Industry Overview
Maize or corn dry milling is a relatively less versatile and less capital-intensive process that focuses on converting maize kernels into value-added products such as grits, flour, germ and related products. In traditional dry-grind operations, corn kernels are hammer milled into medium- to fine-grind meal, while dried distillers grain (DDG) can be produced as a low-value animal feed product in ethanol facilities.
Dry milling technology has been standardized by the Central Food Technological Research Institute (CFTRI), Mysore. Grits are a principal product of the dry milling process and are used domestically as porridge. Processing units can also use grits for ready-to-eat products such as corn flakes and for the manufacture of glucose through direct hydrolysis.
Maize is an important staple food and industrial raw material in India. The report states that annual maize production in India is around 21 million tons, with major cultivation in Karnataka, Andhra Pradesh and Rajasthan. Maize is cultivated across different growing seasons and agro-climatic zones and is widely used for flour, roasted immature cobs, animal and poultry feed, corn flakes and other applications.
Existing small-scale units process limited quantities and generally produce only a few products with restricted demand. A larger dry milling unit can process greater quantities of maize and produce a wider range of value-added products.
Cost Estimation
| Particulars | Details |
|---|---|
| Plant Capacity | 100 MT/Day |
| Land & Building (12,000 sq.mt.) | Rs. 5 Cr |
| Plant & Machinery | Rs. 2 Cr |
| Working Capital for 1 Month | Rs. 4.48 Cr |
| Total Capital Investment | Rs. 11.80 Cr |
| Rate of Return | 28% |
| Break Even Point | 59% |
Content Index
- INTRODUCTION
- USES AND APPLICATION
- GRITS/CONES
- FLOUR
- GERM
- MAIZE KERNEL ANATOMY AND COMPOSITION
- MAIZE KERNEL COMPOSITION
- MAIZE OUTLOOK IN INDIA
- INTERNATIONAL GRAIN COUNCIL’S WORLD CORN PROJECTIONS (IN MILLION METRIC TONNES)
- INTERNATIONAL GRAIN COUNCIL’S INDIAN CORNPROJECTIONS (IN MILLION METRIC TONNES)
- MONTH-WISE AVERAGE PRICES OF MAIZE AT VARIOUS MARKETS
- MAIZE ARRIVALS AND PRICES IN WARANGAL MARKET FOR THE MONTH OF JUNE 2020
- MAIZE PRICE OUTLOOK
- MARKET OVERVIEW OF MAIZE DRY MILLING
- PRESENT MANUFACTURERS/SUPPLIERS
- COMPOSITION OF YELLOW DENT CORN
- SAMPLING PROBE
- CORN TESTING
- GRAIN STORAGE
- CLEANING
- TEMPERING CONVEYOR
- DEGERMINATOR
- DRY MILLING OF GRAIN
- PROCESS OVERVIEW OF CORN DRY MILLING
- TEMPERING
- DEGERMINATION
- ASPIRATION
- GRAVITY SEPARATION
- ROLLER MILLING AND SIFTING
- MILLING SYSTEM OF MAIZE
- PROCESSING OF MAIZE
- DESTONING
- CONDITIONING
- TEMPERING
- CONDITIONING
- DEBRANNING AND DEGERMING
- HORIZONTAL ABRASIVE POLISHER
- HORIZONTAL FRICTION POLISHER
- SIFTING
- SPECIFIC GRAVITY SEPARATOR
- DRYING
- DETAILS OF MAIZE DRY MILLING
- COMPARISON OF PRODUCT YIELD FOR LABORATORY DRY-MILLED MEDIUM-HARD ENDOSPERM AND MEDIUM SOFT ENDOSPERM DENT MAIZE DRIED AT TWO TEMPERATURES
- INDUSTRIAL MAIZE PROCESSES
- TYPES OF DRY GRINDERS
- THREE METHODS USED FOR CORN DRY MILLING
- PROCESS OVERVIEW
- TEMPERING
- DEGERMINATION
- ASPIRATION
- GRAVITY SEPARATION
- ROLLER MILLING AND SIFTING
- MANUFACTURING PROCESS
- CLEANING
- CONDITIONING
- DEGERMINATION
- DRYING
- COOLING
- GRADING
- MILLING
- PROCESS FLOW DIAGRAM
- TEMPERING DEGERMING PROCESS
- TECHNOLOGICAL PROCESS OF CORN GRITS AND FLOUR PRODUCTION LINE
- CORN GRITS AND FLOUR PRODUCTION LINE WITH DRY METHOD
- TECHNOLOGY INTRODUCTION OF CORN GRITS AND FLOUR PRODUCTION LINE
- DETAILS OF DRY MILLING PROCESS OF MAIZE
- EXPERIMENTAL DRY MILLING OF CORN
- MATERIALS AND METHODS
- MATERIALS
- EXPERIMENTAL METHODS
- ANALYTICAL METHODS
- RAW MATERIALS & FINISHED PRODUCTS
- PRINCIPLES OF PLANT LAYOUT
- STORAGE LAYOUT
- EQUIPMENT LAYOUT
- SAFETY
- PLANT EXPANSION
- FLOOR SPACE
- UTILITIES SERVICING
- BUILDING
- MATERIAL-HANDLING EQUIPMENT
- RAILROADS AND ROADS
- PLANT LOCATION FACTORS
- PRIMARY FACTORS
- SPECIFIC FACTORS
- EXPLANATION OF TERMS USED IN THE PROJECT REPORT
- PROJECT IMPLEMENTATION SCHEDULES
- INTRODUCTION
- PROJECT HANDLING
- PROJECT SCHEDULING
- PROJECT CONSTRUCTION SCHEDULE
- TIME SCHEDULE
- PLANT LAYOUT
- SUPPLIERS OF RAW MATERIALS
- HDPE WOVEN BAGS
- SUPPLIERS OF PLANT AND MACHINERY
- BUCKET ELEVATOR
- CYCLONE
- SCREW CONVEYORS
Appendix
- 1. COST OF PLANT ECONOMICS
- 2. LAND & BUILDING
