer milling treatments were combined
with heating to 85°C or 95°C to generate grits with different particle size ranges (Le Gall et al., 2005). It was
shown that protein extraction and degree of hydrolysis decreased with increasing particle size, which was
attributed to an decreased surface area and less destruction of physical barriers to solvent penetration.

CHAPTER THREE

3.0 INSTRUMENTATION AND PROCEDURE

The first milling steps involve equipment that separates maize from seeds and other grains, eliminates
foreign materials such as metal, sticks, stones and straw and scours each kernel of maize. It can take as
many as six steps
1. Magnetic Separator: it is use separate the maize from any iron or metallic particle, the maize first passes
through magnet that removes iron and metal particle

2. Separator

Vibrating screens remove bits of wood and straw and almost anything bigger or smaller than maize
3. Aspirator; Air currents act as a kind of vacuum to remove dust and lighter impurities

4. De-Stoner

Using gravity, the machine separates the heavy material from the light to remove stones that may be the
same size as maize kernels
5. Scourer; The scourer removes outer husks, crease dirt and polish the outer surface with an intense
scouring action. Currents of air pull all the loosened material away.

6. ROLL STAND; The rolls are paired & rotate inward against each other, moving at different speeds just
one pass through the corrugated "first break" rolls begins the separation of bran, endosperm and germ
7.SIFTER; it is use in sifting broken particles of maize are introduced into huge, rotating, box-like sifters
where they are shaken through a series of bolting cloths or screens to segregate the larger from the
smaller particles

8. Purifiers

In a purifier, a controlled flow of air lifts off bran particles while at the same time a bolting cloth separates
and grades coarser fractions by size and quality
 3.1 WEIGHBRIDGE

The maize is received on the weighbridge, the grains and the weight of the vehicle is weighted. The vehicle
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.

3.1.2 HEAD HOUSE

The grain received through the intake points in the head house pass through drum sieves, to remove large
admixtures e.g. wood, glasses and through series of aspirators to remove dust, light impurities e.g.
screenings etc. The dusty air passes through filters, where the dust and screenings are received in bags.
The cleaned air is exhausted in to the atmosphere. The partially cleaned maize is then stored in the silo (6×
900t). The maize is then transferred to the cleaning house through series of conveyors, elevators, and
scale and chain conveyor, to the cleaning house for proper cleaning, into the raw maize bins (6 × 100t).
The quantity to be cleaned weighed over a scale that tips 100kg/tip.

3.1.3 CLEANING OPERATIONS PROCEDURES

From the silo in the head house maize is conveyed with the aid of transfer chain conveyor into the cleaning
house. It will empty its contents into screw conveyors in the cleaning house. The conveyors feed the raw
maize bins (6× 100t). Proper cleaning takes place through flow balancers located at every outlet of the bins
into conveyor. Elevator conveyed it to the last (5 th Floor), into cleaning scale to know the quantity of maize
cleaned. From the scale it goes over magnet into granoster (2×) and aspirators to remove the light and
dusty particles. The grain separator has screens to remove any admixture greater than maize and anything
Smaller than maize. Again the maize runs over series of carter disc separators to separate smaller seeds
and cockles. Elevator conveyed it again to dampener, where water is added to the grain to obtain the
required moisture content. The dampener empties the grains into tempering bins ( 6× 100t) where it is
allowed to stay for at most 24hours after which it undergoes 2 cleaning, and polishing through scourers
(2), aspirators (4×) before emptying into IBK bin almost ready for milling

3.1.4 PRODUCTION PROCEDURES

Milling process: The tempered maize in the IBK bin runs through gravitational force over magnet (2×) unto
the roll stand with corrugated flutes for grinding. With the aid of the high pressure fans the material is
conveyed unto airlocks where separation of the stock and air takes place. The stock goes over a series of
sifter arrangement for classification, according to quality and size, while the dusty air goes to the filters
where cleaned air escapes into the atmosphere through fans and the dusty (Flouring) materials is
circulated into the mill for further processing. The IBK through the sifter gives 2BK and repeatedly; Up to
5BKF where bran is released.

