south africa corn primary, fine and deep processing report

South Africa Primary, Fine and Deep Corn Processing Scientific Research Report

South Africa Corn OverviewSouth Africa Corn Overview

Maize is one of the three most important grains in the world with first

output per area and people make use of maize exceedingly more than rice and wheat. South Africa is the biggest maize consumption country in Africa with yield per year at 6,000,000-13,000,000 tons, ranking first in Africa. In 1998, its planting areas were 3,520,000 hectares and yields were 7,570,000 tons. According to the planting trend in recent years, the maize planted area is increasing and it reached 110,000,000 tons last year. Hence, preliminary, fine and deep maize processing demands have become a new consumption growth in South Africa.

Maize is reputed as soft gold, abundant in VC, VE, protein, carotene, unsaturated fatty acid and crude fiber, which can adjust human body metabolism and strengthen resistance. Coarse cereals like maize can not only provide dietary fiber but sufficient nutrition.

Production base ： Industrial Area, Pingdingshan, HenanToll-free call ： 400-1152-118Tel ： 0375-5938168 Fax ： 0375-5939458Win Tone Machinery Corn and Grain Project Research CenterWin Tone International Trading CenterAddress ： High-tech industrial area, ZhengzhouTel ： 0371-86159555 Fax ： 0371-86629603

South Africa Corn Usage and DistributionSouth Africa Corn Usage and Distribution

In South Africa, 43% maize is for people use, 54% for animals and 1% for industry. In 1999-2000, it was planted 3,200,000 hectares per year. White maize flour is the staple food for 75% people, which is ground in different ways and usually cooked into a porridge.

It can be seen that maize for industry application is very low.


Corn ClassificationCorn Classification

According to shape: dent, sweet, flint, burst, flour.


fuel

chemical raw material

alcohol

food

oil supplement

Corn Usage

starch

feed


Corn Consumption Direction

Seed usage amount 1%

Alcohol usage 9%

Edible usage 9%

Other usage 5%

Starch usage 14%

Feed usage amount 62%


Corn Inner Structure

Bran feed

starch

Corn oil, protein

flour


Corn Nutrition ValueCorn Nutrition Value

• Maize is coarse cereal, rich in dietary fiber.• protein content is approximately 7-10%; it contains high in germ.• lacking in lasine and tryptophan, lower utilization of protein than wheat.• Fat content is up to 3% ～ 4%; maize germ is the important source for

dietary oil with 85% unsaturated fat and rich VE.

• Maize is rich in VB1 and VB2.

• high content of Vitamin PP.• Minerals are mainly P, K, Mg, K is higher than rice and wheat .• Every 100g maize contains 100 ug carotene.• Fresh niblet and baby maize with VC and VB can serve as vegetables.


Corn Primary, Deep and Fine Processing Structure ChartCorn Primary, Deep and Fine Processing Structure Chart


Corn Preliminary ProcessingConceptsCorn Preliminary ProcessingConcepts

Corn primary processing means corn kernels processing by physical method, such as rubbing, hitting and grinding, which can not cause corn chemical composition or structure change. According to the processed products species, we can divide it into single production, double production and co-production technology. And the co-production technology is the most reasonable method with the best cost performance in the primary processing technology.


Corn Preliminary ProcessingProducts HierarchyCorn Preliminary ProcessingProducts Hierarchy

玉米

Corn

Corn grade flour

Corn grade grits

Corn kernels

Corn germs


Corn Priliminary Processing Flow ChartCorn Priliminary Processing Flow Chart

Corn priliminary processing technology:

Cleaning- destoning-measuring- magnetic separation- peeling- degerming- grits making- screening and classifying- purification- milling- screening and classifying- packaging


Primary Processing Technological FlowPrimary Processing Technological Flow

• The project uses new semi dry multi products processing technology, including cleaning, degermination, milling, byproducts treatment and packaging, which orderly connect to guarantee continuous operation of the whole line.

• The whole technology is practical, flexible and easily operated, which can be adjusted according to market demands and maize granularity.


