Discussion created on 01/23/2019

Stem flaking experience for corn

I am having issue with jelly corn on the roller of the flakes, which is causing me to stop production and clean the roller to be able to continue production tempering corn 4 hours steam conditioning 30 min roller gap 0.3 mm mill capacity 5ton/hr. Any suggestions?

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Enrique Diaz Enrique Diaz
Agro Engineer Zootechnist. Product Line Manager Vegetable Oil & Animal Feed Divisions
January 23, 2019

Tempering supposed to be done when the steam chest is undersized and, in addition, 4 hours is a very short time. You need to expose the corn to the water/surfactant mixture for more time in order for the liquid to be absorbed instead of being in the corn surface.

Residence time inside the steam chest @ 30 minutes for corn seems also short, it should be more close to 45-50 minutes. What is the moisture content of the corn entering your flaking mill?

Regards,
ED

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January 23, 2019
Enrique Diaz
Hello Enrique
My steam chest can take capacity of 15 T
Moisture of the corn before tempering 13 to 14 %
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Enrique Diaz Enrique Diaz
Agro Engineer Zootechnist. Product Line Manager Vegetable Oil & Animal Feed Divisions
January 23, 2019

Mohamad;
The moisture content entering the flaking mill should be close to 18% and make sure you have enough residence time in the steam chest in order to hydrolyze the starches. You must be wasting a lot of energy (in form of steam) by trying to transfer the heat into the corn by having an oversized steam chest. I will suggest you to by-pass the tempering step since is not required at this point. You also need to get the right size steam chest to better use the steam and heat transfer.

Reply
January 23, 2019
Enrique Diaz ;
14% moisture of corn is the corn as raw material before tempering, currently what I am doing is the following:
the corn passes thru a chain conveyor while sprinkling water on the corn
then the corn passes thru the holding bin to the chest directly (I have two holding bins 10 T each , but I am bypassing the first batch and holding the corn inside the chest itself)
after 4 hours steam is introduced gradually (4 levels / 5 min delay between each level)
after 20 min temp inside the chest is 95 C
after 15 min flaking start

but the phenomena of corn sticking on the roller is it due to roller gap or corn condition ?
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Enrique Diaz Enrique Diaz
Agro Engineer Zootechnist. Product Line Manager Vegetable Oil & Animal Feed Divisions
January 23, 2019
Could be a combination of both factors.
The rolls surface is corrugated or smooth?

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January 23, 2019
Enrique Diaz ;
corrugated
Reply
January 23, 2019

Dear Mr. M. Kamareddine;
Greetings from Texas my Dear Friend and I appreciate the opportunity to be of assistance to you regarding the best way to properly cook or condition corn and produce the best and most nutritious corn flakes for animal feed rations.
I have been associated with Ferrell Ross for more than 35 years and involved personally in supplying many corn flake feed systems in the USA, Mexico and many other countries, we offer not only the Flaking Mill (new or Rebuilt Guaranteed at 30-40% savings over the price of new) but we also can supply the complete system from reception and proper cleaning of the corn or any other seed or cereal to Flaking and cooling the flakes and bagging them if you wish to do so.
Please let me know via Email if you wish to have a private consultation regarding all the above.
for a private consult to discuss in detail the process and our recommendations please see my contact information below;
Ralph Romero
Email; ralph@rdequipmentco.com
SKYPE; ralphromero1210@icloud.com
817-563-2571
Cel and WhatsAp 1-817 -723 -5587

Reply
January 29, 2019
Most flaking mills designed for steam flaking grain will include scraper blades (sometimes referred to as doctor blades) that will continuously clean the surface of the rolls and prevent material from sticking. Properly conditioned corn will be sticky and normally requires a properly functioning scraper blade to keep the roll surface clean.