The milling process is a repeated grinding and sifting, classifying the stock according to their qualities and
quantities.

The grits (Masavita) is extracted from purifiers while the Masaflour comes mostly from the sifters ad mini
filters. The bran which is meant for animal feeds comes at the end of the processing line passages.

The 1st quality materials are separated on the first three break rolls sifters and purifiers.

The last batch of the milling machines e.g. M6 –M9, bran finishers, 4BK and 5BKF passages produces 3 rd
quality materials.

The products are packed, transported and stored in containers which safeguard the hygiene and
organoleptic qualities of the products.

Also, the packaging, materials protect the product against bacteria and other contaminants as much as
possible against infestation of moisture, insects infestation and leakage.

It does not impact any odour, taste or colour and any extraneous property to the products

3.1.5 GENERATOR HOUSE

This is the division that supplies electrical power requirement where power is not available or power
doesn’t reach the required voltage supply. The plant has four (4) generators, three works at a time to
provide required power output for every section of the plant to operate and the remaining one is a backup
when ever any of the generators got spoiled. The plant electrical power requirement is about 6.3 MVA and
1KV voltage which is stepped up to 3.3 KV.
Flour mill process Diagram

CHAPTER FOUR

4.0 QUALITY CONTROL LABOROTORY

 The Quality control laboratory operates to ensure the quality of the products, through observing the
following parameters.

4.1 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. Ensuring the moisture of the two stated above do
not fall out of standard of maximum moisture of 10.00% for the maize grits and 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.

4.1.2 PROCEDURE FOR MOISTURE CONTENT DETERMINATION

1. A clear standard crucible dish is weighted and it 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 oc for 30min

4. The sample is removed and placed into a desiccator to cool and weighted as W3

Moisture % = Loss in Weight × 100 W2 - W3 × 100

Weight of Sample W2 - W1

When:

W1= Initial weight of empty crucible

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

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

4.2 Ash Content: This is an index of the extraction rate, to determine the % of in organic matters
present in a sample. It also help in determining the correct colour of products, the physiochemical
requirement of ash % (Max) in maize flour (Masaflour) is 0.70% and that of grits (Masavita) is 0.75%

4.2.1 PROCEDURE FOR ASH CONTENT DETERMINATION

Ash can also 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 a decicator.

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

Ash% = A -D × 100

S - D

Where:

A = Weight of dish + ash residue

S = Weight of dish + weight of sample

D = Weight of dish

4.3 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.

4.4 Peker Test: To visually access the colour index of a product using a spatula this test help to access
visually whether some unwanted particles have managed to escape checks and have found their
way into the product.

4.5 Visual Analysis of Raw Material: this is a test conducted on raw materials to determined whether
the raw material is up to the required standard in terms of physical features e.g. Grain size, colour,
impurities e.t.c.
CHAPTER FIVE

5.0 CONCLUSION AND RECOMMENDATION

5.1 CONCLUSION

In conclusion the major priority of Maiduguri flour mills is to produce flour to the populace of the state
and also employment opportunities is created

The quality control unit is of outmost concern is as much as quality test of flour is important because it
deal with analysis when abnormality is found a report will be sent to the milling section of the plant and
will be corrected.

5.2 RECOMMENDATIONS

For efficient and successful operation of the flour milling plant, I recommend the followings:

 The employment of highly skilled personnel specialized in various fields on milling and
environmental contaminations and control is also needed.

 Research on the need to apply modern technology so as to improve the efficiency of the plant.

 Proper maintenance should be made on the milling unit in order to be able to produce more
qualitative product to the public.

 There should be addition of supplement such as vitamin (A) which is very good for vision.

REFERENCE

1. Christie J.Geankoplis (1993): Transport processes and unit operations in Chemical Engineering 3 rd
Edition Prentice Hall USA.

2. ^ "Dadin Kowa Dam" . Goodlife . Retrieved 2010-05-23.

