Maize Processing Equipment

Maize processing and preparation require specific steps and measures to be taken to guarantee product quality and profits. Drotsky offers low capital cost solutions to produce Hammer milled maize meal.

Maize processing and preparation steps:

  1. 1. Pre-cleaning

    1. Pre-cleaning

    The pre-cleaning step is extremely important, as this is where any and all foreign materials are removed from the maize. This can be anything from stones and dust to other plant matter and poisonous seeds. This process can also be used to remove any matter which is too large and heavy or too small and light to be maize, ensuring that only quality product is included in your process.

    • Pre-Cleaner
  2. 2. Cleaning and conditioning

    2. Cleaning and conditioning

    During the determination process the maize product from the pre-cleaning step is placed in the conditioner’s water wheel, with an accurate amount of water. This step aids in washing the maize and helping to remove the skin through the mechanical action of the conditioner’s paddles.

    • Maize Conditioner
  3. 3. Degermination and Cleaning

    3. Degermination and Cleaning

    Once the maize has been thoroughly cleaned it goes into the samp plant, which uses a hammer mill to break the maize and loosen the husks from the germs. Once these husks and germs have been loosened the resulting product is fed through the aspirator, which uses vertical airflow to separate the husk and germs to be separated from the samp.

    • Samp Plant
  4. 4. Milling into the desired product

    4. Milling into the desired product

    Once the samp has been separated by the aspiration process it can finally be put through a high-speed hammer milling process to provide the final product. The screen size in this step will determine the size of your final product.

    • Hammer Mills
1. PRE-CLEANING

1. Pre-cleaning

The pre-cleaning step is extremely important, as this is where any and all foreign materials are removed from the maize. This can be anything from stones and dust to other plant matter and poisonous seeds. This process can also be used to remove any matter which is too large and heavy or too small and light to be maize, ensuring that only quality product is included in your process.

  • Pre-Cleaner
2. CLEANING AND CONDITIONING

2. Cleaning and conditioning

During the determination process the maize product from the pre-cleaning step is placed in the conditioner’s water wheel, with an accurate amount of water. This step aids in washing the maize and helping to remove the skin through the mechanical action of the conditioner’s paddles.

  • Maize Conditioner
3. DEGERMINATION AND CLEANING

3. Degermination and Cleaning

Once the maize has been thoroughly cleaned it goes into the samp plant, which uses a hammer mill to break the maize and loosen the husks from the germs. Once these husks and germs have been loosened the resulting product is fed through the aspirator, which uses vertical airflow to separate the husk and germs to be separated from the samp.

  • Samp Plant
4. MILLING INTO THE DESIRED PRODUCT

4. Milling into the desired product

Once the samp has been separated by the aspiration process it can finally be put through a high-speed hammer milling process to provide the final product. The screen size in this step will determine the size of your final product.

  • Hammer Mills

Maize Plant – Big Plant

The maize plant processes 1 ton raw maize per hour. The plant has one feed point and two product outlets. The product being milled maize and hominy chop. Raw maize is fed by bags or pit through a screw conveyor to the first machine which screens maize, removing foreign materials.

This machine in turns feed clean maize to a 6m 100mm auger which transports said maize to the water wheel which adds a present amount off water per kg of maize. The maize passed through the machine to a condition- ing unit, which allows for a present retention time and pre-removal off husks.

The conditioner feeds into two hammer mill degerminators. The degerminators gravity feed into an aspirator which removes the husk and germ for stamp. The hominy chop is pneumatically transported to a cyclone for collection while the stamp is fed to a M16 hammer mill for final milling into maize meal.

Separation ratios are estimated at 65:35 maize and hominy chop respectively.

1ton/hr Maize Meal Plant

The maize plant was designed to process an estimated one ton of maize per hour at a minimal capital investment.

