Unormak opens corn processing plant in South Africa

Unormak Milling Machines, one of the leading companies in the milling technology sector, put the second phase of white corn processing semolina plant planned with the capacity of 1.600 tons/day into use successfully in South Africa. The plant’s general manager Johannes said that Unormak’s plant and machines meet the market’s demand and needs, adding that he is happy to work with Unormak Milling Machines.

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Unormak Milling Machines, one of the leading milling machines’ manufacturers, completed a successful project in South Africa. The Turkish company completed the second phase of white corn processing semolina plant planned with the capacity of 1.600 tons per day successfully in Free State, a leader region in the corn production of the Republic of South Africa. The second phase that was put into use in September has the capacity of 400 tons per day. The first phase of the plant that has 2*400 tons/day capacity was put into use in November 2015. The company said works have been ongoing to complete the last phase of the plant that is planned to be operational in 2019.
“Unormak Milling Machines laid the foundation of this plant ten years ago based on a good relation that it established. In order to make sure that this facility has been established with the best and optimum way, we use the latest technology and the energy-efficient, environmentally friendly, processes that allow minimization in the workforce that our R&D department has developed. All processes are automatized in the facility. All works from the arrival of corn to the output of flour, semolina, and bran are carried out without human power. Thanks to the installation of this facility, our customer has the significant share of the market in its region,” Unormak said in a statement.

TURNKEY FACILITY INSTALLATION
Placing emphasis on the research and development activities, reserving a significant portion of its budget into these activities, giving importance to the environment-friendly technologies, Unormak has realized five turnkey facilities in South Africa so far. The Turkish company provided machinery and equipment to 12 companies in the African country. Unormak provides aftersales service to its customers with a branch and spare part depot in South Africa.
Unormak shared the following information about the new facility: “The new facility is part of the complex of 200,000 square meters that includes flour, semolina, and feed production facility, and social complex, car parks, and management buildings. Unormak Milling Machines planned this facility as three-phased. In the first two phases of the corn facility, the white corn semolina facility with the capacity of 3*400 tons has been established. Also, Unormak installed a wheat flour production facility with the capacity of 2*150 tons, the yellow corn semolina production facility, feed production facility, corn storage facility with the capacity of 50.000 tons, and wheat storage facility with the capacity of 20.000 tons.
The whole milling buildings have steel construction while floors are set in wood. The capacity of this milling facility can be enlarged if needed, and this can be realized without big changes.
Two cleaning units of the plant work in diagonally, and the cleaning unit can be worked as one or two lines. One cleaning line can help work of two grinding units. In an hour, 70 tons of corn is cleaned. The corn cleaning is not similar to the wheat cleaning, and the rough cleaning only includes the separation of big materials mixed into corn and heavier materials (stone, the ear of corn, big hays, etc.). Besides, the aspiration of the machine and product should be structured well. Later on, corns are heat-treated and rested. The latter period is shorter compared to the wheat’s rest. The organic fractures and protuberances that are separated from the corn are sent to the feed plant together with the corn bran by the hammer mill and used in feed production.
In order to grind corn, vertical degerminators, roller machines, and eight-passaged sieves have been used. The grinned product has sharp edges, and thus meshes inside sieves are made from stainless steel in line with the structure of the corn. The inner side of the mesh is covered with stainless steel metal. All of the flow pipes and materials that the corn semolina, flour, and bran pass through are made of stainless steel. One of the most important points about corn processing is hidden in the internal structure of the machines rather than the number of machines. It means more production with fewer machines, which leads to higher energy savings.
The aspiration of the facility is carried out by medium and high-pressure aspirators and electronic filters. In this way, environmental pollution is not allowed. Since every point of the plant from corn intake to the transportation of semolina, flour, and bran is controlled by means of automation and computers, so every detail is foreseen to minimize human errors.”
South Africa, which ranks 10th in world corn production, is the most important corn producer in Sub-saharan Africa. According to the Turkish company, the region in which the plant located is placed in the middle regions where corn is produced mostly in the country. The plant acquires corn from internal markets and imports wheat.

“QUALITY OF UNORMAK CANNOT BE DISPUTED”
The plant’s general manager Johannes stated that Unormak’s plant and machines meet the market’s demand and needs, adding that he is happy to work with Unormak Milling Machines. Saying that he works with Unormak since 2009, Johannes added that, “Since then, we have productive cooperation. Firstly, we established a corn semolina plant with a capacity of 100 tons/day and a wheat flour plant with a capacity of 100 tons/day. These two plants started operation in 2010 successfully. Demand also increases in South Africa as corn semolina is one of the main nutrients. Therefore, we started the project of 1600 tons/day corn semolina plant as soon as possible. The first phase of this project which was 2*400 tons/day capacity was successfully put into operation in November 2015. In 2016, we carried out the works of increasing the capacity of the existing plants and the 400 tons/day line which is the second phase of the 1,600 tons of corn semolina plant. In March 2017, we operated our 2*150 tons flour mill and ordered machines for the line of 400 tons corn semolina. At the end of the second phase in September 2018, we have successfully completed and operated a total of 1,200 tons of corn semolina production capacity. We plan to commission the last phase of our plant in 2019. We are happy and pleased to work with Unormak Milling Machines. This is because they provide technical services after sales without delay. The quality of the machines they installed cannot be disputed. We are confident that we will have many successes with Unormak.”

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