MILLING OF CEREALS

DRY MILLING

 Milling is removal of bran and germ :

Bran = pericarp + seed coat + epidermis + aleurone layer
 Bran + Germ  High in vit. B, Minerals , Fat, Fiber etc.
 Product is more tasty and store longer

Wet Milling
 Remove bran + germ
 Separate endosperm starch + protein

WHEAT MILLING PROCESS

(1) Cleaning

 Magnetic separator : remove metals

 Milling separator :
Remove stones, sticks, plastic, chaff, straw, lager grains etc.
(use air aspirator)
 Disk separator :
Density of grain = density of foreign materials

Separate base on the shape

 Scourer : Grins rub each other to remove surface adhering dirt

(2) Tempering or conditioning

 Adding H2O to grins before milling (MC 16%)

 easy to remove the bran and germ
 soften or “mellow” the endosperm
 H2O weaken the starch-protein bond  lower the hardness

(3) Roller milling

 Gradual reduction process in to particle size

 Pare of rolls, rotate at opposite directions
 Then flour sieves into different partial sizes

Feed
Fast nip
G
Slow grind
 Wheat Flour
 Roller mill produces different flours

0 10 20 30 40 50 60 70 80 90 100
Whole wheat

Straight grade flour Short and bran

Patent flour Low grade flour

Flour extraction %
Amount of flour obtained from wheat after milling which contains protein and CHOs
Straight flour
 Good flour for bread making
 100% extraction flour
 72% flour from whole wheat
 Other 28% for feed (short and bran)
 Used to make patent flour, clear, and low-grade flours
Patent flour
Centre part of the endosperm highest-quality commercial wheat flour
5 categories
1. First patent: 60-70% straight flour from soft wheat -used for cake
2. Extra short patent: 40 - 60% straight flour used for cake
3. Short patent: 70-80% straight flour from hard wheat highly recommended commercially milled
flour for bread baking
4. Medium patent: 80–90% straight flour excellent for bread baking,
5. Long patent flour: 90-95% straight flour
Clear flour: The by-product of straight flour that remains after patent flour is removed
Chemical composition of the flour depends upon the characteristics of the wheat and the extraction
rate
 Starch 64 - 71%
Insoluble Proteins (Gluten) 9 - 14%
Soluble Proteins 2 - 4%
Sugars 1 - 2%
Fat 1 - 2%
Minerals 0.3 - 0.7%
Water 1 - 15%

Component 50% 72% 80% 85% Extract. Whole Wheat

Extract. Extract. Extract. Extract.
Water 14.5 14.5 14 14 14
Proteins 6-7.5 8-11 8-13 9-14 10-15
Starch 72-74 65-70 64-69 64-68 60-65
Sugars 1-2 1-2 1-2 2 .0-2.5 1.6-2.0
Lipids 0.4-0.6 0.8-1.0 1.0-1.5 1.2-2.0 2.0-3.0
Cellulose 0.1 0.1-0.2 0.2-0.4 0.6-1.0 2.0-5.0
Minerals 0.2-0.5 0.3-0.6 0.6-0.8 0.7-0.9 1.5-2.5

Flour Types Products

Hard Wheat Flours
Top Patent 0.35 - 0.40% ash , 11.0-12.0% protein
Uses: - Danishes, sweet dough and smaller breads and buns
First Baker's 0.50 - 0.55%. ash, 13.0-13.8% protein
Uses: All purpose strong baker's flour, breads, buns, soft rolls and puff
pastry
First Clears 0.70-0.80% ash, 15.5-17% protein
Uses: A dark very high protein flour used as a base for rye bread
production; poor color
2nd Clears Low grade flour, not used in food production.
Soft Wheat Flours
Cake Flour 0.36-0.40% ash, 8.5% protein Cl- pH 4.5
Uses: High-ratio cakes (high amt. sugar and liquid in flour), angel food
cakes and jelly rolls
Pastry Flour 0.40-0.45% ash, 8.0-8.8% protein, chlorinated to pH 5.0-5.5
Uses: Cake, pastries and pies.
Cookie Flour 0.45-0.50% ash, 9.0 - 10.5% protein
Uses: Cookies and blended flours
Whole wheat Various bran coat granulations produce coarse to fine whole-wheat
Flour
Rye Flours
Light Rye (75% extraction) 0.55-0.65% ash
Uses: blend up to 40% with white flour without a major loss of loaf volume

