Lesson 1Reception and intake: objectives, equipment (weighbridge, intake conveyors, magnetic separators), control variables (weight, moisture, documentation)Covers reception goals, sampling plans, and documentation checks for incoming maize, along with weighbridge, intake, and magnetic separation equipment. Emphasizes control of weight, moisture, and identity to prevent errors and contamination at Kenyan mills.
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)Explores milling objectives, from particle size reduction to functional properties for ugali flour. Compares roller and hammer mills and degermination. Highlights control of roll gap, speed, throughput, and temperature to achieve consistent 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)Covers packaging objectives, such as protection, traceability, and market compliance for Kenyan staples. Details weigh-fillers, bagging lines, and metal detectors, and control of fill accuracy, seal integrity, and moisture in the finished product.
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 and classification aims, including particle size control and yield optimization for maize products. Describes plansifters and sifters, selection of mesh sizes, vibration amplitude, and monitoring of yield by fraction and sieve 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 objectives, such as preserving maize quality and preventing spoilage in humid Kenyan climates. Reviews aeration systems, temperature and level monitoring, and control of bulk moisture, hotspots, and insect activity through inspection and records.
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)Describes dispatch objectives, including correct order fulfillment, traceability, and product protection for local markets. Reviews paperwork, lot numbering, QC release, and verification of transport conditions, seals, and loading hygiene.
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 and sorting aims for maize, from impurity removal to uniformity improvement. Details scalpers, aspirators, destoners, and optical sorters, and how to control impurity rate, grain size, airflow, and vibration settings.
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 objectives for maize, including shelf life and safety, and compares continuous, rotary, and fluidized bed dryers. Focuses on inlet and outlet temperatures, residence time, and moisture setpoints to avoid over or under 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