 3. ^ Timawus Mathias (17 February 2010). "Jonathan Needs More Than Good Luck" . Daily Trust.
Retrieved 2010-05-23.

4. ^ a b "FG earmarks N7bln for Dadin Kowa Dam project in Gombe" . Radio Kwara . 2009-03-28.
Retrieved 2010-05-23.

5. ^ William Mark Adams (2001). Green development: environment and sustainability in the Third
World . Routledge. p. 238. ISBN 0-415-14766-2 .

6. ^ Mike Ogbu (23 March 2010). "Gombe Rural Communities Enjoy Potable Water -Isa" . Daily
Independent . Retrieved 2010-05-23.

7. DWAF (2002) Quality of domestic water supplies. Vol. 4:

Treatment Guide.WRC No. TT 181/02, pp 21 to 22.

APPENDIX

DEFINITION OF TERMS AND ABBREVIATIONS

 EDTA Ethylene Diamine Tetra Aceted

 HCL Hydrogen Chloride

 AgNO3 Silver Nitrate

 K2CrO4 Potassium Chromate

 Al2(SO4)3 AluminiumSulphate

 CaCO3 Calcium Carbonate

 BOD Biochemical Oxygen Demand

 DODDissolved Oxygen Demand

 COD Chemical Oxygen Demand

 TS Total Solids

 SS Suspended Solid.

 DS Dissolved Solid
  NTU Nephelometric Turbidity Unit

 µscm-1 Micro Siemens per Centimetre

 ppm Parts Per Million

 Mg/L Milligram per Litre.

 RMP Revolution per Minute.

CHAPTER ONE
1.0INTRODUCTION
HISTORICAL BACKGROUND OF SIWES
The program was initially introduced in Nigeria by the industrial Training
Fund(I.T.F)which was established under decree 47 of 1971 by the supreme military
council headed by Yakubu Gowon and had as its core objectives, the gradual
reduction of the percentage of foreign participation in most of Nigeria’s economic
activities accompanied by systematic cooperation of locally oriented skilled
manpower into the vast economic sector.
SIWES was established by ITF in 1973 to solve the problem of lack of adequate
practical skill preparatory for employment in industries by Nigerian graduate of
tertiary institute
1.1. Aims of SIWES
To provide avenue for student to acquire industrial skills and experience in their
approved course of study
 Providing an avenue for students in higher institution to acquire industrial skill
and experience in their courses of study.
 Preparing students for the industrial work situations which they are expected
to meet after graduation.
 Exposing students to work methods and techniques in handling equipment and
machinery that may not be available in their institutions.
 Making the transition from the academic institution to the world of work
easier and enhancing students contact for later job placement.
 Providing students with an opportunity to apply their knowledge in real work
situation thereby bridging the gap between theory and practice.
 Enlisting and strengthening employers’ involvement in the entire educational
process and preparing students for employment in industry and commerce
 Correlate the knowledge obtained during the student’s stay with the actual
industrial conditions and to develop a critical and realistic approach to
problems and their solutions.
 Strengthening the cordial relationship between the industrial sector and the
educational institutions.
 Serves to introduce brilliant student train for job recommendations in future.
1.2. OBJECTIVES OF SIWES
>>Expose students to work methods and techniques in handling equipment
and machinery that may be readily available in education institutions
>>Provide opportunity for a student to apply their theoretical knowledge in
real work situations there by bridging the gap between the theory and practice
>> ease the transition from school to the world of work and hence student
contact for later job
>>Strengthen employee’s involvement in the educational process of preparing
student of employment in industries
1.3 BRIEF HISTORY OF FLOUR MILLS MAIDUGURI
Maiduguri flour mills is located at No2 bursari road Maiduguri,it was established in
the year 1983b by the former governor of Borno state Alhaji Mohammed
Goni.Maiduguri flour mills have seven unit i.e the headhouse,cleaning unit,milling
unit,packing,ware house,laboratory,mechanical,electrical and power plant.
 CHAPTER TWO
2.0 PROFILE OF PLACE OF ATTACHEMENT

