Food Grade Test Bundles |
| Basic
Food Grade Test Bundle |
| |
This
bundle of tests evaluates those characteristics
which have traditionally been most important
to all food-grade corn handlers and users.
These include:
These
tests may be used to aid processors and
seed companies in hybrid evaluation for
food corn uses. Emphasis is placed on characteristics
that, while are potentially affected by
the growing environment, are largely genetic
in nature. Processors and food corn buyers
have used this type of information to develop
“approved variety lists.” Some
companies may use the information from this
test bundle to prescreen before investing
in other testing.
This
basic bundle can be enhanced with tests
specifically geared to the alkaline
cooking and/or dry
millers industries for hybrid evaluation.
Other
individual tests are available for existing
grain stores, such as stress
cracks, mycotoxins and GMO's.
These characteristics are typically not
important in hybrid evaluation, as they
are largely dependent on post-harvest handling
or other management practices.
|
|
|
| Alkaline
Cooker Bundle |
| |
The
alkaline cooking
process is used to make corn chips, corn tortillas,
and corn tortilla chips. While many tortillas
in the United States are made from wheat flour,
corn tortillas the traditional favorite throughout
Latin America.
The Alkaline
Cooker Test Bundle includes:
|
|
|
|
| Dry
Miller Bundle |
| |
The
corn dry milling
process physically seperates the corn to make
grits, flour and meal.
The Dry
Miller Test Bundle includes:
|
|
|
Physical
Characteristics - (top of
page)
| Thins
Test |
| |
The
Thins Test is also offered as a component
of the
Basic
Food Grade Test Bundle. Kernel
size is very important to all food grade corn
users. Small kernels will result in excessive
cleanout losses. It is difficult for dry
millers to make large grits from small
kernels. Variability in kernel size will affect
the consistency of the alkaline
cooking process. The Thins test provides
a good estimate of the average kernel size
of a sample. The
test is performed by screening 250 grams of
corn over a 20/64 round-hole screen.
The corn passing through the screen is collected
and weighed. Thins are calculated using the
equation: |
|
|
%Thins = Weight
of material in pan
250 g
x
100
The desired Thins percentage will vary
by user, though nearly all would prefer
less than 50%. An Extended Kernel Size Evaluation
is also available. |
| Possible Values
0-100%; Typical Results 5-75% |
| |
| %
Horneous Endosperm |
| |
The % Horneous Endosperm Test is also offered
as a component of the
Basic Food Grade Test Bundle.
This test
provides a measure of endosperm
hardness to alkaline
cookers and dry
millers.
The test is
performed by visually rating the kernels,
placed germ facing up, on a light table.
Soft endosperm is opaque, and will block
light. Hard, or horneous, endosperm is translucent.
A rating is made from standard guidelines
based on the degree to which the soft endosperm
at the crown of the kernel extends down
toward the germ. Ratings for twenty externally
sound kernels are averaged for the reported
result.
Most food
grade corn users prefer a result of 90%
or higher for the % Horneous Endosperm Test,
although some may accept as low as 85%.
Possible Values 70-100%; Typical Results
70-95% |
| back
to IPG Corn Tests List |
| Test
Weight |
| |
Test
Weight, or bulk density, is also offered
as a component of the Basic
Food Grade Test Bundle.
Test Weight
is a measure of the quantity of grain required
to fill a specific volume (Winchester bushel).
There is often, though not always, a strong
correlation between Test Weight and True
Density. As such, Test Weight is often
used as a gauge of endosperm
hardness to alkaline
cookers and dry
millers. High-test weight corn will
take less storage space than corn with a
lower test weight. Test Weight is a part
of the GIPSA Official United States Standards
for Grain grading criteria.
The test involves
filling a test cup of known volume through
a funnel held at a specific height above
the test cup to the point where grain begins
to pour over the sides of the test cup.
A strike-off stick is used to level the
grain in the test cup, and the grain remaining
in the cup is weighed. The weight is then
converted to and reported in the traditional
U.S. unit, pounds per bushel (lb/bu). Because
Test Weight can decrease as moisture content
increases, the moisture
content of the sample is also reported.
It is recommended that the sample be between
12 and 16% moisture for analysis. Most food
grade corn users desire Test Weights higher
than 60 lb/bu with some requesting a minimum
of 62 lb/bu.
Possible Values 48-67 lb/bu; Typical Result
56-64 lb/bu |
| back
to IPG Corn Tests List |
| True
Density |
| |
The
True Density Test is also offered as a component
of the Basic
Food Grade Test Bundle. This
test provides a measure of endosperm
hardness to alkaline
cookers and dry
millers. Density
is calculated by dividing the weight of a
sample of 100 externally sound kernels by
the volume of the same 100 kernels. The weight
is obtained using an analytical balance with
a minimum of four decimal places. The volume
is determined using a helium pycnometer. Two-100
kernel replicates are averaged. The
density (in grams per cubic centimeter), 100
kernel weight (in grams), and average kernel
volume (in cubic centimeters) are reported.
Because true density will decrease as moisture
content increases, the moisture content
of the sample is also reported. It is recommended
that the sample be between 12 and 16% moisture
for analysis. Most food grade corn users want
densities higher than 1.31 grams per cubic
centimeter.
| |
Possible
Values |
Typical
Results |
| 100
Kernel Weight |
15-50
grams |
25-40
grams |
| Average
Kernel Volume |
15-35
cm3 |
20-28
cm3 |
| True
Density |
1.17-1.37
g/cm3 |
1.25-1.35
g/cm3 |
|
| back
to IPG Corn Tests List |
| Moisture
Content |
| |
Moisture
Content is also offered as a component of the Basic
Food Grade Test Bundle, the True
Density, and Test
Weight.
