Grain Processing Technologies

Class 12 – October 19th, 2017

Corn and oat processing

technologies
Prof. Dr. Nathan Levien Vanier
Corn production

Source: FAO (2017)

Corn utilization
Corn processing

Freshly harvested corn

Cleaning, drying and storage processes

Dry milling Wet milling Nixtamalization

Flaking grits Starch Nixtamalized flour

Brewing grits Germ Tortilla
Other grits Bran Chips
Flour Soaking water
Germ
Bran
Product classification according to particle
diameter

Source: Eckhoff, Dry Milling, In: Encyclopedia of Grain Sci., 2004.

Milling quality depends on maize/corn
structural characteristics
Corn endosperm

Source: Delcour and Hoseney, Principles of Cereal Science, Chapter 1, 2010, 260p.
Corn endosperm characteristics
Dry milling
Corn

Cleaning and selection

Milling

Selection and sieving

Whole maize flour

Dry milling
 Dry milling Germ
Pericarp
Corn grains

Cleaning and selection Selection

Conditioning (21% moisture)

Milling
Degermination
Oil extraction
Milling
Starch/Glucose
Selection and sieving Alcohol

Flour from degerminated maize/corn

Conditioning step details
 Conditioning step details

Addition of 6% to 8% of water in relation to grain mass  Tempering for 10 to 40 min.

Corn degerminator
Milling yield of 9 hybrids using a Beall-type
degerminator

Source: Eckhoff, Dry Milling, In: Encyclopedia of Grain Sci., 2004.

Micronization treatment of corn flour with
infrared at different time-temperature conditions

(a) control; (b) infrared at 159 °C/173 s/40%; and (c) infrared at 166 °C/164 s/40%.

Fonte: Deepa & Hebbar et al., Journal of Cereal Science, v. 60, p. 569-575, 2014.
Micronization treatment of corn flour with
infrared at different time-temperature conditions
Increased conservability

Fonte: Deepa & Hebbar et al., Journal of Cereal Science, v. 60, p. 569-575, 2014.
 Wet milling

1) Soaking

Bins with water recirculation set

at 52ºC.

Time varies from 20 to 48 h.

 Wet milling

1) Soaking
2) Germ removal

Mechanical shearing and cutting.

 Wet milling

1) Soaking
2) Germ removal

Mechanical shearing and cutting.

 Wet milling

1) Soaking
2) Germ removal

Mechanical shearing and cutting.

Separation using hydrocyclone.

 Wet milling

1) Soaking
2) Germ removal
3) Fiber separation
 Wet milling

1) Soaking
2) Germ removal
3) Fiber separation
 Wet milling

1) Soaking
2) Germ removal
3) Fiber separation
4) Protein separation
 Wet milling

1) Soaking
2) Germ removal
3) Fiber separation
4) Protein separation Separation by density profile
using a disc centrifuge.
 Wet milling

1) Soaking
2) Germ removal
3) Fiber separation
4) Protein separation
5) Starch
 Wet milling

1) Soaking
2) Germ removal
3) Fiber separation
4) Protein separation
5) Starch

Separation using hydrocyclone.

Nixtamalization
Maize + Ca(OH)2
Cooking for 25-30 min + hydration
for X time
Drainage of solution

Germ removal

Milling Drying

Frying Nixtamalized massa Sieving

Chips Cooking
Nixtamalized maize
flour
Table Tortillas
Mexico - 1836
Nixtamalized maize after water drainage
Nixtamalization
 Nixtamalization – research results

Calcium content in maize fractions and nixtamalized flour.

Fonte: Cornejo-Villegas et al., LWT, v. 53, p. 81-87, 2013.

Nixtamalization – research results

149 μm

420 μm

Fonte: Palacios-Fonseca et al., Journal of Food Engineering, v. 93, p. 45-51, 2009.

Nixtamalization – research results

Fonte: Palacios-Fonseca et al., Journal of Food Engineering, v. 93, p. 45-51, 2009.

Corn flakes
Oat processing
Oat grains

Cleaning and selection

Dehusking

Stabilization (toasting)

Flakes production Cutting Partial milling

Flakes production
Cleaning and selection

Fonte: Ganbmann e Vorwerck, In: The oat crop, Ed. Chapman & Hall, 1995.
Oat processing
Oat grains

Cleaning and selection

Dehusking

Stabilization (toasting)

Flakes production Cutting Partial milling

Flakes production
Dehusking – Rotary impact mill
Greater hulling degrees are obtained at
low moisture levels

Fonte: Ganbmann e Vorwerck, In: The oat crop, Ed. Chapman & Hall, 1995.
Hulling degree as a function of peripheral
speed of a Rotary impact mill

Fonte: Ganbmann e Vorwerck, In: The oat crop, Ed. Chapman & Hall, 1995.
Oat processing
Oat grains

Cleaning and selection

Dehusking

Stabilization (toasting)

Flakes production Cutting Partial milling

Flakes production
Stabilization

83-100 ºC for ±30 min

Moisture level may be increased for
successfull stabilization of oats

Fonte: Ganbmann e Vorwerck, In: The oat crop, Ed. Chapman & Hall, 1995.
Oat processing
Oat grains

Cleaning and selection

Dehusking

Stabilization (toasting)

Flakes production Cutting Partial milling

Flakes production
Cutting is performed in a drum with knives
attaches

Fonte: Ganbmann e Vorwerck, In: The oat crop, Ed. Chapman & Hall, 1995.
Oat processing
Oat grains

Cleaning and selection

Dehusking

Stabilization (toasting)

Flakes production Cutting Partial milling

Flakes production
 Flakes production

94-100 ºC for ±30 min

Effects of tempering time and temperature
on flake thickness

Fonte: Gates et al., Journal of Cereal Science, v. 48, p. 288-293, 2008.