Maize can be processed into different products for various end uses at the traditional level and on an industrial scale. While a large proportion of products utilized in developing countries are obtained via traditional processing, industrial processing meets the bulk of the demand in developed countries.
Nigeria has an annual maize production in excess of 10.3 million metric tons and is ranked as one of the top twenty largest producers in the world.
This report examines the financial viability of establishing a corn flakes processing plant in Nigeria using raw corn as the raw material.
Corn flakes are food made by combining corn with sugar, vitamins and minerals to make them as nutritious as possible. For producing the fancy flakes specially designed flaker will be used. At present, corn flakes are popularly known as breakfast food in the world at large and generally taken with milk. Maize is the major raw material used for the manufacture of corn flakes.
The size and locations of the farm is two hundred (200) hectares of land located in Ogun State. One hundred and eighty – three (183) hectares would be used for the farm while the remaining seventeen (17) hectares would be used for the construction of the office, warehouse and other civil works. The farm is expected to yield five (5) tons of maize per hectare with the use of improved seedling (Oba Super 2) which matures in four (4) months with two production cycle per annum.
The production capacity of the proposed plant is three hundred kilograms (300 kg) per hour of corn flakes, forty kilograms (40 kg) of maize germ, forty kilograms (40 kg) of maize bran and requiring three hundred and eighty kilograms (380 kg) of raw maize. As intermediate products, the plant would produce corn flour and maize grits (300 kg) which would be used in the production of corn flakes.
An input output ratio of 1:1 was assumed for corn flour to corn flakes and one percent (1%) wastage was assumed for the ra maize to allow for dirts, stones and immature seeds.
The plant would operate double shifts of eight (8) hours each per day for three hundred (300) working day producing three thousand, eight hundred and forty (3,840 kg) kilograms of corn flakes, six hundred and forty kilograms (640 kg) of maize bran and maize germ respectively at eighty percent (80%) of the installed capacity per day.