Corn Priliminary ProcessingEconomic BenefitsCorn Priliminary ProcessingEconomic Benefits

Reasonable product structure creates value-added Profits. To count according to local market price, the gross profit reaches to 85USD and 2,550,000 USD per year with 100 ton per day yield.


Corn Fine Processing ConceptsCorn Fine Processing Concepts

Fine processing changes maize molecule through flour mixing, puffing and flaking methods, forming new products with different appearances, textures and tastes. As maize industry develops, maize has been improved to produce various food. By fine processing, maize is added value to become a new product.


Corn Fine Processing Products IntroductionCorn Fine Processing Products Introduction

High gluten maize flour and germ flour: maize contains high fat which will be oxidized to generate odor during storage. The special maize flour contains less than 1% oil. It is suitable to mix with wheat flour. The maize flour is good for children and the aged with more protein and vitamin.

Low fat corn flour

High gluten corn flour


Corn Fine Processing IntroductionCorn Fine Processing Introduction

Puffed Food ： It has been popular since last 70s with features of sponginess, uniformity and softness. Its nutrition and diatery rate are improved as well as the color, smell and taste.

Artificial corn rice

Corn instant noodles

Corn flakes


Corn Fine Processing ProductsCorn Fine Processing Products

The maize germ oil is extracted from the germ, rich in VE and unsaturated fatty acid. For example, the linoleic acid and oleic acid can protect heart and cerebral vessels.

Corn germ oil


Corn Fine Processing Economic BenefitsCorn Fine Processing Economic Benefits

Our processing line design reduces costs at maximum. Reason

able configuration and advanced technology promote diversified digestible products by guaranteeing maize value, which greatly increases economic benefits to 1,500,000USD to 3,000,000USD per year.


Corn Deep-processing ConceptsCorn Deep-processing Concepts

Corn deep-processing can improve industrial structure, increase products added value and solve the issues of agriculture. For example, we can produce HFCS, corn germ oil and refine biological ethyl alcohol. This can solve the energy problem by using corn as alcohol.



Corn is not only food and feed, but also the important industrial raw material. It can be processed into more than 3000 kinds of industrial products. With global corn processing rapid development, corn consumption is increasing substantially. This will have important influence to the corn supply and demand balance and circulation of South Africa and even the whole world.

It has vital meaning to know and research corn deep-processing industry development value and influence, formulate scientific development policy and keep the corn supply and demand in balance.



Industrial corn consumption belongs to the rising industry in corn industry. It is the most rapidly developing industry in corn total consumption. Corn processing has lots of usage in food, medicine and chemical engineering. It has good prospect future. With deepening of corn processing industry, the products links are extending continuously, and corn processing industry has large market potential.



Corn deep-processing uses corn as raw material. It adopts

physical, chemical and fermentation engineering technology to

process corn.

At present, the main corn deep-processing products are: starch

and starch sugar, alcohol, lysine, glutamic acid and citric acid.

Besides, the by-products DDGS, corn oil, protein feed, bran feed

and corn dregs are also paid more attention.


Corn and deep-processing products relations

Chemical process

Physical process


Corn is the basic material for grain biological engineering and feed.

Starch

Corn kernel

Corn grits

Bran feed

Protein feed

Corn oil

Llcohol

DDGS

lysine

Citric acid

Acetic ether

Lactic acid 、 polylactic acidSweetening agnet

Glycerinum

Ethylene and derivativesGlucoamylase

Primary products

Intermediate products

Senior products

More advanced products

Polylysine

Gellan gum

Corn by-products and corn products hierarchy

Basic material


Corn deep-processing products


1960-2009 Global Corn FSI Usage Change

Global corn usage amount

Developmentsituation

Industry classification

注： FSI usage amount includes edible usage, seed usage, and industrial usage ；

Data sources ： USDA

From 2000 ， staple commodity price inceases and energy and resources spurt in prices. Corn deep-processing enterprises also enter into rapid development period at this moment


From 2000, crude oil price trend in the USA

Global resources jump in price

Data sources ： USDA

From 2000, London copper price trend

From 2000, sugar price trend in the USA


1960-2009 America Corn FSI Edible Increasing Amount and Stage

燃料乙醇

淀粉及酒精

食用阶段

USA corn FSI usage （ except feed usage ） experiences three stages: edible usage, priliminary processing and fuel ethanol.