Process
  1. Maize is moved from a pit, silo or bags by a 100 mm auger to the pre-cleaner.
  2. The pre-cleaner removes all foreign materials from the maize.
  3. A 100 mm screw conveyor moves cleaned maize from the pre-cleaner to the water wheel where an adjustable amount of water is added.
  4. The water is allowed to penetrate the maize by the mechanical action of the conditioner.
  5. The conditioner empties into one or two samp hammer mills which break the maize up into samp and chop.
  6. The mixture of samp and chop passes through the aspirator where the husks and germs are separated from the samp. The by-product is collected in a cyclone.
  7. The cleaned samp passes through an M16 hammer mill where it is milled to the desired size.

Big Plant - Machine List
  • 100mm pre-cleaner feed screw conveyor
  • Conditioners
  • Precleaner
  • S6 degerminator hammer mills
  • 100mm waterwheel feeder
  • Aspirator with cyclone separator
  • Water wheel
  • M16 Hammer Mill
Big Plant Power
Power  
100mm Pre-cleaner feed screw conveyor 1.1kW DOL (direct on line starter)
Pre-cleaner 0.55kW DOL
100mm waterwheel feeder 2.2kW DOL
Conditioners 0.75kW DOL
S6 Degerminator hammer mills 11kW x 2DOL
Aspirator with cyclone separator 0.75kW DOL
M16 hammer mill 22kW Star Delta Starter

Super Plant

The S6&S8 Super Plantsare a 3-in-1 solution to maize processing which is available in electrical and diesel models. It consists of:


  1. A slow-speed hammer mill which loosens the husks and germs,
  2. An aspirator which separates these from the samp, and
  3. A high-speed hammer mill which mills the samp into maizemeal.
S6 Specification

Rotor Speed

 

Hight Speed Mill
Hight Speed Mill

3400 rpm
725 rpm

Motor Speed

1450 rpm

kW Required

11 kW

Hp Required

20 hp

Screen Size

1500 x 130 mm

Hammer Mill Size

246 x 175 x 146 cm

Samp – Slow Speed Mill

6/8 mm Screen

150-200 kg/h

Maize – High Speed Mill

0.8 mm Screen
1.2 mm Screen

400 kg/h
500 kg/h

 
S8 Specification

Rotor Speed

 

Hight Speed Mill
Hight Speed Mill

3400 rpm
725 rpm

Motor Speed

1450 rpm

kW Required

15 kW

Hp Required

20 hp

Screen Size

1500 x 190 mm

Hammer Mill Size

246 x 175 x 146 cm

Samp – Slow Speed Mill

6/8 mm Screen

300-400 kg/h

Maize – High Speed Mill

0.8 mm Screen
1.2 mm Screen

450 kg/h
700 kg/h

Samp Plant

The capacity of samp plant is 150 to 200 kg/h.

Process:

  1. Wet maize is put into the feeding tray.
  2. The hammer mill breaks the maize to loosen the husks and the germs.
  3. The product goes through the aspirator where the husks and germs are separated from the samp.
  4. The husks and germs get blown into the cyclone.
  5. The end product (samp) falls out of the outlet on the aspirator.

Pre-Cleaner

The pre-cleaner is used to clean the maize before it is put into the hammer mill or other production processes. This machine separates dust, leaves, cobs and foreign bodies from the maize corn.

Maize Conditioner

The Maize Conditioner operates in conjunction with the water wheel during the determination process. Water is accurately added by the mechanical measuring device in the water wheel for every kilogram input of maize. The conditioner’s slow moving paddles allow for adequate retention time of the maize while the mechanical action aids the removal of the maize skin.

Aspirators

The Aspirator separates heavy and light particles such as maize germ and husk from samp. Product mixtures enter the machine, where they are suspended by air moving vertically. The amount and speed of the air flow is fully adjustable. Waste generated is then separated by means of a cyclone while the final product simply drops to the bottom.

Specifications:

0.75 kW Blower
Capacity 1ton/hr