Corn Production and Processing

Corn has become a global breakfast staple, with over 1 billion metric tons produced annually by the US, China, and Brazil. It is vital as a food staple, livestock feed, and industrial ingredient. The production process involves several stages, from harvesting to packaging.

Harvesting and Initial Processing

Freshly harvested corn is loaded into a hopper and directed to a conveyor system with advanced laser inspection to scan for imperfections and contaminants. Any subpar products are automatically removed. The quality cobs then undergo a meticulous selection process, are aligned on a conveyor belt, and subjected to laser marking and cutting using an enclosed rotary cutter.

Corn Cob Processing

Cobs are transported to a husk remover, where rotating brushes detach the husk from the cob.
The discarded husk is conveyed away, and the clean cobs are stored in a bulk container.
The cobs then undergo inspection for foreign materials and are washed in a rotary drum washer with high-pressure water sprays.
After washing, the cobs are directed to a dewatering roller, which gently tumbles them into designated containers.

Kernel Separation and Milling

The cobs are then transported to a corn sheller machine, which detaches kernels from cobs. The separated kernels are collected and loaded onto a truck, then unloaded at a milling facility into hoppers and further processed in a drum tumbler.

Corn Milling Process

Kernels are transported to an air classifier to separate lighter materials like dust and debris.
They are then conveyed to a multi-stage corn milling process to produce corn grits and refined cornflour.
The resulting flour is stored in bulk bins, while secondary byproducts are gathered and allocated for applications like animal feed and oil extraction.

Corn Flake Production

Corn flakes are produced in a semi-automated plant with significant manual intervention, starting with cleaning and conditioning of kernels, followed by heating, flavoring, and grinding. The kernels are then washed, cooled, flattened into the familiar cornflake shape, air dried, toasted, and cooled again.

Automated Corn Flake Production

Corn kernels are automatically transferred to processing areas, cooked, washed, cooled, and flattened into uniform flakes using high-precision rollers and continuous dryers.
The flakes are then toasted in continuous ovens, imparting a crisp texture and golden color, and assessed for quality by automated optical scanners.
The plant can also produce cereal loops by mixing corn with sugars, flavors, and colors, and then extruding the mixture into loop shapes.

Packaging and Distribution

The final products are then packaged using automated systems. Multi-head weighers precisely measure portions to fill pre-positioned bags on a conveyor belt, which are then sealed and moved to cartons. The cartons are arranged and stacked onto pallets, following quality control procedures, and then loaded onto trucks for distribution to stores, ensuring the product reaches consumers in optimal condition.

Key Vocabulary

Term	Definition	Example Usage
Corn Production	The process of growing, harvesting, and processing corn for various uses.	The US, China, and Brazil are among the top countries in corn production, with over 1 billion metric tons produced annually.
Harvesting	The process of gathering crops, in this case, corn, from the fields.	Freshly harvested corn is loaded into a hopper and directed to a conveyor system for initial processing.
Laser Inspection	A quality control method using lasers to scan for imperfections and contaminants in products.	Advanced laser inspection is used to scan harvested corn for imperfections and contaminants, automatically removing subpar products.
Corn Cob Processing	The stages involved in preparing corn cobs for further use, including husk removal and washing.	Cobs are transported to a husk remover, where rotating brushes detach the husk from the cob, and then washed in a rotary drum washer.
Kernel Separation	The process of detaching kernels from corn cobs.	The cobs are then transported to a corn sheller machine, which detaches kernels from cobs, and the separated kernels are collected.
Corn Milling	The process of grinding corn kernels into flour or other products.	Kernels undergo a multi-stage corn milling process to produce corn grits and refined cornflour.
Corn Flake Production	The process of making corn flakes from corn kernels, involving cleaning, heating, flavoring, and grinding.	Corn flakes are produced in a semi-automated plant, starting with cleaning and conditioning of kernels, followed by heating, flavoring, and grinding.
Automated Production	The use of machines and computers to manufacture products with minimal human intervention.	The plant can also produce cereal loops using automated systems, mixing corn with sugars, flavors, and colors, and then extruding the mixture into loop shapes.
Packaging and Distribution	The process of preparing and transporting products to consumers.	The final products are packaged using automated systems and loaded onto trucks for distribution to stores, ensuring the product reaches consumers in optimal condition.
Husk Remover	A machine used to remove the husk from corn cobs.	Cobs are transported to a husk remover, where rotating brushes detach the husk from the cob.
Rotary Drum Washer	A machine used to wash corn cobs or kernels using high-pressure water sprays.	The cobs then undergo inspection for foreign materials and are washed in a rotary drum washer with high-pressure water sprays.
Air Classifier	A machine used to separate lighter materials like dust and debris from heavier materials.	Kernels are transported to an air classifier to separate lighter materials like dust and debris.

Watch The Video

CORN FLAKES EXPOSED! What’s Really Going on in Those Factories? This is How Cornflakes Are Made!

Vocabulary Quiz

1. Which word means ‘a device that removes the outer covering of corn cobs’?

A) Conveyor system
B) Husk remover
C) Rotary cutter
D) Dewatering roller

2. What is the term for ‘the process of separating kernels from cobs using a machine’?

A) Milling process
B) Kernel separation
C) Corn shelling
D) Dehusking

3. Which stage involves ‘using high-pressure water sprays to clean the cobs’?

A) Harvesting
B) Washing
C) Dewatering
D) Rotary drum washing

4. What does ‘air classifier’ refer to in the context of corn processing?

A) A device that separates lighter materials like dust and debris from kernels
B) A machine that grinds kernels into flour
C) A system that conveys kernels to the milling process
D) A tool that removes husks from cobs

5. Which term describes ‘the process of filling bags with precise portions of product using automated systems’?

A) Packaging
B) Distribution
C) Weighing and filling
D) Multi-head weighing

Answer Key:

1. B
2. C
3. D
4. A
5. D

Grammar Focus

Grammar Focus: Passive Voice

The passive voice is a grammatical construction where the subject of a sentence receives the action described by the verb. It is often used in formal, technical, or scientific writing to emphasize the action rather than the doer. In the context of the provided text, the passive voice is used extensively to describe the stages of corn production and processing. For example, “Freshly harvested corn is loaded into a hopper” emphasizes the action of loading, while “The quality cobs are then subjected to laser marking and cutting” focuses on the process rather than the person performing it. The passive voice can be formed using the verb “to be” in combination with the past participle of the main verb, such as “is loaded”, “are subjected”, or “are conveyed”. This grammatical structure helps to create a sense of objectivity and clarity in technical descriptions.

Grammar Quiz:

1. The corn kernels ____________________ to an air classifier to separate lighter materials like dust and debris.

are conveyed
convey
have conveyed
were conveying

2. The cobs ____________________ in a bulk container after the husk is removed.

are stored
store
have been storing
were storing

3. The resulting flour ____________________ in bulk bins for further distribution.

is stored
stores
has been stored
was storing

4. The flakes ____________________ in continuous ovens to impart a crisp texture and golden color.

are toasted
toast
have been toasting
were toasting

5. The final products ____________________ using automated systems to ensure efficiency and quality control.

are packaged
package
have been packaging
were packaging

Answer Key:

1. are conveyed

2. are stored

3. is stored

4. are toasted

5. are packaged