Corn usage amountin the USA

Data source ： USDA

development



Corn deep-processing industry gradually develops with corn yield increasing and corn deep-processing products species increasing. Corn alcohol is the most ancient corn deep-processing products; people begun to produce corn starch from 1950s. In 1990s, starch sugar, monosodium glutamate and modified starch became popular. In the 21st century, starch sugar continually develops, and lysine and citric acid is also widely used. Recently, the newly developed corn textiles and corn plastic products realize new features of natural degradation and they have no pollution.

Corn deep-processing industry history

development



Corn deep-processing industry conditionCorn deep-processing industry condition

Starch industry is the large industry which consumes lots of

corn. Recently, corn starch processing industry develops towards

large-scale and high level.

Alcohol industry has long production history. At present, the

alcohol production capacity reaches more than 10,000,000t.And

edible alcohol almost saturated. Citric acid, aginomoto and lysine

develops rapidly. The output has leaped to global number one.

But we still have large gap in production technology, processing

cost, species, quality and package compared with developed

countries.


Corn deep-processingEnterprises PurchaseFeatures

Corn deep-processing enterprises raw material purchase

has relations with geographical distribution:

Outside deep-processing enterprises ： large scale

purchase and storage in moist grain period for usage in

summer dry period.

Inside deep-processing enterprises: usage in moist grain

period, less storage.


Consumption Features for Corn Deep-processingProducts

Product

AlcoholStarch and Starch Sugar

Citric Acid

Lysine Aginomoto

Consumption

features

Edible alcohol is consumed annually. And fuel ethanol

and chemical alcohol is

also consumed annually.

There mainly has maltose and fructose,

beer maltose, biopharmacy, zymin

nutrient, papermaking and so on.

Traditionally, the fourth quarter and the

first quarter is the busy season. And fructose additive

amount will become more in coke,

especially in summer.

Citric acid is mainly exported.

The seasonality has no obvious change.

No obvious

change in seasonali

ty.

Stable demand annually

Corn deep-processing products have relations with festivals. On the whole, it has the features of continuous consumption and the downstream products account for large proportion.


Corn deep-processing unit consumption

Product

Alcohol

StarchStarch Sugar

Citric Acid

Lysinegourmet powder

3.2 1.45 1.2 1.9 3.0 2.2Unit

Consumption

Note ： corn unit consumption error will not exceed10%


Alcohol Production Flow Chart


Starch Production Flow Chart

packa

ging

sulfinic acid pr

eparation

starch dryin

g CCP3

oil press

evaporation

germ sep

aration

soak

fibre dry

ing

fibre dehy

drtion

fibre was

hing

crushing

germ wa

shing

germ dehyd

ration

oil immersi

on

fibre sepa

ration

protein se

paration

protein conce

ntraton

protein dehyd

ration

corn sta

rch

starch w

ashing

corn liquor

corn oil

corn bran fe

ed

feed pack

aging

corn protein

feed

starch pac

kaging

corn recieves

CCP1

protein pac

kaging

protein dryi

ng

germ dr

ying

starch dehy

dration

soak

CCP2

corn clea

sing

corn sta

rch


Starch Fructose ProductionFlow Chart

liquidation CCP1

starch milk

size mixing

pH conditioning

saccharifying

filtration

first decoloration

first ion exchange CCP2

first evaporating

isomerism

pH conditioning

second decoloratoin

second iron exchang

e CCP3

second evaporatoin

F42 end products

third evaporation

separation

mixing

refining

fourth evaporation

F55 end products

filling

desalting

barrel cleaning 、 tank-washing vehicle CCP4

refining

Production base ： Industrial Area, Pingdingshan, HenanToll-free call ： 400-1152-118Tel ： 0375-5938168 Fax ： 0375-5939458Win Tone Machinery Corn and Grain Project Research CenterWin Tone International Trading CenterAddress ： High-tech industrial area, ZhengzhouTel ： 0371-86159555 Fax ： 0371-86629603 3

Starch Sugar Products

,麦芽糖浆39. 2%

,结晶葡萄糖16. 5%

,麦芽糊精6. 3%

,果葡糖浆9. 1%

, 8. 7%多元醇

,葡萄糖浆6. 5% , 13. 7%其它

Starch sugar is divided into liquid starch sugar and solid starch

sugar. Liquid starch sugar output accounts for 50~60% of the starch

sugar. Liquid starch sugar includes: malt syrup and HFCS. Solid

starch sugar includes: crystalline dextrose, maltodextrin and

polyhydric alcohols.