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.
 ORGANIZATIONAL CHART

GENERAL MANAGER

FINANCE ADMINISTRATION
PRODUCTION
COMMERCIAL

MAIN CASH COMPUTER PERSONNEL INTERNAL

WARE PURCHASING MECHANICAL
ELECTRICAL
SALES
OFFICE ROOM MANAGER AUDIT
ACCOUN
HOUS
MILLING
STOREPOWER PLANT

SECURITY CANTEEN CLINIC TRANSPORT

QUALITY
CONTROL LAB.

2.1 RAW MATERIAL USED AND ITS SOURCE:

The raw material use for the production of flour is wheat. Wheat is beside
Rice and Maize the most important staple grain in the world. It is the only grain that
can be worked into bread without restrictions due to the content of gluten protein.
The type of wheat used mostly in the Maiduguri Flour Mills is the Hard Red Winter
wheat and the soft Red winter imported from (U.S.A) and it arrived to Lagos by
ship. From Lagos it is loaded in trucks and directed to Maiduguri Flour Mills L.T.D.

With the recent wage of insecurity and financial crisis wrecking the state and
the country at large, crop production at the Lake Chad basin came to a drastic halt
and likewise importation. These setbacks caused the flour mill to switch from wheat
to maize. The maize used are local grains from local markets all over Nigeria.

Maize or corn (zea mays) is a plant belonging to the family of grasses. It is

cultivated globally being one of the most important cereal crops worldwide. Maize is
not only important to human nutrient but also a basic element of animal feed and raw
material for manufacture of many industrial products. These products include corn
starch, corn oil, masavita, and products of fermentation and distillation industries.

Maize grain can be classified into four different layers namely;

Table 2 1. The vitamin and mineral analysis of corn, crude bran, and corn starch.

Vitamin Unit/100g Corn, Whole Corn, Bran Corn, Starch

Calcium mg 7.00 42.00 2.00

Iron mg 2.71 2.79 0.47

7
Magnesium mg 127.00 64.00 3.00

Phosphorus mg 210.00 72.00 13.00

Potassium mg 287.00 44.00 3.00

Sodium mg 35.00 7.00 9.00

Zinc mg 2.21 1.56 0.06

Copper mg 0.31 0.25 0.05

Manganese mg 0.49 0.14 0.05

Selenium µg 15.50 16.5 2.80

 i. Aleuron
ii. Endosperm
iii. Germ layer
iv. Bran

Bran: The bran layer also referred to the back or the outermost layer of the maize,
the excess of bran part in flour in ash content, hence it should be within 2 to 5
percent.

Aleuronic layer: Immediately below the bran layer, it is usually a very thin layer
which provided covering for the Endosperm.

Endosperm: The endosperm is the bulk of fleshy part of the maize reached in
carbohydrate and is usually whitish in appeareace.75 percent extraction rate is
expected.

Germ Layer: The germ layer is the innermost layer of the maize, usually smaller
compared to the size of the maize and it is found at the central middle of the maize.
The germ layer is reached in oil and protein and constitutes the major cause of
maize product particularly.

2.2 VARIOUS UNIT AT MAIDUGURI FLOUR MILLS

Maiduguri Flour Mills have seven units i.e

2.2.0 HEAD HOUSE

The Head house is the section of the factory where raw maize are 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.

2.2.1 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. Itmakes the
milling much easier.
2.2.2 MILLING UNIT: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 maize offal’s.

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

2.2.4 WARE HOUSE:is the final stage because it is the place where all the goods
are stored both the masavita and masa flour.

2.2.5LABORATORY: 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.

2.2.6MECHANICAL UNIT:mechanical unit undertakes the construction of all

mechanical systems whether they are flished or developable.all spoiled machines
and engines are kept in the mechanical unit.

2.2.7ELECTRICAL/POWERPLANT UNIT:electrical is the unit that supplies

electricity to the units,is the supply of electricity from powerplant to electrical unit
via 70mm annorcable.powerplant is where the generator are kept and operated by
the powerplant technicians.