Moisture content
is a critical factor for the long-term storability
of corn grain. Corn will reach maturity
at a moisture level around 30%. Corn should
be dried in the field or artificially to
15% moisture for storage up to 6 months
or 13% for storage up to one year. Over-drying
of corn wastes energy, money, and time.
Dry corn can also negatively affect food
corn processes. True Density and Test Weight
will vary with moisture content, especially
in corn greater than 20% moisture.
The test involves
filling the moisture meter with 250 grams
of corn. A reading is obtained from the
meter which correlates to a specific moisture
content at the testing temperature. The
moisture content is reported as an as
is, or wet basis,
percentage.
The ideal Moisture Content for further
corn grain testing is between 12 and 16%.
Possible Values 5-40%; Typical Results
8-17% |
| |
Visual
Kernel Characteristics |
| |
Crown Score,
Dent Score, Split Kernel Horneous Endosperm,
Color Rating, and Red Streaks |
| The
Visual Kernel Characteristic Ratings are
also offered as a component of the Alkaline Cooker Bundle. The Visual Kernel
Characteristics scores are available individually
or as a group of five tests. Twenty individual
kernel ratings are averaged to determine
the final result.
There are
certain visible characteristics that can
convey a great deal about a corn samples
suitability for food grade corn uses.
Crown
Score The Crown Score is a
measure of kernel hardness.
It is a rating of the amount of opaque soft
endosperm that is deposited at the crown
of the kernel. Ratings of individual kernels
are made on a scale of 1 (soft endosperm
extends half or more of the length of the
kernel from the crown) to 9 (no soft endosperm
visible at the crown). A rating of 6 (soft
endosperm at the crown extends to, but not
over, the shoulders of the kernel)
or higher is preferred by most processors,
but will vary.
Possible Values 1-9; Typical Results 4-8.5
Dent
Score The Dent Score is another
measure of kernel hardness.
As corn kernels mature, soft endosperm at
the crown compresses while the hard endosperm
remains rigid. This results in a dimple,
or dent, in the crown. This
is reason for the term dent corn.
Nearly all corn grown in the US is of the
dent corn type. Softer corn has a deeper
dent. Ratings of individual kernels are
made on a scale of 1 (very deep dent with
wrinkling of the crown and potential kissing
as the edges of the dent are pulled to each
other) to 9 (no dent). A rating of 6 (the
dent is still more of a smooth-edged depression
than an abrupt cavity in the crown) or higher
is preferred by most processors, but will
vary.
Possible Values 1-9; Typical Results 4-8.5
Split
Kernel Horneous Endosperm
The Split Kernel Horneous Endosperm Score
is yet another measure of hardness.
The hard endosperm in corn is preferentially
deposited in specific locations within the
kernel. The first hard endosperm is laid
down on the back side (opposite
the germ face) of the kernel. As kernels
get harder the quantity of hard endosperm
at this location increases to a point where
hard endosperm begins to be deposited on
the germ side (between the germ and the
crown) in increasingly larger amounts. This
phenomenon is easily observed by splitting
a kernel in half through the germ face.
Ratings of individual kernels are made on
a scale of 1 (no hard endosperm visible)
to 9 (very large deposit of hard endosperm
between the crown and germ face). A rating
of 6 (hard endosperm is just beginning to
be deposited on the germ side of the kernel)
or higher is preferred by most processors,
but will vary.
Possible Values 1-9; Typical Results 3-8.5
Color
Rating The Color Rating is
a measurement of the color of the grain.
The color of the raw material can dramatically
affect product color. Individual kernels
are rated by comparison to color standards.
The scale for yellow corn goes from 1 (dark
bronze) to 8 (bright yellow). The scale
for white corn goes from 1 (light yellow)
to 8 (bright white). Most processors desire
ratings of 5-6 (light orange for yellow
corn, or slightly off-white for white corn)
or higher. Cutoffs will vary by user.
The dark reddish-brown
color is usually in the pericarp (outer
kernel coat). On occasion, the endosperm
may be the source of the darker orange color.
During alkaline
cooking, the red pigments in the pericarp
react with the calcium hydroxide, turning
a dark green almost black
color. In addition, the reaction binds the
dark pericarp to the endosperm. This results
in poor pericarp
removal index ratings and undesirable
dark specks in the product.
Possible Values 1-8; Typical Results 3-7.5
Kernel
Red Streaks Rating The red
streaks seen on some kernels are the same
pigments that cause the overall bronze discoloration
described in the Color
Rating section above. Red streaking
is due to a combination of genetic and environmental
causes, but the dynamics are not fully understood.
Some red streaks are caused by a chemical
secreted by the wheat curl mite (Aceria
tulipae). The streaks will often occur nearer
the tip of the ear, and usually near the
tip cap, although they can occur any where
on the kernel. Another type of red streaks
can be induced by peeling back the husks
of maturing susceptible corn plants. Certain
hybrids and inbreds are more susceptible
than others. Some nearly always streaked,
some never show streaks, and some are completely
unpredictable for the occurrence of red
streaks. White corn generally shows less
red streaking than most yellow hybrids.

