South Africa Corn Primary, Fine and Deep Processing Report

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

South 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, Henan
Toll-free call ： 400-1152-118
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Win Tone Machinery Corn and Grain Project Research
Center
Win Tone International Trading Center
Address ： High-tech industrial area, Zhengzhou
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South 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.
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Corn Classification
According to shape: dent, sweet, flint, burst, flour.
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fuel
chemical
raw
material
alco
hol
food
oil
supplement
Corn Usage
starch
feed
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Corn Consumption Direction
Seed usage amount 1%
Alcohol usage 9%
Edible usage 9%
Other usage 5%
Starch usage 14%
Feed usage
amount 62%
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Corn Inner Structure
Bran feed
starch
Corn oil,
protein
flour
Production base ： Industrial Area, Pingdingshan,
Henan
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Corn 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.
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Corn Primary, Deep and Fine
Processing Structure Chart
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Corn Preliminary Processing
Concepts
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.
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Corn Preliminary Processing
Products Hierarchy
玉米
Corn
Corn grade
flour
Corn grade
grits
Corn
kernels
Corn germs
Henan
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Corn 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
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Primary 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.
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Corn Priliminary Processing
Economic 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.
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Corn 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.
Henan
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Corn 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
Henan
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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
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Corn 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
Henan
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Economic Benefits
Our processing line design reduces costs at maximum.
Reasonable 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.
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Corn 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.
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Concepts
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.
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Concepts
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.
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Concepts
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.
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Corn and deep-processing
products relations
Chemical
process
Physical
process
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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 、 polylacti
c acid
Sweetening agnet
Glycerinum
Ethylene and
derivatives
Glucoamylase
Primary
products
Intermediate
products
Senior
products
More
advanced
products
Polylysine
Gellan gum
Corn by-products and
corn products
hierarchy
Basic material
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Corn deep-processing
products
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1960-2009 Global Corn FSI Usage Change
Global corn usage amount
Development
situation
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
Henan
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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
Henan
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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 amount
in the USA
Data source ： USDA
developmen
t
Industry
classification
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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.
industry history
developmen
t
Industry
classification
Henan
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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.
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Enterprises Purchase
Features
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.
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Consumption Features
for Corn Deep-processing
Products
Pr
od
uct
Alcohol
Starch and Starch
Sugar
Citric
Acid
Lysine Aginomoto
Co
ns
um
pti
on
fea
tur
es
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
seasonali
ty 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.
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unit consumption
Pro
duct
Alco
hol
Starch
Starch
Sugar
Citric
Acid
Lysine
gourmet
powder
3.2 1.45 1.2 1.9 3.0 2.2Unit
Consumption
Note ： corn unit consumption error will not exceed10%
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Alcohol Production Flow Chart
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Starch Production Flow Chart
pack
aging
sulfinic acid
preparation
starch
drying
CCP3
oil
press
evaporatio
n
germ
separatio
n
soak
fibre
drying
fibre
dehydrtio
n
fibre
washing
crushin
g
germ
washing
germ
dehydratio
n
oil
immersion
fibre
separatio
n
protein
separatio
n
protein
concentraton
protein
dehydration
corn
starch
starch
washing
corn liquor
corn oil
corn bran
feed
feed
packagin
g
corn protein
feed
starch
packagin
g
corn recieves
CCP1
protein
packaging
protein
drying
germ
drying
starch
dehydratio
n
soak
CCP2
corn
cleasing
corn
starch
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Starch Fructose Production
Flow 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
exchange
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
Henan
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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%
多元醇, 8. 7%
葡萄糖浆,
6. 5% 其它, 13. 7%
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
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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
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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.
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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
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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
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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
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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
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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
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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
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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.
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Corn deep-processing products
F42 HFCS F55 HFCS Maltodextrin Malt Syrup
Corn Lactic
Acid Drink
Corn Starch
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Company 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.
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Company Profile
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.
。
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Company Profile
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.
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Company Profile
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 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 Set
Corn Kneading Degerminator
Moldy Corn Kneading Polisher
Corn Strongly Kneading Brusher
Corn Classificator
Horizontal Type Corn Degerming
Machine
Corn and Coarse Grain Combination
Machine
Four Size Corn Grits Machine
Corn
Processing
Equipment
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Single Machine
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 Rate
Emery Roll
Sorghum Rice Mill
Iron Roll Sorghum
Whitening Machine
Millet Emery Roll Rice
Mill nd Polisher 小
Buckwheat and Pearl Barley
Dehuller
Bean Peeling Machine
Pearl Barley Whitening
Machine
Buckwheat and Pearl Barley
Dehuller
Coarse Grain, Artificial Rice
Grain Noodle Machine
Grain
Processing
Equipment
Wheat Peeler, Barley Dehuller, Highland
Barley Peeler
Tel ： 0375-5938168 Fax ： 0375-5939458
Center
Tel ： 0371-86159555 Fax ： 0371-86629603