Medium Rye (87% extraction) 0.65 - 1.00% ash

Uses: Up to 30% blend with white flour
Dark Rye (100% extraction) 20% flour blend
Other Flours
Stone-Ground (100% extraction) Usually untreated and, because of germ content, is
Flour subject to limited shelf life.
Cracked coarse, medium or fine granulations
 Wheat/Rye
Semolina Semolina a fine meal consisting of particles of coarsely-ground durum.
NOTE: Extraction Rate is defined as the % of flour obtained from a given amount of
grain

STARCH DAMAGE (DS)

 During milling small amount of SG are damaged

 Level of damage varies with
 Hardness of wheat
 Severity of grinding
 DS susceptible to
 fungal α-amylase activity
 Loss birefringence due damage SG
 DS show “ghost” under microscope
 Can stain with Congo red
 DS increases the water absorption of dough
 DS flour not good for cookies production

FLOUR TREATMENT

Bleaching agents
 Bleaching is very common: benzoyl peroxideor, Cl2
 Destroy pigments after bleaching
 Cl2 treatment use for cake flour

Maturing agents
 Long storage flour under go maturing or aging: improve baking performance
 Oxidizing agents (bleaching) use as maturing agents
azodicarbonamide, acetone peroxide, ClO2,
KBrO4 (K-bromate)

Quality improvements
 Increase α-amylase in flour: add malted barley or wheat
 Increase loaf volume
 Self-rising flour for biscuits: flour contain NaHCO 3, acid salt (monocalcium phosphates) and salt

AGGLOMERATION
 Wetting the outside of the flour particles and drying
 Agitation flour in wet air => drying in air stream
 Agglomerated flour:
 dust free
 controlled bulk density
 good flowability
 disperses in H2O without lumping

broken protein
endosperm
broken starch
starch granules
Wheat flour particles
Turbo-milling and Air Classification

 Flour separation: 1. Higher protein 2. Higher starch

 High-speed turbo grinder  fine particle size
Agglomerates endosperm => abrade each other
 In stream of turbulent air: separate starch and protein
 Starch and protein recovered by centrifugation

The Quality of Flour

 Quality of flour: physical and chemical variables

 Important practical: ability to makes a better loaf
 Quantity and quality depends on protein content

CRITERIA FOR JUDGING QUALITY

Flour Color
 Perfectly regular consistency in color “whiteness”
 No any fragments

Texture
 The texture and size: important for kneading and speed of dough rises
(1) Bread flour is slightly coarse falls apart when pressed into a lump
(2) pastry flour is smooth and fine can be squeezed into a lump

Expansion and Extensibility

 Rising ability and elasticity of a flour
 Alveograph or Extensopraph: determine the elasticity and rising power of the dough
 Alveograph

W Comments
<120 Poor quality flours, unusable for bread
120-160 Weak flours
160-250 Medium or average strength flours
used for soft dough products
250-310 high quality and strong wheat
310-320 Flours extracted from strong wheat, used primarily for dough with a long
fermentation
Brabender - Farinograph

 Resistance against the kneading during dough mixing

 Purpose: determine the WHC of dough, firmness and yield of the dough and dough stability
 Water absorption: H2O needed to develop 500 Brabender Units (BU) at the peak curve
 Peak Time: max. dough consistency => strength
 Arrival Time : reaches to 500 BU line
 Departure Time: drop below the 500 BU
 Mixing Tolerance Index (MTI) : Peak Time - Departure Time
 Stability Time : horizontal line under the Peak Time