Ratings of
individual kernels are made on a scale of
1 (complete coloration of the kernel) to
8 (no red streaks). A rating of 7.8 (four
out of twenty kernels may have very slight
red specks) or higher is preferred by most
processors, but will vary. Some processors
may eliminate consideration of a sample
with any red streaking.
Possible Values 1-8; Typical Results 3-8 |
back
to IPG Corn Tests List |
| Pericarp
Removal Index |
| |
The
Pericarp Removal Index is also offered as
a component of the Alkaline
Cooker Bundle.
The alkali
cooking process is used for making products
such as corn tortillas, tortilla chips,
and corn chips. Corn is simmered in a dilute
lime (calcium hydroxide) solution. The lime
dissolves the pericarp to varying degrees
based on the composition of the pericarp.
Water is absorbed by the kernel during cooking.
The test involves
adding samples of corn to a gently boiling
1% lime solution and simmering for 20 minutes.
After the cook time is complete the sample
is immediately rinsed with tap water to
cease the cooking process and rinse any
dissolved pericarp from the cooked grain
(nixtamal). The sample is drained and stained
using a dye that will color the remaining
pericarp material selectively for easier
rating. Individual kernel ratings are made
on a scale from 1 (complete removal) to
5 (essentially no removal). Individual kernel
ratings are averaged for the final reported
result.
  
 
Snack food
makers would like complete removal of the
pericarp. Excess pericarp in the nixtamal
can lead to expensive process disruptions
and also to discolored product. They prefer
results of 1-3. Tortilla makers can accept
more pericarp in their product. In fact,
the cooked pericarp will act to help the
tortilla have a longer shelf-life by retaining
moisture, increasing pliability (softness)
of the tortilla, and reducing the need for
artificial additives. Values from 2-4 are
desired.
Some corn
kernels will have a dark bronze color
or red streaks in
the pericarp (outer kernel coat). During
alkaline cooking, the red pigments react
with the calcium hydroxide, turning a dark
green almost black color.
In addition, the reaction binds the dark
pericarp to the endosperm. This results
in undesirable dark specks in the product.
Possible Values 1-5; Typical Results 1-4
Bad vs. Good Samples |
| back
to IPG Corn Tests List |
| Moisture
Uptake during Cooking |
| |
The
Moisture Uptake Test is also offered as
a component of the Alkaline
Cooker Bundle.
The Moisture
Uptake Test evaluates the ability of the
grain to absorb water during the alkaline
cooking process. Process stability is
critical to a manufacturer. Fewer adjustments
to keep the process within its design parameters
result in production of a more consistent
product. Moisture content of the corn after
cooking is a critical process parameter.
The Moisture Uptake Test allows the cooking
characteristics of corn samples to be compared.
Processors prefer that the corn they use
have consistent cooking characteristics.
Corn samples
are placed in a 1% lime (calcium hydroxide)
solution at room temperature and rapidly
heated to 100°C followed by 25 minutes
of cooking at a gentle boil. The samples
are immediately removed, cooled, and drained
to remove exterior moisture. The moisture
content is determined on the sample using
the Air Oven
method. This final moisture content after
cooking is reported as the Moisture Uptake.
Possible Values 30-50%; Typical Results
35-45% |
| back
to IPG Corn Tests List |
| Germ-to-Endosperm
Percentage (Grit-to-Germ Ratio) |
| |
The Grit-to-Germ Ratio is also offered as
a component of the Dry
Miller Bundle.
This
test relates the amount of grit (endosperm)
in the kernel to the amount of germ (embryo).
This is useful to all food corn users, but
especially dry millers. Dry
millers process the kernel to physically
separate the bran (pericarp) and germ from
the endosperm to produce grits. Larger grit
pieces are more valuable. The germ can be
processed for oil, which is also a valuable
product, but incomplete separation of germ
from the grit pieces greatly reduces the
grit quality. Hence, the desire is for more
grit and less germ in the kernel.
In this test,
kernels are soaked approximately 48 hours
to soften the kernel. Twenty kernels are
hand-dissected to remove the pericarp and
then the germ. The germ and endosperm pieces
are dried, and the percentage of the germ
weight to the weight of the grit is reported
on a dry basis.
A lower percentage of germ is typically
preferred by food corn users.
Possible Values 8.5-14.5%;
Typical Results 10-12%

|
| |
| Extended
Kernel Size Evaluation |
| |
The
Extended Kernel Size Evaluation is also offered
as a component of the Dry
Miller Bundle.
Kernel size
is very important to all food grade corn users.
Small kernels will result in excessive cleanout
losses. It is difficult for dry
millers to make large grits from small
kernels. Some millers may desire the largest
kernels they can get. Conversely, some millers
may prefer a medium-sized kernel with good
size uniformity. This test, as the name implies,
is an extension of the Thins
Test and provides both a broad measure
of the average kernel size range and consistency
of kernel size in a sample.
In the Extended
Kernel Size Evaluation, 250 grams of grain
are screened using 22/64", 20/64",
18/64" and 16/64" round-hole screens.
The percentage passing through each of thise
screens is reported. |
|
|
| Stress
Crack Analysis |
| |
Stress
cracks are internal fissures in the hard
endosperm of a corn kernel. The pericarp
of the kernel is not damaged, so the outward
appearance of the kernel may be unaffected
at first glance.
