Screw Conveyors for Corn in Masa Making Process

General Description

Corn was first cultivated and domesticated about 9,000 years ago in Mexico and within 2,000 years it had spread all over Central and South America. Native Americans brought corn into North America when they migrated. In more recent years, corn is used for livestock feed, ethanol, and a multitude of food and industrial products such as sweeteners, corn oil, and alcoholic beverages.

A large North American food and ingredient company was expanding operations at their plant in Texas. Corn is processed and milled to make corn masa, the primary ingredient in tortillas, tortilla chips, and masa for tamales. KWS designed and manufactured several screw conveyors to be fed by weigh belt feeders and loss in weight feeders on the raw grain side of the process.

Design Parameters

1. Product Type: Whole Kernel Corn
2. Material Density: 40 Lbs. per Cubic Foot
3. Capacity: 375 to 14,700 Cubic Feet per Hour
4. Duty: 24 Hours per Day

KWS Advantages

KWS met with the customer and discussed the specifications and application to develop a long-term, cost-effective solution. Several unique design features were included to improve productivity and reduce downtime and maintenance. KWS used the latest modeling software to ensure proper layout of the systems and to make sure the new screw conveyors would fit perfectly within the space without compromising the processes or functionality. The KWS equipment installed and mated exactly as needed with upstream and downstream units.

KWS Special Features

Three of the new KWS screw conveyors were installed below weigh belt feeders and transferred whole kernel corn to cookers. The fourth new KWS screw conveyor transferred whole corn to three separate batch cookers. KWS designed and manufactured the screw conveyors from 304 stainless steel since the end product was designated for human consumption.

Each new KWS screw conveyor had a cable safety stop control unit to provide quick shutoff in an emergency. A cable is externally mounted around all sides of each conveyor and connected to the control unit. By pulling the cable, output contacts located inside the control unit are activated. The output contacts were wired to two separate circuits, one for an alarm and one for conveyor shutdown.

KWS also provided ports located over the discharge of each screw conveyor. The port covers can be removed after each conveyor is stopped, power removed, and locked out. The ports provide access for inspection, clean out, and maintenance.

Drive units utilized helical bevel gearing with integral motors to create a very compact design and maximize area around the conveyors.