Tempering prior to steam conditioning can be a very useful tool to manage the moisture level of the grain prior to introducing it into the steam chamber. Depending on the moisture and temperature of the corn entering the steam chamber, it may not be possible to add sufficient moisture to the grain to achieve the ideal 18 to 20% moisture level desired for best flaking results. As Enrique has noted, 4 hours temper time may not be adequate to allow the moisture to thoroughly penetrate the kernels of grain. Since you have adequate bin space available, why not utilize all of the space and time available to allow a more homogenous material into the steam chamber.

In your steam chamber, be sure you are adding the steam as high as possible to maximize the retention time of the grain and the steam together. Many people mistakenly assume the steam will rise in the chamber and so condition the entire grain mass but in fact, with the grain constantly moving down in the steam chamber the steam will not in fact be able to move up through the column of grain in motion.

By increasing the temper time and adding steam high in the steam chamber you can insure that the moisture and temperature have a much time as possible to penetrate to the center of the grain, making it soft and pliable before the flaking rolls. In addition, proper conditioning will reduce any surface moisture that may be contributing to the corn sticking to the roll surface. All of that said, fixing your scraper blades (or adding them if they are missing) is the most important first step.



Reply
January 29, 2019
Mark Heimann
Thank you very much for these useful tips
This is what i did in my last batch :
Corn passing thru water sprinklers bypassed the holding bin and directly stored in the steam chamber

After 2 hours the chamber is full
After aditional 2 hours steam is introduced for 40 min
Then flaking starts
In order to prevent roller sticking I had to increse the roller gap resulting in 2 mm flake thickness and 30 lb/bu (wich is not preferred by some major customer)

Will try the scrapper idea since my flaking machine doesnt seem to have a scraper on the movable roller

I was able to have better flake density with smaller roller gap but had a problem with corn wraping the rollers

Will post an update after next batch

Thanks !
Reply
January 29, 2019

By now you have a very good idea as to the best way to flake corn.
Please confirm model and brand of flaking mill so we can supply you with quote on new rolls proper corrugations and also scraper blades or any other wear parts for your flaking mils.
Thank you and if you need another flaking mill we can quote you a new one or a rebuilt and guaranteed flaker.

Sincerely,
Ralph Romero.

Reply
January 29, 2019

Please give us your complete contact info, like email skype and your company name, and I will be glad to send you additional process info on proper flaking process and cooling if required for animal feed rations.

Thank you,
Ralph Romero.

Reply
February 4, 2019

Dear Mr. M.K.
I hope you had a very nice w/end and by now you must have received plenty of process-specific suggestions and recommendations to properly prepare. condition and flake and (store if you wish/Optional) your corn or any other cereal you wish to flake in your plant.
In my company, we will be glad to give you very specific process recommendations if you send us a complete list of the equipment you now have, the various grain, CEREALS you wish to flake and capacities required in Metric Tons/HR. and if you wish to store we can also offer you a complete accurate but very economical complete system with scale, bagging, sewing head and belt conveyor to stack the bags (usually 50-60 lb 25 kilo bags or if you wish to store on a flat warehouse or load on to trucks.
We can also recommend to you the proper Mixer and a Micro Ingredient system so that you can also do the proper mixing and very accurately make the proper Micro Ingredient batches and bag it all if you wish.
Just let us know how we may be able to help you build a new plant or increase capacity or automation to your existing plant to make it more profitable and efficient.
thank you for the opportunity to be of assistance to you.
Ralph Romero
Email; ralph@rdequipmentco.com
SKYPE; ralphromero1210@icloud.com
817-563-2571
Cel and WhatsApp 1-817 -723 -5587

Reply
March 5, 2019

The following technical/process information has been getting a lot of attention lately and we are happy to share with anyone interested:

Processing oilseeds with dry extrusion and mechanical oil extraction of soybeans, organic, non-GMO or regular beans or high oil content seeds like canola, sunflower and many others to produce high protein meal (if we decorticate/remove hulls of soybeans) healthier final products, higher digestibility and in general healthier products by not using solvents like hexane.
Please contact us if you wish to receive additional details, we have the process experience of several decades and will be glad to share with you
Thank you.
Ralph Romero.

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