Small-scale Milling

Lars-Ove Jonsson

doi:10.3362/9781780445922

Small-scale Milling

A guide for development workers

Traditional milling is a time-consuming and laborious task for rural women, and there is a great need to mechanize this operation. However, traditional milling practices have many nutritional advantages for children and women which are not associated with the new milling techniques and instead of being an improvement there is a great risk that improved milling will be a threat to vulnerable groups. This book is essential reading for anyone involved in milling in developing countries, and the target reader is the extension agent promoting improved small-scale milling techniques. The book can be used both as a manual and course material for training at a number of levels.

Published: 1994
Pages: 144

eBook: 9781780445922

Paperback: 9781853392191


FOREWORD xi
PREFACE xiii
1. INTRODUCTION 1
Why Milling? 1
Complexity of Choosing Appropriate Milling Techniques 1
Need for a Manual in Small-scale Milling 2
Approach 2
The Target Reader 3
The Content 3
Definitions 3
2. THE CEREAL GRAIN 4
Anatomy of Cereal Grains 4
Nutrients in Cereals 5
Purpose of Milling 5
Phytic Acid 7
Soaking 7
Malting 7
Fermentation 8
Parboiling 8
Type of Flour 9
Recommendations on Flour Quality 10
3. ELEMENTS OF TECHNICAL CHOICE
IN MILLING 12
Case Study 1: TRADITIONAL MAIZE
PROCESSING IN EASTERN PROVINCE
OF ZAMBIA, AND MALAWI 12
Background 14
Traditional maize processing 14
Comments 15
Experience of sorghum and millet 15
Case Study 2: MECHANIZED MILLING
OF MAIZE IN EASTERN PROVINCE
OF ZAMBIA, AND MALAWI 16
Background 16
Mechanized maize milling with hammermills 16
Comments 16
Experience of sorghum and millet 18
Elements of technological choice in milling 19
o Milling enterprises 19
o Homestead milling 19
o Customs milling 19
o Large-scale commercial mills 20
o Consumers' preference 20
o Retail prices 20
o Geographical distribution 21
o Utilization efficiency 21
o Composite milling 21
4. PROCESSING REQUIREMENTS OF CEREALS,
CASSAVA, LEGUMES AND CONDIMENTS 22
Wheat 22
o Grain structure and composition 22
o Wheat milling 23
o Small-scale milling opportunities 24
Maize 24
o Grain structure and composition 24
o Milling considerations 24
o Small-scale milling opportunities 24
Rice 25
o Grain structure and composition 25
o Milling considerations 26
o Small-scale milling opportunities 26
Sorghum 27
Grain structure and composition 27
Small-scale milling opportunities 27
Millet 29
o Grain structure and composition 29
o Milling considerations 30
Barley and Oats 30
Cassava 30
o Structure and composition 30
o Processing considerations 31
Legumes 32
o Structure and composition 32
o Processing considerations 32
Condiments 32
o Roots 32
o Seeds 32
o Bark 32
o Dried whole fruits 32
o Dried bulbs 32
o Dried leaves 33
Salt 33
Bone Meal 33
VI
5. MILLING PROCESSES 34
Pre-treatments 34
o Grain cleaning 34
o Foreign material 34
o Pesticide residues 35
o Peeling and drying roots 35
o Legume splitting 35
o Moisture and drying 35
o Cleaning 35
Husk and Bran Removal 36
o Manual husk and bran removal 36
• Pestle and mortar 36
• Dheki 36
o Mechanized husk and bran removal 36
• Abrasive disc dehuller 36
• Steel huller 37
• Centrifugal dehusker 38
• Rubber roll dehusker 39
• Under-run disc dehusker 40
• Friction whitener 40
• Cone whitener 42
• Abrasive whitener 42
Grinding 43
o Manually operated grinders 43
• Pestle and mortar 44
• Saddlestone 44
• Quern 44
•Hand-operated rotary mill 44
o Mechanized mills 45
• Stone mills 46
• Plate mills 47
• Hammermills 48
• Roller milling 51
