TE WORLD BANK FAU9 FA U-09 Public Disclosure Authorized 1 SECTORAL LIBRARY INTERNATIONAL BANK FOR RECONSTRUCTlON AND DEVELOPMENT FEB 12 1986 Public Disclosure Authorized *~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ Public Disclosure Authorized Agro-Industry Proffles CORN Public Disclosure Authorized PROFILES IN THIS SERIES: OILCROPS - OVERVIEW ........... FAU-01 OIL SEEDS ................ .. FAU-02 OIL PALM. .........*e.o.......... FAU-03 COCONUT. ... * .e.***** e ***oFAU-04 SUGAR. sooe.......* .eo....... **o FAU-05 ETHANOLo........e ee.............FAU-06 WHEATo........o.o..*.......o....o . FAU-07 RICEo....... .o..o.o.o.o.......... FAU-08 CORN. oo ooo... .o.o.. .. o..FAU-09 CASSAVA .........ooo.......... oFAU-10 ANIMAL FEEDS ..o.... ..... ... oFAU-11 FRUITS AND VEGETABLES........FAU-12 RUBBER. ... ... ..........o..o ...oo. FAU-13 COFFEEo.....o.oo................... FAU-14 TEA ....oo.ooo.ooo...o.o.oo..o..FAU-15 COCOA. e.eoe......oooooe geooege..o.FAU-16 COTTON. .. .. ....o.........o...o ..*FAU-17 MEAT. ......... .....o.oo .....oo s o.FAU-18 SPICES AND ESSENTIAL OILSo....FAU-19 - S ABSTRACT The objective of this Profile is to provide processing a review of the corn industry. It outlines the corn industry from harvest and preparation the of raw material to the milling and marketing of the finished product. The Profile specifications provides of composition, yields and uses, a glossary words, and a bibliography of key of useful references. It traces the milling process and reviews marketing aspects, grade/quality, such as uses and characteristics. Environmental concerns, economies of scale, and corn by-products are Annexes also discussed. showing conversion factors, conversion (Metric/US) tables, and examples of investment and operating costs are included at the end of the Profile. 4 . 5 0 I i i I I FOREWORD The nature of project and sector work in the World Bank is such that staff are often called upon to work fields outside their major of specialization, if only to make an initial the utility of further, judgement on often costly, investigation. Under these circumstances, up-to-date and authoritative essential. reference material is The profiles in this series are designed for use by staff with experience operational in the agricultural sector but who do not have a technical knowledge of the particular discussion. commodity under Their purpose is not to substitute for expertise but technical to provide a reliable inhouse reference which help Bank staff to determine will when and what expertise is needed in the detailed evaluation of investment proposals processing. in agro- The conditions for any particular proposal are bound to be unique in a number of respects, and the use of project norms and general data in analyses could give rise to significant errors. other hand, by providing On the responsible staff with a guide to the issues on which appropriate expertise should profiles be sought, these can contribute to the overall quality of agro investment. Used processing with care, they should also facilitate broad pre-screening such as may occur during sector reconnaissance. work and Questions, comments and further inquiries should be addressed to: Agro-Industries Adviser Finance and Agro Industry Unit Agriculture and Rural Development Department The contribution of Ibberson International, Inc. in the review of this profile is gratefully acknowledged. September 1985 i I~~~~ ~~~~~~~~~~~~~~~~~~~ ~~~ ~~~ ~~~ ~~~ ~~~ ~~~ ~~~ ~~~ ~~~ ~~~ ~~~ ~~~ ~~~ ~~~ ~~~ ~~~ ~~~ ~~~ ~~~ ~~~ ~~~ ~~~ ~~~ ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ l Corn CONTENTS DATA SHEET ............................---------- INTRODUCTION ........... 1 GLOSSARY ............ RAW MATERIALS.......... 3 INTRODUCTION TO MILLING .......... 7 WET MILLING .......... 8 MARRKETING ASPECTS ............ 1 OTHER FACTORS .......... 15 BIBLIOGRAPHY .......... 17 ANNEX I INVESTMENT AND OPERATING COSTS ANNEX II CONVERSION TABLES (METRIC/US) ANNEX III CORN PRODUCT CONVERSION FACTORS . 0 I 0~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ Corn DATA SHEET Corn Yields (World Bank, 1982): World Average (1979) - 3,270 kg/ha. Range - From a high of 6,700 kg/ha (the average OECD-country among principal producers) to 3,400 kg/ha (the average among principal producers in the planned centrally- economies) to 1,500 kg/ha (average among principal developing-country producers). Six types of corn are of major commercial 1982): importance (Considine, Dent - Hard grains, characterized by concavity of the kernel O resulting from shrinkage of the endosperm moisture; with the loss of the majority of U.S.