Starch Sugar Varieties

Alcohols

Starch

Others


Hedging Direction Puzzle

To analyze carefully, we can see that there still

have some problems about raw material hedging.

Deep-processing enterprises hedging in the futures

market belongs to buying hedge. Due to logistics, this

will cause adverse effect to the northeast deep-

processing enterprises hedging.

For deep-processing enterprises, though there has

no products hedging, how about the future goods

varieties? Can we hedge against the raw material?

Corn Flow Direction

Hedging Awkwardness

Raw Material Hedging

Products Hedging

Future Trend


Hedging Policy Influence

Because South Africa is the main production area for corn

products, meanwhile the major income source of the local

farmers depends on agriculture, South Africa will become the

main area for corn fine and deep-processing products

purchase replying on the market.

Relying on market for corn compresses trader’s space and

constricts futures market survival condition-speculator’s

imagination space and participation passion.

With more and more attentions from the government to

agriculture, peasants and country, it will become normal for

the government to purchase farm products relying on the

market.


With global corn deep-processing industry rapid expanding, the whole industry over capacity problem is gradually obvious. At present, the whole usage rate of corn deep-processing industry in South Africa is almost zero.

Deep-processing industry over capacity


The corn deep-processing industry in South Africa has very low concentration ratio. But corn processing capacity just accounrts for 1% of the whole country. Compared with the several large deep-processing enterprises in Europe and the USA, its corn processing

enterprises are less.

Low Industry Concentration Ratio


At present, the medium and small scale enterpries which use corn as raw material for production spread all over the world. Due to technology and scale limit, the corn usage as raw material just accounts for 50 ％－ 60 ％， which makes it difficult to realize comprehensive usage and clean production. During 1990s, petrochemical industry once had the similar phenomenon. By the drive of economic profits, there emerged lots of small scale of oil refineries, which caused serious pollution. Finally, to improve environmental protection awareness, we reversed the situation of chaos by recifying these small oil refineries.

Many Small Scale Enterprises Have Obvious Problem of Energy Saving


Due to corn deep-processing industry over capacity and small scale, industry integration will become the theme in the later stage.

The country will guide corn deep-processing industry healthy development and help to form scale production, which will effectively utilize corn resources, reduce energy consumption and improve corn deep-processing industry core competitiveness.

Industry Integration, Concentration Improvement


Corn deep-processing will not cause any threat to the national food safety. Oppositely, this is an effective food transformation way. This not only saves resources, but also is condusive to keep continuous income increasing for farmers, which has important meaning to socialism new contryside construction.

Guarantee for Farmers' Income Increasing


The marketization degree of biomass chemical industry is continuously improved. The market concentration degree for starch, starch sugar and HFCS industry is gradually improved. It has large integration space. We should give them priority to develop and make them form scale production. Starch is the basic biochemistry product, which is the origin for all the down-stream products. Therefore, biomass chemical engineering development should start from starch products development, and gradually extend to fine and deep processing direction. Closer to the market, closer to the customers.

Develop Towards Scale and Fine&Deep Chemical Engineering


Deep-processing Enterprises Hedging Demand Is Increasing

With enterprises processing scale becoming larger and larger, the enterprise risk awareness should be strengthened. With corn market prices fluctuation intensifying and market demands uncertainty factors increasing, enterprises hedging demands are increasing. This is quite helpful to activate futures market and increase its mobility.


Corn deep-processing productsCorn deep-processing products

F42 HFCS F55 HFCS Maltodextrin Malt Syrup

Corn Lactic Acid Drink

Corn Starch


Company ProfileCompany Profile

Lushan Win Tone Machinery Manufacture Co., Ltd. was established in 1995. It owns total assets of 150,000,000USD with 280 staff including 53 professional technicians and 21 engineers.