The
cause of stress cracks is pressure buildup
due to large gradients of moisture content
and temperature within the kernels
hard endosperm. The internal stresses
are not able to build up as much in the
soft, floury endosperm. A kernel may have
zero, one, two, or multiple cracks. High-temperature
drying is the most common cause of stress
cracks. Therefore, high levels of stress
cracking can serve as a guide to poor
suitability for particular uses.
|
- Wet Milling
larger amounts of broken corn lost
in cleaning (screening to remove chaff,
broken grain and small kernels), lower
starch yield due to high-temperature drying
- Dry Milling
larger amounts of broken corn lost
to cleanout, lower yield of the most valuable
products (large grits)
- Alkaline Cooking
larger amounts of broken corn lost
in cleaning, disturbance of process balance
leading to overcooking or undercooking
|
The IPG
lab evaluates stress cracks using a backlit
viewing board to accentuate the cracks. Two
replicates of 100 intact kernels (no external
damage) are examined. The severity of the
stress crack damage is related to the total
number of stress-cracked kernels and the number
of cracks in each kernel. Many corn users
will specify the acceptable level of cracks.
The Stress Cracks Test report includes: |
|
Lower
numbers for the percentages and index are
always better. If stress cracks are present,
singles are better than doubles or multiples.
Many contracts are written with a stress crack
allowance of 20%, but this may vary from case
to case.
| |
Possible
Values |
Typical
Results |
| % Stress
Cracks |
0-100% |
0-60%
|
| % Single
Stress Cracks |
0-100%
|
0-30%
|
| % Double
Stress Cracks |
0-100%
|
0-20%
|
| % Multiple
Stress Cracks |
0-100% |
0-50% |
| Stress
Crack Index |
0-500 |
0-300 |
On
November 29, 1995, the Grain Inspection, Packers,
and Stockyards Administration (GIPSA) published
in the Federal Register (60 FR 61194) a final
rule offering stress crack testing of corn
effective January 1, 1996. The method developed
at the Identity Preserved Grain Laboratory
was selected as the official GIPSA method
for stress crack analysis. |
| |
| Whole
Kernels / Cracked & Broken |
| |
The exterior
integrity of the corn kernel is very important
to alkaline cookers. Any nicks or cracks
in the kernel will allow water to enter
the kernel much faster than in an intact
one. Too much water uptake during cooking
can result in expensive process shutdown
time or a product that does not meet specifications
for quality and composition. No company
can afford to have these occur at a high
frequency. Some companies even pay extra
premiums, over and above contracted premiums,
for corn delivered above a specified level
of whole kernels. While hard endosperm texture
lends itself to preservation of more whole
kernels than does soft corn, the primary
factor in delivering whole kernels is handling
during and after harvest. The type of conveyance
(bucket elevators are better than screw
augers), number and length of conveyances,
and even combine configuration will have
a profound effect on kernel integrity.
In the Whole
Kernels Test, 50 grams of cleaned (BCFM-free)
corn is inspected kernel-by-kernel. Cracked,
broken, or chipped grain, along with any
kernels showing significant pericarp damage
are removed, the whole kernels are weighed,
and the result is reported as a percentage
of the original 50 gram sample. Some companies
perform the same test, but report the Cracked
& Broken percentage. A Whole Kernels
score of 97% equates to a Cracked &
Broken rating of 3%.
Possible Values 0-100%; Typical Results
0-20% |
|
|
| Stenvert
Hardness Test |
| |
The Stenvert
Hardness Test provides a measure of endosperm
hardness to alkaline
cookers and dry
millers.
The Stenvert
Hardness Test measures the time-to-grind
a corn sample to produce 17 ml of ground
material using the Stenvert micro-hammer
cutter mill fitted with a 2 mm screen. Harder
corn will take longer to grind. The time
required to grind the sample is reported.
Possible Values 4-25 seconds; Typical Results
5-15 seconds |
| back
to IPG Corn Tests List |
| Wisconsin
Breakage Susceptibility Test |
| |
The
Wisconsin Breakage Test (WBT) provides a
measure of the likelihood that a sample
of corn will be physically damaged, particularly
by high-speed impact (such as falling from
the top of a bin to the floor below) in
handling. Pieces of broken corn will affect
the process parameters for alkaline
cookers. Dry
millers will obtain more large grits
and less lower-value flour from unbroken
grain. Breakage susceptibility is largely
influenced by endosperm hardness and Stress
Cracks.
A specialized
piece of equipment is used for this test.
The Wisconsin Breakage Tester uses a rapidly
spinning horizontal disc to fling a sample
of BCFM-free corn kernels against a vertical
steel surface. The feed rate is specified
at 200 grams in 20 seconds. The ensuing
sample is collected from the tester and
screen over a 12/64 Round Hole Screen,
as is done for measuring BCFM. The percentage
of material passing through the screen is
reported.
Possible Values 0-30+%; Typical Results
0.5-15% |
| back
to IPG Corn Tests List |
| Broken
Corn & Foreign Material (BCFM) |
| |
Broken
Corn & Foreign Material is part of the
GIPSA Official United States Standards for
Grain grading criteria. Higher levels of
BCFM will indicate that a sample may have
been through more, or rougher, handling
than another sample with lower BCFM. Higher
levels of BCFM lead to decreased storability
and can be a dust explosion hazard.