Fermenting Ability and Enzyme Content

 The quantity of enzymes (amylases) contained: starch  sugar for yeasts

 α-amylase is the specific enzyme measured by the Falling Number (Hagberg Index)
 rapid gelatn of flour in water
 measures the degradation of starch at rising Temperature ≡ similar to bread making
 Falling No. α 1/ amylase activity
 High amylase: high fermentation sugar in dough
 Low amylase: dough with low gassing retain power

Falling No. Comments

6 - 150 Elevated amylase activity
Flour from germinated grains
Unusable for bread : sticky breads
Mixed with high Falling Number flour
150 - 220 Superior amylase activity
Using particular bread making methods during production
220 - 280 Normal amylase activity
280 – 300 Weak amylase activity
Under deve. bread => low V dry crumb
(>280) Requires the addition of malt

Moisture Content
 MC < 15% for good storage potential
Absorption Ability
 Amt. of H2O absorbed by a given quantity of flour
 bread making : absorb a large amount of water
Maltose Number
Relates to the gassing power of the flour
Stronger flours have higher gassing power
 DRY CORN MILLING

 Problem of milling: large, hard, flat and lager germ (12% kernel)
 Germ fat – 34%

Kernels conditioned Degerminator loosen to 21% MC (two rotating cone)

hull+ germ+ endosperm
Remove hull at (jets of air) dried to 15% MC
Hull = (pericarp + seed coat + aleurone)

 Entoleters (pin mill)  use for degerming (remove germ)

 CORN endosperm size reduction grits
hull + germ oil extraction

WET MILLING
“Wet milling is separation of parts according to their chemical constituents”
 Production of starch, protein and oil

 Cleaning
 Corn steeping : Submerging the corn in H2O + 0.2% SO2 + 50 oC @ 30-50 h
* 45% MC – corn get soft (squeezable)
* 6% corn get soluble

Use of SO2
1) Stop putrefactive MOs
2) Bisulfite ion react with disulfide bonds in protein
a. low Mol. Wt of protein easy to extract
b. hydrophilic in nature starch
c. more soluble
protein-S-S-protein + NaHSO3  protein-SH + protein-S-(SO3-) Na+
 SO2 + 50 oC good for lactic acid bacteria
pH – stop growth of other MOs
 Swollen rubbery germ
Coarsely ground (oil)
Steeped in H2O by degerminator
soft corn “Attrition mill” mill
liquid
cyclone
coarse particles kernel
“hydroclone”
+ bran + hull
Fiber
wash &
starch + protein + fiber sieving adherers
(75 μm) starch+ protein
Centrifugation Protein (corn gluten meal) (σs > σp)
or hydro-cyclone
Starch starch syrups
(1% protein) modification solid
Sorghum
 Sorghum wet milling ≡ corn wet milling
 Problems
1. Small grain (no valuable oil recovery)
2. Presences of pigments (polyphenolics) in pericarp
3. starch color of sorghum
4. Bran process into fine pieces

Wheat
 Production of Starch and Gluten
 Raw material: damage starch from dry milling
Kneading
Flour + H2O (Wash gluten from starch) Starch
(dough) Gluten
Wash with
Protein (75% gluten) Centrifugation
H2O
A starch B starch
-Large lenticular SG - Small SG `-Spherical SG - Pentosans - Damage SG
 Reasons for not using SO2
 Water alone softens the wheat
 Destroy the vital wheat gluten (gas retain character)
 Wheat starch fine (dusts)  can form explosive mixture

RICE Starch
 Very strong association of starch-protein SG
 Difficult to weakened by soaked in H2O/ Na-bisulfite

Broken rice soaks in 0.3% NaOH @ 12 h

centrifugation
wash & dry
Rice starch starch soluble protein

(Cattle feed) protein washes and neutralize with dil. HCl

Cereal oil production

 Cereal oils: Rice oil, Corn oil, wheat oil etc.

 Unsaturation: Wheat oil > other cereal oils
 Rice oil  extracted from bran
Other cereals  oil from germ
 Corn oil has high premium => due to nutritional image
 Corn oil: salads oil, cooking oil, frying oil and margarine production