The company has a new modern standard workshop of 96,000 ㎡ , which owns first class coarse grain processing and manufacturing equipments as well as a national technology research and development center. It is a leading company integrated with research, manufacture and marketing of grain projects.



Win Tone has a modern manufacturing base, a precision casting factory, a research and development center for grain, oil and starch syrup processing lines and an international trade center, guaranteeing efficient technology as well as high quality and precision equipments. Win Tone provides processing designs according to client’s different needs, creates new value for them and offers complete solutions for grain processing machinery. We have professional after-sales service team to timely solve problems during operation, and provide complete after-sales service technology to eliminate client’s worries.

。



Win Tone lead through ISO9001:2008 international quality system certification and achieved more than 20 new practical products patents.

Located in Henan, we serve our customers both home and abroad. We have 300 sales agencies. Our products are popular in over 30 provinces and cities in China and also exported to more than 40 countries and areas in Latin America, Africa and Southeast Asia.



Win Tone upholds the idea of looking at the enterprise as the core, customers as the carrier, science and technology as the support, win-win situation as the goal. Our independent products have been used in healthy food enterprises, alcohol enterprises, starch enterprises, and sugar enterprises. This is a deep revolution in idea and technology of grain deep processing.

Single MachineSingle Machine

玉米脱皮制糁机组

多能米面机

玉米精脱机

玉米脱皮抛光机双体

玉米搓揉脱胚机

霉变玉米搓揉抛光机

玉米强力搓揉刷光机

玉米精选机

卧式玉米脱胚机

玉米粗粮组合机机

四分离精糁机

玉米加工设备

Corn Peeling and Grits Machine Set

Multifunctional Rice and Flour Machine

Corn Fine Peeling Machine

Corn Peeling and Polishing Machine SetCorn Kneading Degerminator

Moldy Corn Kneading Polisher

Corn Strongly Kneading Brusher

Corn Classificator

Horizontal Type Corn Degerming MachineCorn and Coarse Grain Combination MachineFour Size Corn Grits Machine

Co

rn

Pro

cessing

E

qu

ipm

ent



多能米面机

玉米精脱机

Millet Emery Roll Rice Mill

玉米搓揉脱胚机

玉米精选机

卧式玉米脱胚机

玉米加工设备

Bean Polisher without Broken RateEmery Roll Sorghum Rice MillIron Roll Sorghum Whitening Machine

Millet Emery Roll Rice Mill nd Polisher 小Buckwheat and Pearl Barley Dehuller

Bean Peeling Machine

Pearl Barley Whitening MachineBuckwheat and Pearl Barley Dehuller

Coarse Grain, Artificial Rice

Grain Noodle Machine

Grain

P

rocessin

g

Eq

uip

men

t

Wheat Peeler, Barley Dehuller, Highland Barley Peeler



多能米面机

玉米精脱机

Medium Speed Bucket Elevator

玉米精选机

玉米加工设备

Suspended Screen, Vibrating ScreenLine Self-balance Moving Screen

Anti-cracking Elevator

Air Seal Machinery

Cleaning and Destoner Machine Set

Peeling and Polishing Machine SetClose Single and Double-cabin Sieve

Combinational and Movable Cleaning and Refining Machine

Destoner Machine

Each Kind of Precast Tube, Air Aspirator and Vacuum Condenser

Oth

er P

rocessin

g

Eq

uip

men

t

Saccharifying Tank, Bleaching Tank, End Products Storage Tank, Single Effect Evaporator