This test
determines the amount of all matter that
passed through a 12/64 inch round-hole sieve
and all matter other than corn that remains
on the top of the sieve. The IPG lab is
not an officially designated grain inspection
facility, and, therefore, can not issue
official grades. The data from the IPG lab
can be useful in making decisions, but cooperative
arrangements can also be made with the local
official inspection station in the case
that official documentation is required.
BCFM is reported as a percentage of the
initial sample.
Possible Values 0-20+%; Typical Results
0-5% |
| back
to IPG Corn Tests List |
| Total
Damage |
| |
Total
Damage is part of the GIPSA Official United
States Standards for Grain grading criteria.
This test determines the amount of damaged
kernels from various reasons such as mold,
insects, heat, ground, sprout, or cob rot.
Most of these types of damage result in
some sort of discoloration or change in
kernel texture. It does not include broken
pieces of grain that are otherwise normal
in appearance. The IPG lab is not an officially
designated grain inspection facility, and,
therefore, can not issue official grades.
The data from the IPG lab can be useful
in making decisions, but cooperative arrangements
can also be made with the local official
inspection station in the case that official
documentation is required.
A representative
working sample of corn is visually examined
by a proper-trained individual for content
of damaged kernels. Damage is reported as
the weight percentage of the working sample
that is damaged grain.
Possible Values 0-15+%; Typical Results
0-5% |
| back
to IPG Corn Tests List |
| |
| Floaters |
| |
The Floaters,
or flotation, test provides an estimate
of average density of a sample, as well
as the range of individual kernel densities
within the sample. As with True
Density, the Floaters test is a measure
of endosperm
hardness to alkaline
cookers and dry
millers.
In the Floaters
test, a solution with specific gravity (density)
of exactly 1.275 grams per cubic centimeter
is prepared. Externally intact kernels are
placed in the solution. Harder kernels,
with a density higher than 1.275, will sink.
Softer kernels, with a density lower than
or equal to 1.275, will float. The percentage
of kernels that float is reported. The test
is performed using two replicates of 100
kernels.
This test
has, to a large degree, been replaced by
the True Density
test due to the accuracy of the True Density
test, as well as the complexity and potential
hazards of preparing the Floaters test solution.
Possible Values 0-100%; Typical Results
0-100% |
| back
to IPG Corn Tests List |
| Class |
| |
A corn sample will belong to one of the three
classes of corn yellow, white or mixed.
This test is part of the GIPSA Official United
States Standards for Grain grading criteria.
The kernels from a 250 gram sample are separated
by color. Class is defined by the following
criteria:
| Yellow
Corn
Yellow kerneled and contains
not more than 5.0 %of corn of other
colors.
White
Corn
White kerneled and contains
not more than 2.0 % of corn of other
colors.
Mixed
Corn
Corn that does not meet the
requirements for the other classes
and includes white capped Yellow corn. |
The result is
reported as Yellow, White, or Mixed. The IPG
lab is not an officially designated grain
inspection facility, and, therefore, can not
issue official grades. The data from the IPG
lab can be useful in making decisions, but
cooperative arrangements can also be made
with the local official inspection station
in the case that official documentation is
required. |
| Back
to IPG Corn Tests List |
Chemical
Components - (top of page)
| NIR
Proximate Analysis Corn |
| |
NIR Proximate
Analysis is also offered as a component
of the Basic
Food Grade Test Bundle, NIR
Extractable Starch, and NIR
Complete Analysis Corn.
Proximates are the
major components of the grain. For corn,
the NIR Proximate Analysis includes Oil
Content, Protein Content, Starch Content
(or Total Starch), and Moisture Content.
The test does not include Fiber Content
or Ash Content. This procedure is nondestructive
to the corn. Proximate Analysis is also
available using wet chemistry methods for
protein content, oil content, and moisture
content but the sample must be ground.
Various end
users have different demands for grain composition.
A hog feeder may want increased oil and
protein levels to increase feeding efficiency.
A dry-grind ethanol manufacturer may want
more starch, since that should increase
his product yields.
Results
(other than Moisture Content) are reported
on a dry basis
percentage (percent of non-water material).
Moisture Content is reported as
is (percent of total sample weight).
| |
Possible Values |
Typical Results |
| Oil Content |
2-20+% |
3-8% |
| Protein Content |
5-20+% |
6-16% |
| Starch Content |
50-80% |
62-75% |
| Moisture Content |
5-35% |
8-17% |
|
|
|
| NIR
Extractable Starch |
| |
NIR Extractable
Starch provides a prediction of the yield
of starch in a corn sample from the wet
milling process. This procedure is nondestructive
to the corn. The calibration was developed
at the Agricultural and Biological Engineering
Department at the University of Illinois
at Urbana-Champaign using the 100
Gram Wet Milling test as the reference
method.
The primary
purpose of wet milling is to efficiently
separate kernel components to obtain starch.
Some hybrids contain more starch than others.
Differences in the grain can affect the
amount of Total Starch in the corn sample
that is recovered in the wet milling process
as starch product. The remaining unrecovered
starch goes into lower-value feed products.
So, even in samples containing the same
amount of Total Starch, one sample may yield
considerably more starch product after milling
than another.
The starch
recovery is the amount of starch product
(predicted starch yield or extractable starch
content) divided by the total starch present
in the sample. This number can serve as
a guideline to the millability, or efficiency
of separation, of the sample.