Single Machine
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 Set
Close Single and Double-
cabin Sieve
Combinational and Movable Cleaning and
Refining Machine
Destoner Machine
Each Kind of Precast Tube, Air Aspirator and Vacuum
Condenser
Other
Processing
Equipment
Saccharifying Tank, Bleaching Tank, End
Products Storage Tank, Single Effect Evaporator
Tel ： 0375-5938168 Fax ： 0375-5939458
Center
Tel ： 0371-86159555 Fax ： 0371-86629603

Complete Set of Project
Corn Complete Set of
Equipments Technology
DryMethodCornFlour
Technology
Semi-dryCornGermExtraction
andFlourMillingTechnology
DryMethodCornKernel
Technology
DryMethodCornKerneland
CornFlourTechnology
Semi-dryCornGermExtraction,Grits
andFlourMillingTechnology
Semi-dryAlcoholPlantandFeed
MillGermExtractionTechnology
Semi-dryBreweryGermExtraction
andGritsProductionTechnology
HighGlutenCorn
FlourTechnology
ArtificialCornRice
Technology
InstantCorn
Noodels
Technology
Technologyfor50TBelow
LowFatCornFlourSpecialfor
HFCS
Technologyfor50TBelow
Semi-dryCornFlour
MillingTechnology
Tel ： 0375-5938168 Fax ： 0375-5939458
Center
Tel ： 0371-86159555 Fax ： 0371-86629603

Technology for
Grain Complete Set
of Equipments
DryMethodBeanPeelinga
MillingTechnology
BeansRefining
Technology
DryMethodBeanPeelingand
KernelsProductionTechnology
SweetBuckwheatRice
andFlourMilling
Technology
SorghumRiceandMillet
ProcessingTechnology
PearlBarley
Processing
Technology
Barley
Processing
Technology
HighlandBarley
Processing
OatRiceandOatFlour
Technology
WheatWholeGrainFlour
MillingTechnology
SesameCleaningand
PeelingTechnology
WholeGrainCoarse
GrainsFlourMilling
Tel ： 0375-5938168 Fax ： 0375-5939458
Center
Tel ： 0371-86159555 Fax ： 0371-86629603

Series of Functional Health
Food and Drinks Technology
BreakfastCorn
FlakesTechnology
WholeGrainHealthFlour
Technology
NutritionOat
FlakesTechnology
WholeGrain
WheatenFood
Technology
RicePartenerFood
Technology
BitterBuckwheat
TeaTechnology
CompleteStool
BitterBuckwheat
TeaTechnology
CornSnackFood
Technology
MedicalStoneMilling
FlourTechnology
WholeGrainSnackFood
Technology
Tel ： 0375-5938168 Fax ： 0375-5939458
Center
Tel ： 0371-86159555 Fax ： 0371-86629603

Series of Functional Food
and Biological Fermentation
Technology
CornGermsPre-pressing,Infusionand
RefiningTechnology
CornStarch
Technology
SpecialGrainOilandRefining
Technology
CornandGrainDrinks
Technology
PotatoStarch
Technology
GrainStarch
Technology
MaltSyrup
Technology
F42HFCSTechnology
MaltodextrinTechnology
F55HFCSTechnology
GlucoseSyrupProducedbyLowFatCorn
FlourTechnology
MaltSyrupProducedbyLowFatCorn
FlourTechnology
5WheatGermProtein
ExtractionTechnology
StoneMillingWholeSetof
Equipments
CornGermsPressingand
RefiningTechnology
Tel ： 0375-5938168 Fax ： 0375-5939458
Center
Tel ： 0371-86159555 Fax ： 0371-86629603

Thank you ！
Henan
Tel ： 0375-5938168 Fax ： 0375-5939458
Center
Tel ： 0371-86159555 Fax ： 0371-86629603

South Africa Corn Primary, Fine and Deep Processing Report

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