CHAPTER THREE
3.0ACTIVITIES AT THE ORGANISATION:
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.

3.0.0WEIGHBRIGDE

The weighbridge is located at the entrance of the industry. 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.

3.1HEAD HOUSE

The head house is multi-story cleaning tower, in which its primary function is to
remove coarse impurities, such as strings, straw, parts of bags and foreign matters.
These impurities usually become mixed with the grain in the field and during its
transfer through the various stages of the grain-handling system.

Operations carried out at Head House are mainly intake, pre-cleaning, storage and
transfer. These operations are carried out with the aid of some machines. These
include:-
>>The dump bridge
>>conveyor
>>Elevator
>>Metric scale (for Intake and Transfer);
>> Drum-Sieves
>> Filters and silos
A typical Intake process commences as grains is dumped at the dump-bridge
from delivery trucks. The dump-bridge has a receiving hopper which direct raw
grains 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 drumsieve. The drum-sieve separates maize from other large foreign
matter such as metal, sticks, 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. The intake scale measures 500Kg of maize per tip each of its automated
running, an average of three tips equals 1500kg of maize per minute is recorded.
That is between (18 which -20) seconds per each tip. The weighted maize is then
channel by gravity through conveyor pipeline to elevator 2 or 3, any direction (2 or
3) may be chosen at a particular time. The elevator 2 or 3 again lifts the maize and
discharge it at the entry point (inlet) of the chain conveyor 2 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.
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.
HEAD HOUSE FLOORS AND MACHINES

Table 2.2 Head house floors and machines

S/N FLOORS MACHINES

ND
1 2 UNDERGROUND FLOOR BASE OF ELEVATOR 1,2, AND 3

ST
2 1 UNDERGROUND FLOOR CONVEYOR 101 AND 102
 3 GROUND FLOOR SCREEN WEIGHING SCALE

4 SECOND FLOOR INTAKE SCALE

5 THIRD FLOOR BASE OF TRANSFER ELEVATOR

6 FOURTH FLOOR ASPIRATORS 1,2,3 AND 4

7 FIFTH FLOOR TRANSFER SCALE AND DRUM SIEVES

8 SIXTH FLOOR FILTERS, BLOWERS AND TRANS. CONV.

9 SEVENTH FLOOR FANS, CONVEYOR 112 AND 113

10 EIGHTH FLOOR COMPRESSOR AND EXHAUST PIPE

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 stored in bins which are also six in number.

Pictorial View of the Silos

3.2 MILLING SECTION

The milling section is the heart of the flour mill industry. It is the section
which involves separation of the bran layer from the endosperm and reduces the
endosperm to flour. The main function these section is the gradual reduction of the
endosperm through several sub processes of repeated grinding, scalping, sifting,
grading and purification, for the extraction of flour, masavita, masaflour and maize
offal’s.
The grains are drawn from the silos prior to milling are thoroughly cleaned,
tempered, milled and packaged within the mill section. The quality control section
(laboratory) which is also an extension of the mill building to ascertain that the
best quality required is achieved at every step in the production process.

The MFM mill building comprises of six different floors with a basement, and
each floor has plays a significant role in the grain processing. Below are the several
floors which make up the mill building in descending order (i.e. from the last floor to
the ground floor) with brief description of the operations carried out in each;

 Cleaning Floor

 Screening Floor

 Air lock Floor

 Sifter Floor

 Spout Floor

 Roller Floor

 Basement

Cleaning Floor: The cleaning floor is the topmost floor in the mill building. It is
where the proper cleaning starts, after the grains are pre-cleaned at the at the Head
house. It contains many machines which plays significant role in the cleaning process
at the mill building. The machines include conveyors (both chain and screw),
dampener, cleaning scale, scourer, the opening of dirty and tempered bins etc.