The NIR Extractable
Starch test report includes the Extractable
Starch Content (predicted starch yield),
NIR Proximate Analysis
Corn, and the Predicted Starch
Recovery. Extractable Starch is reported
on a dry basis
percentage.
| |
Possible
Values |
Typical
Results |
| NIR Extractable
Starch |
45-72% |
60-70% |
| Predicted
Starch Recovery |
60-100% |
85-95% |
|
| back
to IPG Corn Tests List |
| Protein
Content Combustion Method |
| |
The
Combustion (Dumas) Method can be used to measure
the protein or nitrogen content in a wide
range of substances. It has replaced the slow,
dangerous, and environmentally unfriendly
Kjeldahl procedure for most applications.
The combustion method is an approved method
and has become the most common reference (wet
chemistry) method for NIR calibrations
for protein content. The combustion method
is typically employed for samples for which
no NIR calibration exists. The IPG lab does
offer protein content
for corn using NIR. There are situations
in which the combustion method may not be
suitable.
In this test,
a 50-300 mg representative sample (liquid
or ground solid) is burned at high temperature
in a sealed system. The nitrogen in the sample
is converted to nitrogen gas, separated from
the other chemical components, and measured
by thermal conductivity. The nitrogen content
can be converted to protein content by using
a conversion factor (typically 6.25 x nitrogen)
to obtain the as
is protein percentage. This test
is performed in duplicate, and the moisture
content in the original sample is determined
by the air oven method
to convert the protein content to dry
basis.
Protein
contents measured by the combustion method
can range from very low (0.1% to 90+%). |
|
|
| Oil
Content Ether Extraction |
| |
Ether
extraction can be used to quantify the amount
of fat or oil in a sample. The ether extraction
method is an approved method and is a common
reference (wet chemistry) method
for NIR calibrations
for oil content. The ether extraction method
is typically employed for samples for which
no NIR calibration exists. The IPG lab does
offer oil content for corn using NIR. There
are situations in which ether extraction may
not be a suitable method for oil measurement.
In this test,
a representative sample is ground and extracted
in refluxing petroleum ether. Extracted oil
is captured in the boiling flask. The oil
is separated from the ether and weighed to
determine the percentage of the original sample
weight collected as oil to obtain the as
is oil percentage. This test is
performed in duplicate, and the moisture content
in the original sample is determined by the
air oven method to convert the protein content
to dry basis.
Oil contents
measured by the ether extraction method can
range from very low (0.2% to 50+%). |
|
|
| Moisture
Content Air Oven |
| |
The Air Oven
method can be used to quantify the amount
of water in a sample. The air oven method
is an approved method and is a common reference
(wet chemistry) method for NIR
calibrations for moisture content. The air
oven method is typically employed for samples
for which no NIR calibration or other reliable
rapid method (NIR or Moisture
Meter) exists. There are situations in
which the air oven method may not be a suitable
method for moisture measurement.
In this test,
a representative sample (liquid or ground
solid) is weighed into a tared cup and placed
in an oven. Oven temperatures and residence
times vary by substance. The dried sample
is cooled is a dessicator and the weight of
the remaining material is recorded. The weights
may be used to determine the amount of water
removed in the oven. Moisture content is reported
as the amount of water removed from the original
sample. Solids content is the weight of material
remaining after drying divided by the original
sample weight. Moisture content and solids
content are reported as an as
is, or wet
basis percentage. They are related by
the equation:
Moisture Content (as is)
+ Solids Content (as is) = 100%
|
| back
to IPG Corn Tests List |
| Amino
Acid Profile High Performance Liquid
Chromatography |
| |
The
High Performance Liquid Chromatography (HPLC)
method can be used to quantify the amount
of various amino acids in a sample. The HPLC
method is an approved method and is a common
reference (“wet chemistry”) method for NIR
calibrations for amino acid contents. The
HPLC method is typically employed for samples
for which no NIR calibration exists. The IPG
lab does offer amino
acid profile for corn using NIR.
Various procedures
must be employed depending on the amino acids
of interest. The moisture content in the original
sample is determined by the air
oven method to convert the amino acid
contents to dry
basis. |
|
|
| Fatty
Acid Profile Gas Chromatography |
| |
The
Gas Chromatography (GC) method can be used
to quantify the amount of various fatty acids
in a sample. The GC method is an approved
method and is a common reference (“wet chemistry”)
method for NIR calibrations
for fatty acid contents. The GC method is
typically employed for samples for which no
NIR calibration exists. The IPG lab does offer
fatty acid profile
for corn using NIR.
Various procedures
may be employed depending on the fatty acids
of interest. The moisture content in the original
sample is determined by the
air oven method to convert the fatty acid
contents to dry
basis. |
|
|
| Amylose
Content CRA Method |
| |
The Amylose
Content test measures the amount of amylose
starch in a starch sample. Starch can be
thought of as a chain where each link is
a sugar (glucose) molecule. Corn starch
is comprised of two types of starch
amylose and amylopectin. Amylopectin starch
chains branch every 12-60 links.
Amylose starch chains have no branching
and reach 100-1000 links in length. Because
of these differences, starches with various
levels of amylose and amylopectin have different
functional characteristics in food and industrial
uses.
Most corn
grown in the US has approximately 27% amylose
and 73% amylopectin. Waxy
corn is 100% amylopectin. Hybrids have
been developed with amylose contents reaching
50-80%.
