MILLING TECHNOLOGY FOR CEREALS

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1 DEPARTMENT OF APPLIED BIOSCIENCES (BW15) LABORATORY OF CEREAL TECHNOLOGY MILLING TECHNOLOGY FOR CEREALS Filip Van Bockstaele, , QAQC training on flour fortification, Lusaka, Zambia

2 CEREALS 2

3 WHAT ARE CEREALS? Ceres Grass family (Gramineae) One seeded fruits Caryopsis = kernel = grain Germ Endosperm Bran: seed coat and fruit coat Developes in glume (chaff, husk) 3

4 GENERAL ASPECTS Easy to cultivate High yield Stable when not processed Both in moderate as in dry climates Storage in dry conditions Insect and rodents cause major losses Mycotoxins are a food safety issue Spoilage is mostly caused by moulds 4

5 (Million tonnes) CEREALS IN THE WORLD Annual production of major cereals in 2010/ Corn Rice (paddy) Wheat Barley Sorghum Millet Triticale Rye Buckwheat (based on faostat.fao.org) 5

6 NUTRITIONAL IMPORTANCE OF CEREALS Macronutrients: Carbohydrates (50-80%) Staple food Digestable: starch Undigestable: dietary fiber Proteins (8-15%) Lipids (1.5-7%) Micronutrients: Vitamins Minerals (1-2.5%) 6

7 WHEAT 7

8 WHEAT PRODUCING COUNTRIES 25 EU (source: faostat.fao.org) Million tons (average ) 8

9 WHEAT KERNEL 9

10 WHEAT KERNEL (80%) (17%) (3%) 10

11 11

12 MILLING: ONE STEP? 12

13 GOAL OF MILLING Semolina 13

14 FROM CEREAL TO FLOUR Milling: Separation of bran/germ from endosperm Size reduction of endosperm -> flour Processing steps involved Reception and pre-cleaning Cleaning Conditioning Milling Sieving Blending 14

15 15

16 16

17 CLEANING 17

18 CLEANING TECHNOLOGY Disk separator ASPIRATOR SIEVE SEPARATOR MAGNET 18

19 CLEANING TECHNOLOGY SCOURER ENTOLETER 19

20 20

21 TEMPERING controlled addition of water (and heat) intensive mixing to ensure uniform distribution resting for a period of time (3-36 h) optimal distribution in different parts of kernel reduce hydration differences 25 C Soft wheat: % Hard wheat: 17-18% 21

22 TEMPERING = adjustment of moisture content not too dry bran should become elastic to avoid splintering and contamination of flour better separation of endosperm-bran less power required to grind to flour not too wet endosperm too soft, no creation of sharp particles no efficient sieving 22

23 TEMPERING Blending Before After goal: to produce a standard quality wheat flour eg. breadmaking quality 23

24 24

25 MILLING: BREAK ROLLS 4-5 breaks, corrugated rolls first break opens kernel subsequent breaks: scraping endosperm from the bran gradually smaller but more corrugations differential from 2.5 to 1 25

26 ROLLER MILLING 26

27 PLANSIFTER 27

28 PLANSIFTER FLOUR To reduction rolls To break rolls To purifier 28

29 REDUCTION ROLLS Smooth rolls coarse reduction (scratching or sizing) removing small pieces of bran and germ from endosperm smaller particles endosperm fine reduction grinding endosperm into flour minimum in crushed germ and bran powder optimum in damaged starch granules 29

30 PURIFIER Separating bran and endosperm particles of similar size Combinations of sieving and aspiration 30

31 MILLING SCHEME 31

32 MILLING SCHEME 32

33 MILLING: CONCLUSION Milling process multi-stage process size reduction, separation (sieving) and purification operations different materials at different stages BUT no fraction completely pure Milling efficiency flour extraction degree pureness of the fractions 33

34 MILLING: FINAL STAGE Wheat flour: blending all flour streams streams Flour In Premix Feeder Mixing Conveyor Flour Out Packaging 34

35 EXTRACTION RATE Source: principles of cereal science and technology, Hoseney 35

36 36

37 MAIZE 37

38 CORN PRODUCING COUNTRIES (source: faostat.fao.org) Million tons (average ) 38

39 CORN/MAIZE Most produced grain Highest yielding cereal (world average) Maize: 4.3 tonnes/hectare Paddy rice: 3.8 tonnes/hectare Wheat: 2.7 tonnes/hectare Animal feed Human food: tortillas, porridge Starch production: wet milling 39

40 MAIZE GRAIN 40

41 MAIZE TYPES TYPES Dent Soft Waxy Popcorn Sweet White 41

42 MAIZE PROCESSING: TANZANIA 42

43 MAIZE CLEANING AND TEMPERING 43

44 DEHULLING 44

45 DEHULLING 45

46 HAMMER MILL: SMALL SCALE MILLING 46

47 HAMMER MILL: FORTIFICATION 47

48 48

49 ROLLER MILL: LARGE SCALE OPERATIONS Gradual size reduction Sieving + roller milling Flour streams are blended in mixing conveyer 49

50 MAIZE MEAL COMPOSITION Maize variety / type of milling / extraction rate

51 MAIZE MEAL QUALITY Courtesy: Philip Randall 51

52 CONCLUSIONS 52

53 Different wheat and maize types Processing of wheat and maize is different Milling in large scale operations is multistep process which includes consecutive milling, sieving and purifying Extraction rate is important and also determines flour or meal quality 53

54 Filip Van Bockstaele Ph.D LABORATORY OF CEREAL TECHNOLOGY E filip.vanbockstaele@ugent.be T M Ghent Ghent University

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