Complete Set of ProjectComplete Set of Project

Corn Complete Set of Equipments Technology

Dry

Meth

od

Co

rn F

lou

r T

echn

olo

gy

Sem

i-dry C

orn

Germ

Extractio

n

and

Flo

ur M

illing

Tech

no

log

y

Dry

Meth

od

Co

rn

Kern

el Tec

hn

olo

gy

Dry

Meth

od

Co

rn K

ernel an

d

Co

rn F

lou

r Tech

no

log

y

Sem

i-dry C

orn

Germ

Extractio

n, G

rits an

d F

lou

r Millin

g T

echn

olo

gy

Sem

i-dry A

lcoh

ol P

lant an

d

Feed

Mill G

erm E

xtraction

T

echn

olo

gy

Sem

i-dry B

rewe

ry Ge

rm

Extrac

tion

and

Grits P

rod

uc

tion

T

echn

olo

gy

Hig

h G

luten

Co

rn

Flo

ur T

ech

no

log

y

Artificial C

orn

R

ice T

echn

olo

gy

Instan

t Co

rn

No

od

els T

echn

olo

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Sem

i-dry C

orn

Germ

Extractio

n

Tech

no

log

y fo

r 50T

Belo

w

Lo

w F

at Co

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lou

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ecia

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HF

CS

Sem

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Extractio

n

Tech

no

log

y fo

r 50T

Belo

w

Sem

i-dry C

orn

Flo

ur

Millin

g T

echn

olo

gy



Technology for Grain Complete Set of Equipments

Dry

Meth

od

Bean

Peelin

g a

M

illing

Tech

no

log

y

Bean

s Refin

ing

T

echn

olo

gy

Dry

Meth

od

Bean

Peelin

g a

nd

K

ernels P

rod

uc

tion

T

echn

olo

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Sw

eet B

uckw

heat R

ice

and

Flo

ur M

illing

T

echn

olo

gy

So

rgh

um

Ric

e and

Millet

Pro

cessing

Tec

hn

olo

gy

Pea

rl Barley

Pro

cessing

T

echn

olo

gy

Barley

P

rocessin

g

Tech

no

log

y

Hig

hlan

d B

arley

Pro

cessing

Oat R

ice and

Oat

Flo

ur T

ech

no

log

y

Wh

eat W

ho

le Grain

F

lou

r Millin

g

Tech

no

log

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esam

e Clean

ing

and

P

eelin

g T

ech

no

log

y

Wh

ole G

rain

Co

arse G

rains

Flo

ur M

illing



Series of Functional Health Food and Drinks Technology

Bre

akfast Co

rn F

lakes

Tech

no

log

y

Wh

ole G

rain

Health

Flo

ur

Tech

no

log

y

Nu

trition

Oat F

lakes T

echn

olo

gy

Wh

ole G

rain

Wh

eaten

Fo

od

Tech

no

log

y

Rice

Parten

er Fo

od

Tech

no

log

y

Bitter B

uck

wh

eat

Tea T

ech

no

log

y

Co

mp

lete Sto

ol B

itter B

uckw

heat T

ea T

echn

olo

gy

Co

rn S

nack F

oo

d T

echn

olo

gy

Med

ical Sto

ne M

illing

Fl

ou

r Tech

no

log

y

Wh

ole G

rain

Sn

ack F

oo

d T

ech

no

log

y



Series of Functional Food and Biological Fermentation Technology

Co

rn G

erm

s Pre

-pressin

g ,In

fusio

n an

d

Refin

ing

Tec

hn

olo

gy

Co

rn S

tarc

h

Tech

no

log

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Sp

ecial Gra

in O

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Re

finin

g

Tech

no

log

y

Co

rn an

d G

rain

Drin

ks Tec

hn

olo

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Po

tato S

tarch

Tech

no

log

y

Grain

Sta

rch

Tech

no

log

y

Malt S

yrup

T

echn

olo

gy

F42 H

FC

S T

ech

no

log

y

Malto

dextrin

Te

chn

olo

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F55 H

FC

S T

ech

no

log

y

Glu

cose

Sy

rup

Pro

du

ced b

y Lo

w F

at Co

rn

Flo

ur T

ech

no

log

y

Malt S

yrup

Pro

du

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y Lo

w F

at Co

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Flo

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ech

no

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5Wh

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rotein

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xtractio

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Sto

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Millin

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f E

qu

ipm

ents

Co

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erm

s Pre

ssing

an

d

Refin

ing

Tec

hn

olo

gy


Thank you ！


south africa corn primary, fine and deep processing report

Business

win tone machinery corn

south africa corn usage

maize planted area

zhengzhou tel

corn classification

use of maize

starch usage

feed usage