PHILMECH COMPACT CORNMILL
Developed by:
Dr. Michael A. Gragasin
Dr. Romualdo C. Martinez
Engr. Jayvee P. Illustrisimo
Philippine Center for Postharvest Development
and Mechanization (PHilMech)
Department of Agriculture (DA)
The Philippines is the 8th largest rice producer in the world, accounting for 2.8% of global rice production. However, the Philippines was also the world's largest rice importer in 2010.
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2004 2005 2006 2007 2008 2009 2010 2011 2012 2013
MT
Production Imports Beginning Stocks Total Demand
Sufficiency
Levels (%) 81.9 85.8 81.3 93.9 92.1 97.2
2004-2013
Rice is thinly traded in the world market, accounting for only 5-6% of the total world production in 2010.
To keep pace with the growing demand of rice in the country, the Aquino Government embraced the Food Staple Sufficiency Plan
The Food Staple Sufficiency Plan aims to increase rice production, maintain per capita consumption of rice and increase consumption of other staple foods such as CORN.
The poor quality of corn grits is one of the major causes of the diminishing consumption of white corn in the country
20% in 1980s
15% in 2010’s
Main Product
By-Products
CRITERIA PERFORMANCE
DATA
Main Product Recovery, percent, min
a) Grit # 10
b) Grit # 12
c) Grit # 14
d) Grit # 16
e) Grit # 18
28
21
7
6
2
Main Product, percent, min 64
By Product, percent, min 31
Losses, percent, max 5
Grits of other sizes, percent, max 7
Degerminator Eff., percent, min 80
Noise Level, [db (A)], max 92*
PERFORMANCE CRITERIA FOR CORNMIL Philippine Agricultural Engineering Standard
Source: PAES
AMTEC’S ACTUAL TEST RESULTS OF EXISTING VILLAGE TYPE CORNMILLS
* Below the minimum standard set by PAES
PERFORMANCE PARAMETER
Cornmill A
Cornmill B
Cornmill C
Cornmill D
Output Capacity, kg/hr 128.8 52.0 88.2 97.5
Milling Capacity, kg/hr 200 125.6 120.0 161.3
Main Product Recovery, % (64%,minimum)
64.4 39.4* 73.5 60.5*
Degerminator Efficiency, % (80%, minimum)
76.7* 100 45.6* 44.0*
Power/fuelConsumption 3.06 kW
1.32 L/H diesel
2.52 kW
1.55 L/h diesel
Labor requirement, persons
2 3 2 2
Source of Data: AMTEC
General: To develop an improved village type cornmill for white corn.
Specific: 1. Establish parameters in coming up with an
improved design;
2. Design and fabricate an improved village type corn mill;
3. Examine the technical performance of the proto-type village cornmill; and,
4. Determine the economic viability of the cornmill.
RESEARCH OBJECTIVES
What TO BE IMPROVED on the existing design of
corn mills?
Recovery is lower than 64%
High postharvest losses
Lower supply of corn grits
in the market
1st Design Consideration
What to be improved?
High presence of Impurities
(tip cap, hull & germ) in the corn grits
Displeasure on the part of
consumers to eat corn
2nd Design Consideration
Shift to rice
What to be improved?
High production cost per kg
output of corn grits due to high power
requirement of existing design
and the high fixed cost of existing
cornmills (18-20 Hp)
3rd Design Consideration
What to be improved?
Milling Fee (Corn): Php 2.00 -3.00/kg (Input) Php 3.50-4.70/kg (Output) Milling Fee (Rice) : Php 1.75-2.25/kg (Output)
Php675,000
Sagbayan Public Market, Bohol August 28, 2013
Cebu City Public Market June 15, 2012
How to satisfy the demand of the
market ?
5th Design Consideration
Size No. 14 Size No. 16
Laboratory scale model of the Degermer and milling Components
Laboratory scale model of the Grading component
DEGERMER
HAMMER MILL
GRADER
DESIGN CONCEPT
75-79%
60-64% Grits #10-12
Corn Kernels Cracked Corn
Corn Grits
Grits #14-18
Corn Flour
Grits > #10
Performance of cornmill using different types of degermer mechanism
Milling Performance
Parameters
Emery
Stone
Dented Screen
Huller
Input Cap. (kg/h) 257.55a 201.65
a
Output Cap. (kg/h) 85.50a 149.23
b
Milling Rec. (%) 71.27a 80.00
b
Milling Cap. (kg/h) 119.90a 181.73
b
Degerminator Eff. (%)1/ 66.16
c 18.48
a
Degerminator Eff. (%)2/ 91.45
a 94.73
a
Note: Means having the same super scripts are not significantly different at 1% level. 1/ After degerming process 2/ After milling and grading processes
Performance of the hammer mill with different number of blades
NO. OF
BLADES
Grits Sizes (%)
> # 10 # 10-12 # 14-18 Corn
Flour
36 46.94 a 32.86
a 9.18
a 11.02
a
44 30.04 b 43.96
b 10.36
b 15.64
b
66 25.18 c 47.53
c 18.43
c 8.86
c
Specifications:
Materials : Round bar, flat bar, galvanized iron and steel matting.