-produced corn is Dent. Flint - Early-maturing, very hard grains (more so to the presence than Dent), due of a hard layer of starch beneath the endosperm; grown principally in Argentina and Africa. Flour or Soft - Large, soft grains with friable endosperm, permitting easy grinding; grown largely in America. South and Central Sweet - Soft, sweet kernels which contain a greater sugar to ratio of starch than other corns; marketed fresh, canned, frozen for human consumption. or Popcorn - Very hard, small, elongated grains, which are consumed in puffed-kernel form. Kwax - Waxy-textured grains often used in of cornstarch. wet-milling production 0 Typical corn kernel composition (Uhlig, 1979): Bran - 6%, with a high fiber content; Germ - 12%, of which about 35% is oil; and Endosperm - 82%, of which about 86% is starch. Dry milling yields are detailed in Table 1 below. Particle size range Yield Product Mesh* mm (% by weight) Flaking grits 3.5-6 5.8-3.4 12 Coarse grits 9-12 2.0-1.4 15 0 Medium grits 12-16 1.4-1.0 60% Fine grits 16-26 1.0-0.65 23 Coarse meal 26-48 0.65-0.3 10 Fine meal (coarse cones) 48-90 0.3-0.17 10 Corn flour through 80 below 0.17 5 Germ 6.7-0.5 14 Hominy feed --- 11 * Tyler Standard Screen Scale sizes Table 1: Dry-Milled Maize Product Yields Source: Kent (1983) Wet Milling Yields (Considine, 1982): A 56-lb (25.4 kg) bushel yields - 32 lb (14.5 kg) starch; - 14.5 lb (6.5 kg) feed and feed products; - 2 lb (0.9 kg) oil; and - water. ii INTRODUCTION (Note: This commodity is known as 'corn' among English-speakers of North America and as 'maize' among other English-speakers. The terms can be used interchangeably.) Corn ranks third in world tonnage of grains produced, wheat behind and rice . The majority is consumed as an energy supplement in livestock and poultry feed where its advantages are ease of digestion, high energy content, and price. South In parts of and Central America and Africa, however, it is human consumption. a staple of While sweet corn is palatable to humans in its fresh state, it comprises only a small portion of the total corn human consumption of products. Other corn varieties, the sugar content is much of which lower, require processing prior to human consumption. Milling enhances the water absorption properties thereby of maize starch, expanding food preparation possibilities. It also facilitates the addition of supplemental vitamins and proteins to .Scompensate for corn's nutritional deficiencies in these respects. Additional information on corn milling processes is available in Kent (1983), Technology of Cereals. GLOSSARY Amioca Starch obtained from wet-milling of waxy maize; makes a non-gelling paste character- ized by its clarity, fluidity, and adhesive properties. Bran Thin outer coat of the kernel with a high fiber content. ,.~~~~~~~~~~~~~ Corn Flour Fine, pulverized endosperm particles pro- duced by dry milling. Decortication Removal of outer layers of bran from the grain. Degerminated Meal Highly refined meal from which bran and germ have been almost completely removed; particle size and uniformity are controlled. Has less than 1.2% fiber and less than 2.25% fat content on a moisture-free basis. Dextrose A sweetener which is about 75% as sweet as (Glucose) sucrose (sugar); formed when corn starch is completely hydrolyzed; the main source of body energy. Dextrose A measurement of the degree of conversion of Equivalent starch, expressed as the ratio of the reduc- (DE) ing power of the syrup to that of pure dextrose. Endosperm The starch and protein component of a corn kernel, contained within the bran walls. Germ The embryo or sprouting section of the seed, distinguished by its high oil content. HFCS High fructose corn syrup, an enzyme-converted syrup that is sweeter than traditional acid- converted syrups. Hominy/Grits Degerminated coarsely-milled endosperm with bran removed; particle size ranges from 5.8-0.65 mm; a product of dry-milling. Hybrid The first generation of a cross that involves two or more inbred lines; incor- porating a variety of desireable character- istics. Instant Starch Pre-gelatinized starch obtained from heated and dried maize starch/water slurries; thick- ens when mixed with cold water. Maltodextrins Solutions having a DE of less than 20. 2 Meal Ground endosperm, classified as coarse and fine, with particle size ranging from 0.65- 0.17 mm. Semi-Sifted Meal Meal from which part of the (Bolted bran and germ Meal) has been removed, and in which particle size and uniformity have been partially controlled. Max: 1.25% ash on a moisture- free basis. Sweet Corn Soft grain corn characterized by a relatively high glucose content; eaten as a vegetable, either fresh, canned, or frozen. Syrups Solutions of starch and water (in which the starch is broken down chemically by hydroly- sis) having a DE of 20 or more. Whole Meal Milled product containing all parts of the grain, i.e., germ and bran as well as endosperm. RAW MATERIALS Corn is a warm weather plant grown in both temperate and tropical climates, in high and low rainfall areas, and and short in zones with long summers. It is a hardy plant, known to withstand extreme heat. even The ideal temperature for germination is 86 degrees F (30 C); slower germination rates temperatures. result under lower Relatively warm day and night temperatures are required during the growing season, which traditional is about 140 days for varieties, 90 to 200 for hybrids. A precipitation level of 25-50 inches (63-127 cm) is preferred (Considine, 1982).