Quality control for community maize millers – Roff Milling

Quality control plays an important role in every stage of the production of maize products, from intake to packing. This is also true for community millers, since their customers are often reliant on maize meal as their staple food.

Why is quality control important?

Keeping up consistent product quality is essential for customer satisfaction and of course, food safety. While large mills may have fully equipped laboratories where routine quality checks are carried out, community millers can’t afford such laboratories, so they need to find practical alternatives for these tests.

There are a few tests the community miller can do with relative ease using what they already have on hand. Let’s take a look at moisture testing:

Moisture testing

If the moisture content in maize meal is too high, it may go rancid or bitter, especially during Africa’s hot summer months and in areas of high humidity. Therefore the recommended moisture level of maize meal in South Africa and many other African countries may not be higher than 14%.

It can be challenging to do moisture testing on maize meal without or with limited access to electricity, but it can be done using alternative methods. One such a method that is commonly used in rural areas is the oven-drying method.

The miller will need:

Maize meal sample
Oven or a reliable heat source
A scale
A clean, dry container
Timer or watch

Steps to follow

01. Sample collection
Begin by collecting a sample of the maize meal you want to test. Take a small, but sufficient quantity that will fit into the container. Make sure the sample is well mixed to ensure accuracy.

02. Container preparation
Weigh the clean, dry container and record its weight. This weight will be used later to determine the moisture content of the sample.

03. Sample weighing
Weigh the maize meal sample and record its weight. Ensure that you accurately record the weight in grams.

04. Oven-drying
Preheat the oven, if available, or use a reliable heat source like a gas stove or open fire. The ideal temperature for drying maize meal is around 100°C (212°F).

05. Drying process
Place the maize meal sample in the container and put the container into the oven or over the heat source. Let it dry for several hours. The exact drying time will depend on the moisture content and quantity of the sample, as well as the heat source used. It may take several hours to reach a stable weight.

06. Weighing after drying
Periodically remove the container from the oven and weigh it. Continue to do this until the weight remains constant over successive measurements. This shows that the sample has reached a stable, dry weight.

07. Calculating moisture content
Calculate the moisture content using the following formula:

Moisture Content (%) = [(Initial Weight - Dry Weight) / Initial Weight] x 100

- Initial Weight is the weight of the sample before drying.

- Dry Weight is the weight of the sample after it reaches a stable weight.

08. Recording and interpretation
Record the moisture content as a percentage. This value represents the moisture content of the maize meal.

This method provides an approximate moisture content and may not be as precise as using specialised moisture testing equipment with electricity.

But it is a practical solution for rural or community millers in areas without electricity to get a rough estimate of the moisture content in maize meal, which is important for quality control and food safety.

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Frequently Asked Questions

Find answers to common questions below

Why should a maize producer consider investing in a maize mill?

A maize mill gives producers the opportunity to add value to their own maize instead of relying only on the raw grain price. By milling, packaging and marketing maize meal, producers can create an additional revenue stream and reduce the impact of maize price volatility on their business. By-products like maize germ and bran can also be sold or used in feed operations, helping ensure that more of the maize kernel contributes to the bottom line.

How can milling help protect farmers from maize price fluctuations?

Maize prices are constantly influenced by market conditions, weather, climate changes and global events. When prices are low, producers may feel pressure on margins, especially when input costs remain high. Milling helps producers move further up the value chain by selling a finished product rather than only raw maize, giving them more control over their margins and market position.

What products can be made from a maize milling plant?

A commercial maize mill can produce maize meal, while some configurations can also produce grits for snack products. The milling process also creates by-products such as maize germ and bran, which can be sold to feedlots or used in a producer’s own animal feed operation. In Idlani’s case, this has become a useful additional income stream alongside their main maize meal business.

What makes the Roff R-70 a good option for maize milling entrepreneurs?

The Roff R-70 is a compact commercial maize mill designed for entrepreneurs who want to produce maize meal at scale. It has a milling capacity of 4 to 5 tons per hour and can produce up to 120 tons of maize per day, depending on the configuration. Roff positions the R-70 as a compact, all-in-one maize mill built around simple, high-quality milling principles.

What support does Roff provide with the R-70?

Roff supplies the mill, electric panel boards, installation, set-up and training. The blog also highlights the value of choosing a manufacturer with a strong reputation, industry knowledge, after-sales support and locally available parts, especially when downtime can directly affect profitability.