Screening Floor: The screening floor is the second floor from the top, just
immediately after the cleaning floor. It is where large air-filter tanks and other
grain cleaning machines such as the De-stoner are being operated.
Air lock Floor: This is the floor next to the screening floor from the top. In this
floor, there is a machine called Air-lock whose sole function is to separate air from

12
the grist which comes through pneumatic means in a conveyor pipe from the roller
machines.

Sifter Floor: This is the fourth floor from the top. Apart from other machine which

participate in the cleaning process, there are series of mechanical sifters installed to

classify the grist into five (5) different size range. Hence the collection of
masaflour and masavita are also trapped from the purifiers.

Spout Floor: This is the second floor from the ground. The floor has
interconnected network of conveyor pipes which are used to connect and convey
products (truce and over tail) of the same class 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 is the ground floor, its consist of mainly rollers (first break and
reducing rolls) which are used in the grinding of grains. Other machines, installed
on this floor include scourer and aspirator. 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.
3.4 THE PRODUCTION PROCESS

In general, the operations which made the production process can be

classified in to six (6). These include:

 Cleaning

 Tempering

 Milling

 Packaging

 Storage

3.4.1 CLEANING

There is a whole section in the mill industry called the “cleaning section or
unit”. The pre-cleaned maize from Silos in the Head house are transported to the
Cleaning section and subjected to further cleaning using several machines/devices.
These machines eliminate foreign materials such as metal, sticks, stones and straw
from the maize grain. The heterogeneous physical characteristics of maize grains
(namely, different dimensions, specific weight, and shape even in one load)
contribute to the difficulties of separating unwanted materials. Hence, 5 principles
are used in eliminating these unwanted/foreign materials from the maize grains.
These are;

 Sorting by size

 Sorting by specific weight

15
  Sorting by air resistance

 Sorting by natural characteristics

 Sorting by shape

SORTING BY SIZE

It is the sorting method which is one of the easiest cleaning principles so far.
Substance that are smaller or larger than the maize grains are sorted by revolving,
shaking, and reciprocating motions. In this stage, machinery such as the Granuster
separator is being used.

SORTING BY SPECIFIC WEIGHT

Some of the foreign matters may have the same size as the maize grain and cannot
be eliminated by sorting by size. Such sorting can be achieved by using vibration
and adjustable air steam. Machine which can handle sorting by specific weight is
the De-stoner.

SORTING BY AIR RESISTANCE

This process helps to clean materials that are lighter than the maize grains as well
as other dust, sand and fodder. The grains are cleaned from the said contaminants
by using equipment such as the Aspirator, with the aid of air current.

SORTING BY NATURAL CHARACTERISTIC

The nature of the material is being considered here. Material such as metals, are
sorted from the grains using Magnet. Elimination of metals from the process is
important, as it may damage the machinery and pose a risk of dust explosion.

SORTING BY SHAPE
When the size and specific weight of waste materials is the same as the maize
grain, sorting by shape can be used. This is achieved by using disc, spiral and
cylinder separators. These process has become more efficient in the recent years.

Before the cleaning starts, the pre-cleaned maize is temporary stored in Bins
called “Dirty Bin”. The dirty bins are six (6) in numbers within the Mill building,

16
each with a capacity of 124 metric tons. The cleaning process commences by
passing the maize through the;

FLOW BALANCER: The flow balancer is a device attached to the conveyor pipe
connecting the Bins to the screw conveyor. It has graduation on it which enable the
flow rate of the maize grains discharged from the Bins to be regulated by adjusting
to the required reading, so that to avoid choking.

Figure 3.1 Pictorial view of flow balancer

Then, the maize grains are collected in the screw conveyor and transferred to
elevator 1, which lifts the maize to the cleaning floor and discharged by gravity
into cleaning scale.

CLEANING SCALE: This is a scale that measures the quantity of maize grains
that passes through the cleaning process. It measures by tip, and each tip is 100kg
which take approximately 35-40 seconds. The readings are taking on hourly bases.
The maize grains are then discharged by gravity through conveyor pipe to a
magneticseparator