In this test,
starch is first isolated from the grain
using a series of steeping, grinding, screening,
and centrifuging steps. The starch is then
chemically treated to form a colored solution.
Higher amylose levels correspond to deeper
blue coloration. The degree of color is
read on a spectrophotometer and compared
to known standards to obtain the result.
The amylose content is reported as the dry
basis percentage of the total starch
that is amylose.
Possible Values 0-85%; Typical Results
23-80%
|
|
|
| Waxy
Purity |
| |
The waxy
purity test measures the contamination of
non-waxy corn in a waxy corn sample.
Starch can
be thought of as a chain where each link
is a glucose sugar molecule. Corn starch
is comprised of two types of starch
amylose and amylopectin. Amylopectin starch
chains branch every 12-60 links.
Amylose starch chains have no branching
and reach 100-1000 links in length. Because
of these structural differences, starches
with various levels of amylose and amylopectin
have different functional characteristics
in food and industrial uses.
Most corn
grown in the US has approximately 27% amylose
and 73% amylopectin. Waxy corn is 100% amylopectin.
In this test,
two replicates of 100 kernels each are evaluated.
The crown, or starch cap, of each kernel
is removed, and the exposed endosperm is
sprayed with an iodine solution. Waxy kernels
stain reddish-brown. Any kernels containing
amylose stain blue. A visual rating is made
and reported as percent waxy kernels.
Possible Values 0-100%; Typical Results
95-100%
|
|
Corn
Kernels with Soft Endosperm Exposed to Iodine
|
 |
 |
Normal
Dent
(28% amylose/72% amylopectin) |
Waxy
(99+% amylopectin) |
| Amylose
starch stains blue, while amylopectin stains
reddish-brown. |
|
|
| Aflatoxin
ELISA Method |
| |
Aflatoxin
has been described as the most potent naturally
occurring carcinogen. It is a mycotoxin
(fungal toxin) produced by the fungus Aspergillus
flavus. The fungus does not produce the
toxin unless environmental conditions are
favorable. Sustained high temperatures (nighttime
lows above 70°F) and drought stress are
typically required. As such, aflatoxin is
usually more of a concern in south Texas
than in the Corn Belt, but aflatoxin can
potentially turn up anywhere. Several Midwestern
states saw increased occurrence of aflatoxin
in the 2002 harvest.
For this test,
a GIPSA-approved Enzyme-Linked Immunosorbent
Assay (ELISA) is utilized to quantify the
aflatoxin level of a sample. The US Food
and Drug Administration set maximum levels
for aflatoxin contamination according to
these guidelines: 20 parts per billion for
food for human consumption and feed for
some animal species; 300 ppb for feedlot
cattle; 200 ppb for market hogs; and, 100
ppb for breeding cattle, breeding hogs and
mature poultry. The test result is reported
in parts per billion.
Possible Values 0-300+ ppb; Typical Results
0-30 ppb
|
|
|
| Fumonisin
ELISA Method |
| |
Fumonisin
is a corn mycotoxin (fungal toxin) produced
by the fungus Fusarium moniliformae. Fumonisin
is known to cause equine leukoencephalomalcia
in horses and pulmonary edema in pigs that
eat contaminated corn.
For this test,
a GIPSA-approved Enzyme-Linked Immunosorbent
Assay (ELISA) is utilized to quantify the
aflatoxin level of a sample. The test result
is reported in parts per million (ppm).
The US Food and Drug Administration has
set guidance levels for fumonisin content
in corn and corn products that vary depending
on use.
Possible Values 0-50+ ppm; Typical Results
0-6 ppm
|
|
|
| Vomitoxin
(Deoxynivalenol DON) ELISA Method |
| |
Vomitoxin
is a grain mycotoxin (fungal toxin) produced
by the fungus Fusarium graminearium. Vomitoxin
appears to affect swine to a larger degree
than other animals. The most common effect
of feeding corn containing DON to swine
is weight loss or reduced weight gain due
to refusal of feed, reduced feed intake,
or vomiting after eating. This has been
observed at levels as low as 5 ppm.
For this test,
a GIPSA-approved Enzyme-Linked Immunosorbent
Assay (ELISA) is utilized to quantify the
vomitoxin level of a sample. The US Food
and Drug Administration sets maximum levels
for vomitoxin contamination according to
these guidelines: 1 part per million for
wheat products for human consumption, 10
ppm for ruminating beef and feedlot cattle
(not to exceed 50% of the diet), and 5 ppm
in grain and grain products destined for
swine and all other animals (not to exceed
20% of the diet).
Possible Values 0-20+ ppm Typical Results
0-2 ppm
|
|
|
Processing
Characteristics - (top of
page)
| Ethanol
Fermentation Test |
| |
Fermentation
of starch to fuel ethanol is the fastest
growing use of corn grain in the U.S. Two
processes have traditionally been used –
wet milling
and dry-grind.
Dry-grind processing has shown the highest
adoption in recent years, although a number
of plants are introducing prefractionation
steps similar to both wet milling and dry
milling. These processes remove non-fermentable
parts of the grain, such as the germ and
bran, for use in food or feed products.
The standard ethanol fermentation test
is done using the typical dry-grind method.
Corn is ground, slurried with water and
enzyme, and cooked. This process is referred
to as liquefaction as it produces a pumpable
mixture of solublized starch and begins
to break the long starch molecules down
into smaller pieces (dextrins). This slurry
is then cooled. The acidity level is adjusted
for optimum fermentation, and nutrients
for use by the yeast are added.