- 3. PLANT AND MACHINERY
- 4. FIXED CAPITAL INVESTMENT
- 5. RAW MATERIAL
- 6. SALARY AND WAGES
- 7. UTILITIES AND OVERHEADS
- 8. TOTAL WORKING CAPITAL
- 9. COST OF PRODUCTION
- 10. PROFITABILITY ANALYSIS
- 11. BREAK EVEN POINT
- 12. RESOURCES OF FINANCE
- 13. INTEREST CHART
- 14. DEPRECIATION CHART
- 15. CASH FLOW STATEMENT
- 16. PROJECTED BALANCE SHEET
Frequently Asked Questions
Maize dry milling is a process used to convert maize kernels into products such as grits, flour and germ. The process generally involves operations such as cleaning, conditioning or tempering, degermination, aspiration, separation, milling and sifting. The report describes dry milling as a comparatively less capital-intensive process and highlights its use for producing products for food and other applications. The technology can be configured to produce different fractions according to product requirements and processing conditions.
The main products identified in the report are maize grits, flour and germ. Grits are an important product and can be used for domestic porridge preparation and in value-added food applications such as ready-to-eat products including corn flakes. Flour can be used in food applications, while germ represents another separated fraction of the maize kernel. The report also discusses dried distillers grain as a low-value animal feed product associated with traditional dry-grind ethanol facilities.
The principal steps include cleaning, conditioning or tempering, degermination, aspiration, gravity separation, roller milling and sifting. The report also covers operations such as destoning, debranning, polishing, drying, cooling and grading. Depending on the selected process configuration, these operations help separate the maize kernel into different fractions and prepare them for further milling and classification. Detailed process descriptions and process flow diagrams are included in the project report.
Tempering is a conditioning operation used as part of maize dry milling before subsequent processing stages. It prepares the grain for operations such as degermination and milling. The report separately identifies tempering and conditioning among the processing stages and includes dedicated sections on the tempering and degerming process. The precise operating conditions depend on the characteristics of the maize and the selected processing system, so plant design and operating parameters should be established according to the intended product and technology.
Equipment used in maize dry milling can include cleaning systems, tempering conveyors, degerminators, destoners, polishers, sifters, specific gravity separators, dryers, roller mills and material-handling systems. The report specifically includes suppliers and equipment sections covering bucket elevators, cyclones and screw conveyors. Equipment selection depends on the process configuration, required product specifications, material-handling requirements and plant capacity. The report also provides sections dealing with equipment layout and material-handling equipment.
A maize dry milling plant should consider raw material availability, plant location, storage, building requirements, floor space, utilities, equipment layout, material handling, transportation access and safety. The report contains dedicated sections covering plant location factors, primary and specific factors, storage layout, equipment layout, utilities servicing, roads, railroads and plant expansion. Product requirements and the desired processing configuration are also important because they influence the equipment arrangement and process flow. Proper planning helps integrate processing, storage and material movement within the facility.
Maize dry milling can support value-added processing because the kernel can be separated and processed into multiple useful fractions, including grits, flour and germ. The report notes that small-scale units may produce only a few products with limited demand, whereas a larger unit can process greater quantities of maize into different value-added products. Grits, for example, can be used in ready-to-eat snack applications such as corn flakes and for glucose manufacture through direct hydrolysis. The range of potential products depends on the selected technology and market requirements.
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