Adding Value toMaize Products.

Instant Maize MealCereal Based Porridge

Stefan Lutz

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Agenda

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2 Cereal Based Porridge

Instant Maize Meal

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Agenda

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2 Cereal Based Porridge

Instant Maize Meal

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Instant Maize Meal.Consumer expectations.

Reduction of cooking timeAuthentically texture and elasticityTaste and mouth feel must be thesame as traditionally produced maizemeal

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Instant Maize Meal.Facts.

Maize meal is a staple food inSub-Saharan AfricaIt is eaten up to three times per dayToday’s maize meal is processed intraditional maize millsTraditional maize meal cooking timeis around 25 – 35 minutesThe total consumption is~16 mio. t / year

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Instant Maize Meal.Solution - Process flow

maize cleaning

degerminator

gritsconditioning

tempering

drying + cooling

final grinding

packing

Back packsolution forexisting mills

flaking

steaming

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Instant Maize Meal.Back pack Solution.

before after

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Instant Maize Meal.Flaker.

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Instant Maize Meal.Control system.

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Instant Maize Meal.Summary.

Instant Maize Meal has a cookingtime of two to five minutes.Texture and elasticity is very similarto traditional product.Instant Maize Meal has an identicaltaste and mouth feel as thetraditional cooked.Accepted by Consumers

Consumer benefits:Easy to prepareLess preparation time = more freetime

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Agenda

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2 Cereal Based Porridge

Instant Maize Meal

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Cereal Based Porridge.Market Demand.

Wide spread staple food inSub-Saharan Africa.Other applications possible.Different variations on the marketwith maize, soya, sorghum, millet…Flavored products commerciallyavailable.Fortified products for various foodprograms and school feeding.

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Cereal Based Porridge.Market Opportunity.

Germ Flour 10-20%

Bran 5-10%

SingleScrewExtruderPlant

Vitamin,Minerals,etc.

CerealBasedPorridge

Soya,Maize,Sorghum…

Maize Mill

Grits 70-80%Grits,Semolina,Flour

Maize

Feed

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Cereal Based Porridge.Key Machines.

Single Screw Extruder AHSF Fluid-Bed Dryer-Cooler OTW-Z

Hammer Mill AHZC-655-F High-Speed Batch Mixer AHML

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Cereal Based Porridge.Trials.

Trials done at Buhler.Positive Feedback of ConsumerTasting Session

Texture and structure adaptable toregional food preferences and eatinghabits

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Production of highly nutritiousfoods for human consumption

Use of local grains and by-productsfrom maize mill

Improve economics and addingvalue for maize mills

Cereal Based Porridge.Customer Benefit.

Alternative pictures see following slide

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One step ahead.