Corn Coarse Crusher

What is a Corn Coarse Crusher?

A corn coarse crusher is used to crush whole corn kernels into particles of a specific size. Corn consists of a hard, horny endosperm, a floury endosperm, and a highly resilient germ. It is typically crushed through compression, shearing, and impact, effectively separating the kernels while preserving the germ as much as possible. Simultaneously, it breaks the endosperm into uniform particles of 4-10mm or even finer, with a processing capacity of 1-10 tons per hour. This is completely different from a hammer mill, which directly grinds corn into a fine powder. Corn coarse crushers emphasize controlling particle size, reducing dust, and preserving the original nutrients of the corn.

What are the uses of a corn coarse crusher?

A corn coarse crusher is used in corn feed, alcohol production, and corn grits production to crush different varieties and sizes of corn, including dry corn and high-moisture corn, to the target size.

Corn grits processing: Used to peel and crush selected corn kernels to produce large, medium, and small-sized corn grits, a high-quality and healthy whole grain for making porridge and rice.

Feed-grade corn crushing: Coarsely crushes whole corn kernels into 2-6 pieces for use in poultry and livestock feed formulation. Compared to fine powder, coarsely crushed corn promotes rumination and digestion, significantly improving feed conversion rate.

Alcohol and starch deep processing: Before wet or dry corn starch production and alcohol fermentation, a corn crusher is used to pre-crush corn kernels to increase the material contact area and improve soaking, fermentation, and extraction efficiency.

Biomass pelleting and oilseed pressing: As a pretreatment device, crushed corn kernels are pressed into flakes or pellets for corn oil pressing or biomass fuel molding.

Snack food production: Customized large-particle coarsely crushed corn is an important base material for producing snacks such as tortilla chips and puffed corn sticks.

What types of corn coarse crushers are there?

Depending on the moisture content, hardness, and finished product requirements of corn feed, corn coarse crushers mainly come in three types: hammer mill, roller mill, and toothed claw. The appropriate type can be selected based on process requirements and particle size specifications.

Hammer Mill Corn Coarse Crusher: Uses high-speed rotating hammers to strike corn kernels, with the output particle size controlled by a specially designed large-aperture screen at the bottom. Suitable for high-yield coarse crushing of dry corn with a moisture content of <15%, it boasts high output and strong adaptability. However, at extremely high speeds, it may produce a significant amount of fine powder, which is detrimental to germ protection.

Roller Mill Corn Coarse Crusher: Utilizes two alloy steel rollers with special toothed profiles rotating at different speeds in opposite directions to compress and shear the corn kernels. Employing purely mechanical extrusion without high-speed impact, it effectively preserves the integrity of the corn germ, resulting in uniform particles with extremely low powder content. Particularly suitable for corn grits processing and beer feedstock processing.

Toothed Corn Coarse Crusher: This type of crusher uses a shearing and grinding mechanism between moving and stationary toothed discs to crush corn. It has a wide tolerance for material moisture content and is less prone to clogging even with slightly damp corn. However, it produces a slightly higher fine powder ratio compared to roller crushers and is commonly used in small farms or integrated feed processing plants.

What are the advantages of a Corn Coarse Crusher?

A Corn Coarse Crusher equipped with a screening device or adjustable-gap rollers ensures uniform particle size at the output. For example, a hammer mill crusher using a 4.5mm mesh screen produces corn kernels with very few larger than 4mm, resulting in excellent fine powder control. In corn grits processing, the germ has a high oil content, and crushing it will contaminate the grits and cause rapid rancidity. The Coarse Crusher uses low-speed, high-torque or roller extrusion to avoid high-impact crushing of the germ, effectively protecting it. Furthermore, the feed inlet is equipped with a high-strength magnetic separator to prevent nails and screws mixed in with the corn from damaging internal working parts, ensuring the cleanliness of the corn. The hammers, screens, and rollers are all made of wear-resistant alloy steel or chilled cast iron, significantly improving wear resistance and lifespan when dealing with the hardness of the corn kernels. A quick-opening door facilitates thorough cleaning of residual corn dust, preventing mold and cross-contamination.

How does the Corn Coarse Crusher work?

After the Corn Coarse Crusher starts, as the corn enters the crushing chamber through the feed inlet, the high-speed rotating hammers continuously strike the corn kernels, while simultaneously creating intense rubbing and shearing action between the screen and the hammers. Particles smaller than the screen mesh size after crushing pass through the screen under centrifugal force and airflow; larger particles remain in the crushing chamber and continue to be impacted until they can pass through the screen. The final output particle size can be controlled by adjusting the screen mesh size.

Corn Coarse Crusher Parameters

What sizes of corn can be ground?

The actual particle size of a corn cob crusher can vary slightly depending on the screen type, corn variety, and moisture content. In feed production, 6-12 mesh is commonly used for pig feed, 8-14 mesh for poultry feed, and 20-60 mesh for aquatic feed.

Corn Coarse Crusher Case

In a large feed mill in Ethiopia, 200 tons of local white corn are processed daily to produce broiler feed. Previously, a conventional hammer mill was used, which severely over-crushed the corn, resulting in excessively fine corn flour and reduced broiler feed intake. After switching to our SFSP corn cob crusher, equipped with an 8mm mesh screen, 90% of the finished corn kernels remained between 2-4mm. This not only reduced the feed flour content but also reduced equipment power consumption by 25%.

Corn Coarse Crusher Manufacturers

MACHRISE Corn Coarse Crusher manufacturers produce coarse crushers for corn grinding, with prices ranging from $250 to $3500. Prices are typically determined by the model, material, and customization options. Types include hammer mill, roller mill, toothed claw, and low-temperature milling, among others. Custom functions such as dust removal and magnetic separation can be added based on the corn's hardness and moisture content.