The test utilizes simultaneous saccharification
and fermentation (SSF). A second enzyme
is added along with yeast inoculum. This
begins the process of breaking the dextrins
into glucose molecules that can be converted
by yeast into ethanol. The laboratory fermentation
process takes 64 hours.
 
Ethanol yield is determined by the loss
in weight of the sample from the beginning
of fermentation (yeast addition) to the
fermentation cutoff time. As the starch
(now glucose) is consumed by the yeast,
liquid ethanol and carbon dioxide gas are
formed in constant ratio and in nearly equal
amounts by weight. The carbon dioxide bubbles
out of the mixture and is vented to the
surroundings, so the loss of weight can
be converted to grams of ethanol produced.
This method has been compared to HPLC measurement
of ethanol concentration after fermentation,
with generally higher yields but more consistent
repeatability. Coefficients of variation
for replicates are less than 1%. Ethanol
yield is reported as gallons of 200 proof
undenatured ethanol per bushel (56 lb) of
corn at 15% moisture content
Test Weight and
NIR
Proximate Analysis are included
with the standard dry-grind fermentation
test.
Possible Values 1.7-3.0 gallons per bushel
Typical Results 2.55-2.90 gallons per bushel
|
| 100
Gram Wet Mill Process Test |
| |
Wet
milling is the process of separating
or refining corn into its components: starch,
gluten (protein), fiber, germ, and soluble
material. An individual industrial plant
may do this at a rate of 100,000 to 500,000
bushels per day. The starch may be converted
to sugars, ethanol, or other products. The
germ is processed for its oil. The remaining
components are primarily used as animal
feed.
The 100 gram wet mill process test mimics
the industrial process to evaluate small
samples for suitability in this process.
This can be used to select hybrids or evaluate
other physical or chemical treatments.
This test is performed at the Agricultural and
Biological Engineering Department at the
University of Illinois at Urbana-Champaign.
Results are
reported as the dry
basis percentage yield of the initial
corn sample.
| |
Possible
Values |
Typical
Results |
| Starch
Yield |
55-70% |
62-69% |
| Gluten
Yield |
8-13% |
9.5-12% |
| Germ
Yield |
4-7.5% |
4.5-7% |
| Coarse
Fiber Yield |
3.5-7% |
4-6% |
| Fine
Fiber Yield |
5.5-11% |
6-9% |
| Total
Fiber Yield |
11-16 |
11.5-14 |
| Steepwater
Solids |
3.5-4.7% |
3.6-4.4% |
| Total
Recovery |
97.80-100+% |
98.4-100% |
The starch
from the 100 gram wet mill test can be analyzed
for protein
content, a key quality factor to wet
millers. Other product analysis (oil
content of the germ, protein
content in the gluten, etc.) is also
available.
The test is
labor-intensive; the number of samples milled
per day is quite limited (40 per week).
The NIR Extractable
Starch test may alternatively or additionally
be used to rapidly obtain the predicted
starch yield of the sample.
|
|
|
| 1
Kg Wet Mill Process Test |
| |
The
1 kg wet mill
process test produces the same type of
data as the 100
gram wet mill test. The 1 kg method is
often used by researchers desiring to have
substantial product after milling to perform
additional testing. There is no distinction
made between coarse fiber and fine fiber in
the 1 kg process.
This test is performed at the Agricultural
and Biological Engineering Department at the
University of Illinois at Urbana-Champaign.
Results are
reported as the dry
basis percentage yield of the initial
corn sample. |
| Back
to IPG Corn Tests List |
| Pilot
Scale Wet Milling |
| |
Pilot
scale wet milling
is used primarily by entities that require
very large (20-60 lbs) quantities of starch
or other components for additional testing.
This test is performed at the Agricultural
and Biological Engineering Department at the
University of Illinois at Urbana-Champaign.
Results are
reported as the dry
basis percentage yield of the initial
corn sample. |
| Back
to IPG Corn Tests List |
| 1
Kg Dry Mill Process |
| |
Dry
milling is the process of processing corn
by physically separating the pericarp, germ,
and endosperm components. The endosperm is
captured as grits of various size, meals,
and flour. The germ is processed to recover
the oil. The remaining components are primarily
used as animal feed.
The 1 kg dry mill process test mimics the
industrial process to evaluate small samples
for suitability in this process. This can
be used to select hybrids or evaluate other
physical or chemical treatments. This test
is performed at the Agricultural and Biological
Engineering Department at the University of
Illinois at Urbana-Champaign.
Results are
reported as the
dry basis percentage yield of the initial
corn sample. |
| Back
to IPG Corn Tests List |
| Pilot
Scale Dry Milling |
| |
Pilot
scale dry milling
is used primarily by entities that require
very large quantities of starch or other components
for additional testing.
This test is performed at the Agricultural
and Biological Engineering Department at the
University of Illinois at Urbana-Champaign.
Results are
reported as the dry
basis percentage yield of the initial
corn sample. |
|
|
(top of page)
Home
| Corporate
Overview | Contact
Us | Services
| Related
Links | Forms
| Log
In
News |
Seed Certification
| Quality
Assurance | Identity
Preserved | Other
Programs
Publications
| Seed
Laboratory | Field
Services | Identity
Preserved Grain Lab
Puerto Rico
Winter Farm Services | Support
Team | Management
Team
|