DEVELOPMENT OF A PRINCIPAL TECHNOLOGICAL SCHEME FOR PERFORMING TECHNICAL-TECHNOLOGICAL OPERATIONS IN THE PRODUCTION OF FEED CORN

ABSTRACT

The article presents the results of research on the development of a technological scheme comprising modern equipment, aimed at improving the production technology of food-grade corn with optimized nutritional, energy, and biological value. The findings indicate that the use of equipment included in the new technological line for food-grade corn production enables the creation of comprehensively optimized products.

АННОТАЦИЯ

В статье представлены результаты исследований по созданию технологической схемы, состоящей из современного оборудования, с целью совершенствования технологии производства продовольственной кукурузы с оптимизированной пищевой, энергетической и биологической ценностью. По результатам определено, что применение оборудования, предусмотренного в новой технологической линии для производства продовольственной кукурузы, позволяет производить всесторонне оптимизированную продукцию.

Keywords: corn ear, Zea mays L., conveyor belt, inspection, heat treatment, biological activation, thermal vacuum, washing, dosing, cutting, packaging, thermostat.

Ключевые слова: початок кукурузы, Zea mays L., конвейерная лента, инспекция, термическая обработка, биологическая активация, термовакуумная обработка, мойка, дозирование, резка, упаковка, термостатирование.

Introduction. Corn (Zea mays L.) is one of the world’s most popular grain crops and serves as a key food source in many countries [1]. In Latin America, Africa, and most Asian countries, corn is a staple food. It is consumed directly, boiled, or prepared in various traditional dishes using either the whole ears or kernels [2,6].

Products obtained through wet or dry milling of corn grains can either be consumed without further modification or undergo additional processing. These products are used for breakfast cereals, snacks, tortillas, and various other food items [3,12].

The significance of corn also lies in its rich nutritional content. For instance, 100 grams of corn flour with a moisture content of 15% provides 355 kcal of energy-higher than wheat flour (352 kcal), rye flour (348 kcal), and hulled barley (346 kcal) [4,10,11].

As a leading grain crop globally, corn plays an important role in human nutrition. While in some cases it is consumed directly without special processing, it is more commonly processed through industrial methods [5,7,8,9].

Methods section. The experiments were based on soaking the corn ears at a temperature of 30°C for 36 hours prior to thermal treatment. This process aimed to increase the content of certain biochemical substances, such as essential amino acids, vitamins, macronutrients, and micronutrients, which are crucial for human health, and to reduce the level of phytic acid, an antinutritional compound found in corn. The goal was to develop a principal technological scheme for producing feed corn with optimized nutritional, biological, and energy values.

In addition, the technological line for producing feed corn includes the stages of receiving corn ears harvested during the milk stage of ripeness at the production facility, followed by initial processing. This includes trimming both ends of the ears, cleaning them of leaves, husks, and fibers, sorting and inspecting, washing, soaking, thermal treatment, cooling, salting, and packaging. The selection of modern, optimal technological equipment for each of these stages was carried out to ensure efficient production.

Research results. The technological line for processing corn ears into feed corn is presented in Figure 1. The production process begins when corn ears are delivered in containers and transferred to a tilting conveyor (1) using lifting equipment controlled remotely. The corn is then transferred from the buffer conveyor (2) to the inclined dosing conveyor (3). This conveyor directs the ears to the laser-guided conveyor (4) for inspection by workers. Here, the workers remove the initial layers of leaves and place the ears evenly into the conveyor’s cutting device (5). After cutting, the ears automatically pass into the husk removal machine (6). The husked ears are then passed to the fiber-cleaning machine (7), which thoroughly removes any remaining silk and fibers. The cleaned ears are transferred via the conveyor (8) to the automatic sorting and inspection machine (9), where damaged or defective ears are removed. The sorted ears are washed in an automatic washing machine (10) and soaked in a soda water container (11) for a specified period. The soaked ears undergo thermal treatment in the steaming machine (12). After steaming, the ears are immersed in a salt solution (13) for cooling and flavoring before packaging. The packaged ears are vacuum-sealed using a thermal vacuum sealer (14).

Figure 1. Technological Line for Feed Corn Production

1. Container lifting and dumping device for corn cobs. 2. Buffer conveyor. 3. Inclined belt conveyor. 4. Laser beam alignment and transfer conveyor for corn cobs.5. Device for cutting corn cobs to uniform size. 6. Equipment for removing outer husks from corn cobs. 7. Equipment for removing residual silk from corn cobs. 8. Conveyor for transporting cleaned corn cobs. 9. Sorting and inspection equipment. 10. Automatic washing equipment. 11. Water tank for long-term soaking of corn cobs. 12. Equipment for steam thermal processing of corn cobs. 13. Vessel for cooling heat-treated corn cobs and treating them with salt water. 14. Packaging machine for finished edible corn.

Equipment specifications. The husk removal machine selected was the KUK2401233 model, manufactured in Croatia, with a capacity of processing up to 3,000 ears per hour or 1,500 kg/hour. The equipment includes conveyors for transportation and dosing, with adjustable speed controls. The cutting apparatus trims the ears from both ends to achieve uniform size. The husk removal system includes an initial washing mechanism and two counter-rotating rollers made from specialized material that removes the husks without damaging the kernels.

The automatic washing machine selected was the MDW-400 model, manufactured in Poland. This machine has adjustable front and rear legs to modify the angle of inclination, allowing it to align seamlessly with the preceding equipment. The continuous rotation of the washing drum ensures efficient cleaning via spray nozzles, after which the ears are discharged onto a collection table.

The soaking container, model SCM-SP, manufactured in China, has a capacity of up to 16,000 liters and is made of stainless steel with thermal insulation. The corn ears are biologically activated by soaking in distilled soda water at 27-30°C for 36 hours.

The thermal treatment machine, model KOCATEQ RS24NW, manufactured in South Korea, uses steam at 180°C for 15 minutes to process the ears. To prevent the kernels from wrinkling or excessive drying after thermal treatment, the ears are soaked for 5 minutes in saline solution at a cold temperature in an SCM-SP container.

The final product is vacuum-sealed using the Variovac Multipower DR3420 thermal vacuum packaging machine. The packages, made from heat-resistant polymer blends with a capacity of no more than 5.0 dm³, are sealed under a vacuum pressure of 0.08-0.09 MPa.

Conclusion. To develop the principal technological line for producing feed corn, advanced, energy-efficient, automated equipment from leading international manufacturers was selected. The KUK2401233 equipment set, equipped with conveyors, precise laser-guided cutting devices, and husk and fiber removal rollers, is a prime example of this. After vacuum-sealing, the finished product is stored in a thermostat room at 30-35°C for seven days for observation. Any swollen packages caused by errors in the technological process are removed, while intact packages are released for consumption.

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