Lesson 1Reception and intake: objectives, equipment (weighbridge, intake conveyors, magnetic separators), control variables (weight, moisture, documentation)This covers goals for receiving maize, sampling, and paperwork checks, plus tools like weighbridges, conveyors, and magnetic separators. Key focus on checking weight, moisture, and identity to avoid mix-ups and dirt.
Reception quality and safety objectivesTruck scheduling and traffic managementWeighbridge operation and calibrationSampling, grading, and moisture testingMagnetic separation and foreign body controlLesson 2Milling: objectives, equipment (roller mills, hammer mills, degerminator), control variables (roll gap, speed, throughput, temperature)We explore milling aims from breaking down particles to getting right properties. It compares roller and hammer mills plus degerminators, stressing control of gaps, speed, flow, and heat for steady flour quality.
Milling objectives and product specificationsRoller mill configuration and roll gap controlHammer mill operation and screen selectionDegerminator role in maize processingThroughput, temperature, and energy balanceLesson 3Packaging and finished product storage: objectives, equipment (weigh-fillers, bagging lines, metal detectors), control variables (fill accuracy, seal integrity, moisture in finished product)This lesson on packaging goals like protection and tracking, details fillers, bagging lines, metal detectors, and checks for accurate filling, strong seals, and right moisture in final goods.
Packaging objectives and material selectionWeigh-filler calibration and accuracy checksBagging line setup and seal integrity testsMetal detection and foreign body controlFinished product storage and rotation rulesLesson 4Sieving and classification: objectives, equipment (plansifters, sifters), control variables (mesh sizes, vibration amplitude, yield by fraction)Explains sieving goals for size control and better yields, describing plansifters and sifters, picking mesh sizes, vibration strength, and tracking yields per fraction for efficiency.
Sieving objectives and cut point definitionPlansifter layout and flow diagramsMesh size selection and maintenanceVibration amplitude and sieve loadingYield by fraction and efficiency trackingLesson 5Storage in silos: objectives, equipment (aeration, temperature sensors, level indicators), control variables (bulk moisture, temperature, insect activity)Details silo storage to keep quality and stop spoilage, covering aeration, temp and level sensors, and managing moisture, hot spots, bugs via checks and logs.
Storage objectives and risk assessmentSilo design, loading, and unloading patternsAeration system setup and operationTemperature and level sensor managementInsect monitoring and fumigation basicsLesson 6Dispatch: objectives, paperwork and logistics controls (lot numbering, QC release, transport conditions)Covers dispatch aims for right orders, tracking, and safe transport, reviewing papers, lot numbers, quality checks, and verifying truck conditions, seals, and clean loading.
Dispatch planning and customer requirementsLot numbering and full traceabilityQC release, certificates, and recordsLoading checks and vehicle hygieneTransport conditions and seal controlLesson 7Cleaning and sorting: objectives, equipment (scalpers, aspirators, destoners, optical sorters), control variables (impurity rate, grain size, airflow, vibration)Explains cleaning to remove dirt and sort for evenness, detailing scalpers, aspirators, destoners, optical sorters, and settings for impurities, size, air, vibration.
Cleaning and sorting performance objectivesScalpers and coarse impurity removalAspirators and airflow adjustmentsDestoners and density based separationOptical sorters and defect detectionLesson 8Drying: objectives, types of dryers (continuous tray, rotary, fluidized bed), control variables (inlet/outlet temperature, residence time, moisture setpoints)Describes drying for longer shelf life and safety, comparing tray, rotary, fluidized bed dryers, focusing on temps in/out, time, moisture targets to avoid too much or too little drying.
Drying objectives and product quality impactContinuous and rotary dryer configurationsFluidized bed dryer design basicsInlet and outlet air temperature controlResidence time and moisture setpoint tuning