6. SOURCES OF POWER 52
Human Power and Draught Power 52
Diesel Engines 54
o Old-fashioned diesel engines 55
o The modern diesel engine 55
o The hot-bulb engine technique 56
Electric Motor 57
Water-mills 57
Wind Power 58
Battery-powered Mills 58
Steam Engines 60
Coupling Arrangements 60
o Direct drive 60
o Flat belt drive 61
o V-belt drive 61
o Centrifugal clutch coupling 61
o Multiple drives 62
vii
7. OPERATOR'S MANUAL FOR DIESELPOWERED
HAMMERMILL 64
Introduction (Case 3.1) 64
The Hammermill Operation 64
o Daily pre-operation tasks 64
• Checking and filling of oil (Case 3.2) 65
• Checking, filling and recording of fuel (Case 3.3) 66
o Engine operation tasks
• Starting and stopping of engine (Case 3.4) 66
o Milling tasks 67
• Milling and recording grain (Case 3.5) 67
Post-operation tasks
• Cleaning hammermill and shelter daily (Case 3.6) 68
Hammermill Maintenance 69
o Weekly maintenance tasks
• Check and tighten selected bolts (Case 3.7) 69
• Check and tighten beater bolts (Case 3.8) 69
• Cleaning of air filter elements (Case 3.9) 70
• Cleaning shelter and divider (Case 3.10) 71
o Monthly maintenance tasks
• Cleaning of cooling fins (Case 3.11) 71
• Checking and adjusting V-belts (Case 3.12) 72
o Maintenance tasks after 300hrs of operation
• Greasing of mill bearings (Case 3.13) 73
• Changing of oil and replacing oil filter (Case 3.14) 73
• Changing of fuel filter element and cleaning of ceramic
filter (Case 3.15) 74
• Changing of air filter element (dry type) (Case 3.16) 74
• Removing soot from exhaust silencer (Case 3.17) 75
Hammermill Repairs
o Removing and replacing of damaged screen (Case 3.18) 75
o Turning or replacing beaters/hammers (Case 3.19) 76
o Changing of damaged V-belts (Case 3.20) 76
Major repairs
o When and how to get outside repair service (Case 3.21) 77
Management
o Record keeping (Case 3.22) 77
o Daily Repair Form (Case 3.23) 78
o The Weekly Records Form (Case 3.24) 78
8. INSTALLATION AND SAFETY OF MILLING 81
Installation and Layout of Equipment 81
o Basic requirements 81
o Hand-operated mills 81
o Animal-powered mills 81
Vlll
Motor-powered Mills 81
o Diesel engine 81
o Electric motor 83
o Steam engine 83
Water-powered Mills 83
Wind-powered Mills 83
Safety 83
9. SUMMARY OF MILLING PROBLEMS 85
10. SMALL-SCALE MILLING MACfflNERY 87
11. MANAGEMENT 89
Introduction 89
How to Choose a Mill 89
Comments 90
Financial Costing 91
o Pay-back method 91
o Budgeting procedure 91
Follow-up 93
Case Study 4: MANAGEMENT 94
o Daily Records Form 95
o Weekly Records Form 96
o Cash Book 97
o Milling Project Description 98
o Profitability Projection 101
o Cash-flow Analysis 104
APPENDIX 1: Glossary 106
APPENDIX 2: Further Reading and Information 108
References 108
APPENDIX 3: List of Useful Contacts 110
APPENDIX 4: Product Details 114
Machinery Suppliers and Manufacturers 114
Further List of Manufacturers and Suppliers 125
APPENDIX 5: Sources of Illustrations 128

Profit efficiency of small- and medium-scale maize milling enterprises in South Africa

Abu, Orefi

Kirsten, Johann F

Development Southern Africa, Vol. 26 (2009), Iss. 3 P.353

https://doi.org/10.1080/03768350903086663 [Citations: 6]

Design and development of solar energy powered maize milling machine

Sharma, Kirtika

Kothari, Surendra

Panwar, N. L.

Rathore, Neelam

International Journal of Ambient Energy, Vol. 43 (2022), Iss. 1 P.1671

https://doi.org/10.1080/01430750.2020.1712241 [Citations: 11]

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Small-scale Milling

A guide for development workers

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