Screens : 1 rotary wire mesh screens of # 18 2 slotted sheet screen #10 & # 14
GRADER ASSEMBLY
Speed : 30 RPM
Dimensions (L x W x H) mm : 1,105 x 695 x 879
Performance of PHilMech Compact Cornmill VS Other Models Based on AMTEC Test Results
PERFORMANCE PARAMETER
Cornmill A
Cornmill B
Cornmill C
Cornmill D
PHilMech Cornmill
Output Capacity, kg/hr 128.8 52.0 88.2 97.5 240
Milling Capacity, kg/hr 200 125.6 120.0 161.3 260
Main Product Recovery, % 64.4 39.4* 73.5 60.5* 72.3
Degerminator Efficiency, % 76.7* 100 45.6* 44.0* 81.2
Power/FuelConsumption 3.06 kW
1.32 L/H diesel
2.52 kW
1.55 L/h diesel
5.47 kW
Labor Requirement, persons 2 3 2 2 2
Aflatoxin content of corn grits and corn by products after milling, ppb
Trial 1 Trial 2 Ave.
Corn Grain 334 329 331.5
Degermed/Cracked Corn 27 30 28.5
By Product (Hull, Germ, Tip Cap) 647 633 640.0
Grits No. 10 & 12 5 5 5.0
Grits No. 14, 16 & 18 19 18 18.5
Corn Flour 48 51 49.5
Corn on cobs Corn grains Cracked corn Corn grits # 12
Economic Analysis
Basic AssumptionsInput Capacity (kg/hr) 300 kg/hrOutput Capacity @64% recovery (kg/hr) 192 kg/hrOperating time per year (hrs ) 792 hrs
No of days per year (days @ 4 hrs/day) 198 4 hrs/dayTota l Capacity per year (kg/yr) 152,064 kgs/yrInvestment Cost (pesos) 350,000 pesosPower Requirement (kw/hr) 6.60 KW/hrLi fespan of cornmi l l (year) 10 years
I. Fixed Cost Per Year 43,750
Depreciation Cost 26,250
Repairs and Maintenance 17,500
II. Variable Cost Per Year 122,681
Electricity Cost 73,181
Labor Cost (1 Operator) 49,500
III. Total Cost per Year 166,431
IV. Cost of Milling Per kg Output (P/kg) 1.09
V. Profit (P/kg) 0.91
VI. Payback Period (Yrs) 2.54
VII. Financial Internal Rate of Return (%) 84.74%
Higher grits recovery
Higher degerming efficiency
Recover corn grain contaminated with aflatoxin
Low operating cost per kg output
Adequacy of corn grits supply
Accessibility of good quality corn grits
Availability of sufficient and safe supply of corn grits
Affordability of corn grits in the market
Potential Impact of the Developed Technology
Induced consumption
of corn as food
Reduced pressure to DA rice program in producing the food requirements of the
country
Output Impact (4A’s)
Effect
Food Sufficiency in the country
• Detailed design and AutoCAD drawing of the PHilMech cornmill technology with 52 sheets is readily available
Legend:
Degermer Assembly
Rotary BladeAssembly
Rotary Grader Assembly
Suction Blower
Cyclone
Corn grain hopper
Degermed Corn hopper
Electric motors
Control Panel
Mainframe
Design of the Village-Type Cornmill
16 leading manufacturers of agricultural machineries have applied for license to manufacture: Luzon Visayas
1. Rollmaster 9. Suki Trading
2. PI Farms 10.Machine System Corp.
3. Agricom Mindanao
4. ACT Corporation 11. G & R
5. Marinas 12. Payo Manufacturing Corp
6. Douglas Eng. & Mach Shop 13. Orophil Industries Corp
7. Tramat Mercantile 14. Green Valley
8. JHT Micro Enterprise 15. RJR Agro Industrial
16. D. Perez
Application of Patent to the Intellectual Property Office (IPO) Philippines for the invention “Compact Corn Mill System” Application No. 2215000046 Filing Date: 4 February 2015
Michael Gragasin, Ph.D. Supervising Science Research Specialist Philippine Center for Postharvest Development and Mechanization (PHilMech) Department of Agriculture, Philippines Tel No : +63-44-4560-290 loc 400 Fax No : +63-44-4560-110 E-mail: [email protected]