Roff Milling: roller vs hammer mills explained

Q: 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.

Q: 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.

Q: 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.

Q: 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.

Q: 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.

Published February 3, 2022 • Updated November 4, 2025

In regions that prefer very fine maize flour, like Angola, Tanzania and Uganda, hammer mills are traditionally considered more cost-effective at producing a fine meal compared to roller mills. Roller mills, in turn, are better known for producing coarser flour. But which is the most profitable in the long run?

Choosing the right grinding technology is one of the fastest ways to lift the profit of a maize-milling business. Below we compare roller and hammer mills across the metrics that matter—power, extraction, throughput, operating cost and safety—using real data from Roff products and independent studies. We then show how combining both machines in a single flow-sheet unlocks the best of each world.

1. Energy efficiency

Electricity typically makes up 20–25% of a small mill’s running cost. Independent trials show roller mills use roughly 25–30% less kWh per tonne than hammer mills. Cutting that load means lower bills and a smaller generator or solar array.

2. Product quality and extraction

Roller mills nip and shear the kernel instead of shattering it, producing far fewer fines (<250 µm dust). The result is:

Higher extraction – Roff customers typically gain 3–5% more saleable meal; some report up to 10%.
Consistent granulation – Uniform particles cook evenly, reduce sieving losses and command better prices.
Less starch damage – Lower gelatinisation helps extend shelf-life and prevents stickiness in packaging.

3. Throughput and capacity

Roller mill vs hammer mill: quick comparison
Metric	Roff roller mill	Roff hammer mill	What it means for you
Rated capacity	MK6D: 1 t/h	SHM 845: 2.5 t/h (fine)	Hammer mills can push higher flow, but only with more power and a wider particle spread.
Typical screen change	None during run	Needed when spec changes	Downtime and spare-screen costs add up on hammer mills.

(Capacities are for maize, clean and 13–14% moisture.)

4. Maintenance and total cost of ownership

Roller flutes last 8-12 months on white maize before sharpening; screens and hammers may need monthly checks on high-volume hammer mills. Over five years, parts and energy often outweigh the sticker price, so the lower-wear, lower-kW roller mill usually wins on cost-per-ton milled even at a higher purchase price.

5. Safety, dust and ESG

Less dust means less housekeeping, maintenance, a healthier workspace and lower explosion risk. Noise levels on roller mills are much lower than on comparable hammer mills, helping plants comply with occupational-health legislation.

6. Why a hybrid flow-sheet beats either machine alone

A proven Roff recipe for refined/sifted maize meal production:

Degermination – remove bran and germ.
Roller mill (e.g., MK2S or MK6D) – strip residual bran, tighten PSD, boost extraction.
Hammer mill (e.g., SHM 845) – polish the uniform stock to the ultra-fine flour preferred in markets like Angola, Tanzania and Uganda.

Because the hammer mill now receives pre-sized, low-bran stock, it can run at higher throughput and 15–20% lower amperage, slashing unit cost.

7. 100% extraction? A case for unsifted maize meal

In some markets, unsifted maize meal is popular due to it’s lower cost, as only the hammer mill is used to mill the complete maize kernel, effectively achieving close to 100% extraction. Many community mills around Sub-Sahara that serve low income markets make use small hammer mills, so Roff developed the SHM-U, an complete hammer mills system with an inlet capacity of up to 2.5 tons/hour.

👉 Next step: Speak to one of our sales consultants for a tailored mill best suited to your budget and market.

References

MK2S maize roller mill specifications, Roff Milling. (Roff Milling)
MK6D maize roller mill specifications, Roff Milling. (Roff Milling)
Hammer 100 specifications, Roff Milling. (Roff Milling)
SHM 845 hammer mill specifications, Roff Milling. (Roff Milling)
“Roller mill vs. hammer mill: what’s the difference?”, RMS Roller-Grinder. (RMS Roller-Grinder)
“Hammermills and roller mills”, Engormix technical article. (Engormix)
“Advantages and disadvantages of particle-size reduction techniques”, CPM White Paper. (One CPM)

All extraction and cost calculations are illustrative. Always validate figures with your own maize quality, energy tariff and market prices before making investment decisions.

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.

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