Description

Maize or corn is a cereal crop that is grown widely throughout the world in a range of agro-ecological environments. More maize is produced annually than any other grain. About fifty (50) species exist and consist of different colors, textures and grain shapes and sizes. White, yellow and red are the most common types. The white and yellow varieties are preferred by most people depending on the region.

Maize was introduced into Africa in the 1500s and has since become one of Africa’s dominant food crops. Like many other regions, it is consumed as a vegetable although it is a grain crop. The grains are rich in vitamins A, C and E, carbohydrates, and essential minerals, and contain nine percent (9%) protein. They are also rich in dietary fiber and calories which are a good source of energy.

Maize is the most important cereal crop in sub-Saharan Africa (SSA) and an important staple food for more than one billion, two hundred million (1,200,000,000) people in sub-Saharan Africa (SSA) and Latin America.

All parts of the crop can be used for food and non-food products. In industrialized countries, maize is largely used as livestock feed and as a raw material for industrial products. Maize accounts for thirty to fifty percent (30−50%) of low-income household expenditures in Eastern and Southern Africa.

Worldwide production of maize is seven hundred and eighty-five million (785,000,000) tons, with the largest producer, the United States, producing forty-two percent (42%). Africa produces six point five percent (6.5%) and the largest African producer is Nigeria with nearly eight million (8,000,000) tons, followed by South Africa. Africa imports twenty-eight percent (28%) of the required maize from countries outside the continent.

Most maize production in Africa is rain fed. Irregular rainfall can trigger famines during occasional droughts.
According to a food and agriculture organization (FAO) estimates (2007), one hundred and fifty-eight million (158,000,000) hectares of maize are harvested worldwide. Africa harvests twenty-nine million (29,000,000) hectares, with Nigeria, the largest producer in sub-Saharan Africa (SSA), harvesting three percent (3%), followed by Tanzania.
Worldwide consumption of maize is more than one hundred and sixteen million (116,000,000) tons, with Africa consuming thirty percent (30%) and sub-Saharan Africa (SSA) twenty-one percent (21%).

However, Lesotho has the largest consumption per capita with one hundred and seventy-four (174) kilogrammes per year. Eastern and Southern Africa uses eighty-five percent (85%) of its production as food, while Africa as a whole uses ninety-five percent (95%), compared to other world regions that use most of its maize as animal feed.

Ninety percent of white maize consumption is in Africa and Central America. It fetches premium prices in Southern Africa where it represents the main staple food. Yellow maize is preferred in most parts of South America and the Caribbean. It is also the preferred animal feed in many regions as it gives a yellow color to poultry, egg yolks and animal fat.

Maize is processed and prepared in various forms depending on the country. Ground maize is prepared into porridge in Eastern and Southern Africa, while maize flour is prepared into porridge in West Africa. Ground maize is also fried or baked in many countries.

In all parts of Africa, green (fresh) maize is boiled or roasted on its cob and served as a snack. Popcorn is also a popular snack.

Corn flour is derived from grinding of dried corns and it is also used as common staple food. Corn flour comes in white and yellow colored and is used for preparation of bread and in blend with other flours in bakery products. It is also used for skin exploitation.

Corn flour is used in healthy pet foods. It also finds various applications in food industry such as in bakery products, in snacks, soups, ready to eat food etc. Corn flour is used as substitute for rice and wheat or mixed with wheat flour as a gluten-free product. It is also used in preparation of corn starch.

Rising demand of pasta and soups has increased the consumption of maize flour meanwhile, accelerating the corn flour market. It is also used in numerous ready to eat and ready to cook products, which will propel the market size.
This report examines the financial viability of establishing a maize flour processing plant in Nigeria that would produce maize flour, maize grit, maize bran/germ through the dry milling process.

Maize flour is a major ingredient in home cooking while maize bran used in animal feed production. Thirty percent (30%) of the maize flour output would be blended with high quality cassava flour (HQCF) on a mixing ration of sixty percent (60%) cassava flour and forty percent (40%) maize flour.

The maize bran /germ is the primary product for making corn oil and one of the important ingredients of animal fodder and maize grits as well as being used for food is used in beer production.

The production capacity of the proposed plant is one hundred (100) tons per day and would operate three (3) shifts of eight (8) hours each for three hundred (300) working day at eighty percent (80%) of the installed capacity, the plant would produce one thousand, five hundred and eighty-four (1,584) tons of maize flour, one thousand, five hundred and eighty-four (1,584) tons of maize grits, seven hundred and ninety-two (792) tons of maize germ/bran bi-monthly. One percent (1%) waste (dirt, stones, sticks etc) was accounted for.

One thousand, one hundred and nine (1,109) tons of maize flour which represents thirty percent (30%) of one thousand, five hundred and eighty-four (1,584) tons of maize flour would be blended with seven hundred and twelve (712) tons of high quality cassava flour (HQCF) bi-monthly.

The plant would blend and produce one million, one hundred and eighty-seven thousand (1,187,000) kg of premium blend of maize flour and cassava flour mix bi-monthly.

The plant would come with a two thousand (2,000) MT capacity steel cone base bottom silo, for the storage and preservation of the raw material. The silo would come with a cleaning and transport system that would clean and transport the raw material to the milling plant.