TECHNOLOGY OF MAIZE AND ALLIED CORN PRODUCTS CORN Introduction TYPES OF CORN Dent and flint corn Sweet Corn Popcorn BOTANY OF CORN Description of the Plant Genetically Engineered Corn CULTIVATION PRACTICES Varieties Rotations and Fertilizer Fertilization Plant Population Tillage Diseases and Pests Insects Diseases Structure and Composition CARBOHYDRATES AND RELATED COMPOUNDS Nitrogenous Compounds Lipids and Related Compounds Vitamins and Minerals Other Constituents QUALITY FACTORS Field Corn Aflatoxin Quality for wet milling Feed grain quality TRADITIONAL FOOD PRODUCTS FROM CORN Bulgur Tortillas Lye Hominy CORN MILLING Introduction Dry Milling of Corn The Dry Milling Process Cleaning and Conditioning Degermination Reduction and Classification Uses and specifications of Products Further Processing Wet Milling of Corn History Modern Processes Cleaning Steeping Degermination Separation of hulls and fiber Gluten starch separation Recent Development Wet milling other Grains Starch Conversion Acid Hydrolysis Enzyme Hydrolysis Isomerization Process Further processing and Products Dextrose Maltodextrins Processing Corn Oil Extracting the Oil Some Characteristics of Corn Oil Refining of Oil Bleaching Winterization Hydrogenation PRODUCTS AND THEIR USES Quality Control Tests PROCESSING READY TO EAT BREAKFAST CEREALS Flakes Corn Flakes Bran Flakes Flakes from other grains Shreds Shredded wheat biscuits POPCORN Four types of Popcorn Mechanism of Popping Quality factors Processing Commercial poppers Sifters Coaters Caramel corn factories FORMULATED PUFFED SNACKS Ingredients Other grain products Expandable ingredients Fats, Oils, Emulsifiers and Antioxidants Shortenings Frying fats Antioxidants Sweetners Other ingredients Factors affecting quality of Puffed Snacks Effect of Moisture Content Effect of pH Added Flavours of Colours Extruders and Extruding Types of Extruders Low Pressure Forming High pressure cooker extruder Example of a twin screw Extruder MANUFACTURING CORN CHIPS Snacks That are cooked and formed Half product Processing Direct or One Stage Puffing Drying MAIZE PRODUCTS Maize Rava Idly Maize Dosa MAIZE STARCH Maize Starch Powder Structure Industry Application Liquid Glucose/Corn Syrup Industry Application Malto Dextrin Powder Maize Germ Maize Gluten Corn steep liquor SWEET CORN Cultivation Harvesting and Yield Yield Thrust Areas of Research Cost of production and returns BABY CORN Uses of Baby Corn Nutritive value of baby corn (on dry weight basis) Scope for baby corn cultivation Quality of baby corn as measured at the international level standard Local food processors grade baby corn as follows Problems associated with the Baby corn production in India Cultivation of baby corn in India leads to Climatic Requirements Seasons Soil Requirements Land Preparation Planting Method Selection of suitable variety Other Varieties Other Hybrids Seed Rate Optimum Plant Population Numbers of Plants per Hill Fertilizer Management Irrigation Management Nature and importance of Irrigation Management Methods of Irrigation Scheduling of Irrigation Water Requirement Effect of water strss on growth, yield and quality of baby corn Water use efficiency Intercultivation Earthing up Weed management Diseases and insect pests Detasseling and stage of harvest Stage of harvest Processing and Marketing Marketing of Baby Corn Precooling Grading and Packaging Storage Transportation Nutritive value of baby corn fodder Product development using baby corn Problems and Research needs Cost of baby corn production and returns Tips for baby corn production EXTRUDED SNACKS Terminology Extrusion Process Preconditioning Con guration Extruder Configuration Die Configuration Expanded Snacks Fried Collettes Product Description Process Description Formulation Baked Collettes or Shapes Process Description Formulations Quality Control Considerations Third Generation Snacks Product Description Process Description Formulations CORN FLAKES Introduction Plant Economics of Corn Flakes Rated Plant Capacity Plant and Machinery Fixed Capital Raw Material Total working capital/Month Total Capital Investment Turn Over/Annum Profit Sales Ratio Rate of Return Break Even Point (B.E.P.) LIQUID GLUCOSE Starches Plant Economics Liquid Glucose Plant and Machinery Fixed Capital Raw Material Total working capital/Month Total Capital Investment Turn Over/Annum Profit Sales Ratio Rate of Return Break Even Point (B.E.P.) MAIZE/CORN OIL Plant Economics of Maize/Corn Oil Rated Plant Capacity Plant and Machinery Fixed Capital Raw Material Total working capital/Month Total Capital Investment Turn Over/Annum Profit Sales Ratio Rate of Return Break Even Point (B.E.P.) MALTO DEXTRIN FROM MAIZE Introduction Plant Economics of Malto Dextrin from Maize Plant and Machinery Fixed Capital Raw Material Total working capital/Month Total Capital Investment Turn Over/Annum Profit Sales Ratio Rate of Return Break Even Point (B.E.P.) PLANT ECONOMICS OF NON ROASTED CORN FLAKES(POHA) Plant Economics of Non Roasted Corn Flakes (POHA) Rated Plant Capacity Plant and Machinery Fixed Capital Raw Material Total working capital/Month Total Capital Investment Turn Over/Annum Profit Sales Ratio Rate of Return Break Even Point (B.E.P.) STARCH FROM MAIZE Starches Natural Starches Plant and Machinery Fixed Capital Raw Material Total working capital/Month Total Capital Investment Turn Over/Annum Profit Sales Ratio Rate of Return Break Even Point (B.E.P.) SNACK FOOD Plant Economics of Snack Food Rated Plant Capacity Plant and Machinery Fixed Capital Raw Material Total working capital/Month Total Capital Investment Turn Over/Annum Profit Sales Ratio Rate of Return Break Even Point (B.E.P.) YEAST DRY POWDER FROM MAIZE Plant Economics of Yeast Dry Powder from Maize Rated Plant Capacity Plant and Machinery Fixed Capital Raw Material Total working capital/Month Total Capital Investment Turn Over/Annum Profit Sales Ratio Rate of Return Break Even Point (B.E.P.).