The corn processing sector continues to develop in line with the increasing demand in food, feed, and industrial applications. Today, products such as corn flour, grits, and starch are used as critical raw materials in a wide range from the food industry to bioplastics. In this strategic sector, a turnkey facility installation provides investors with unique advantages in terms of time, cost, and coordination.
As Tanış A.Ş., with more than 60 years of experience, we have become one of the leading experts in the sector in the design, production, installation, and commissioning of corn processing facilities. We offer comprehensive and integrated solutions to our customers from the feasibility stage to full operational competence.
As Tanış A.Ş., our turnkey corn processing facility services include:
- Feasibility study and project planning: We analyze the financial and technical feasibility of your investment in detail
- Engineering and facility design: We develop facility designs that are customized to your needs and provide optimum efficiency
- Equipment manufacturing and procurement: We integrate quality equipment from our own production and reliable suppliers
- Construction and infrastructure coordination: We manage facility construction and infrastructure requirements
- Assembly and installation: We provide professional assembly services with our expert teams
- Commissioning and testing: We perform gradual commissioning of systems and comprehensive performance tests
- Personnel training: We organize training to ensure the competence of operation and maintenance personnel
- Maintenance and technical support: We provide long-term maintenance and support services
- Project financing consultancy: We provide financial solutions and investment consulting services
Feasibility and Planning Phase
Our corn processing facility projects begin with a detailed feasibility study:
- Customer needs and targeted product portfolio are determined
- Optimum capacity planning and scale studies are conducted
- Raw material sources and supply chain are evaluated
- Facility location is analyzed and logistics plans are created
- Detailed market analysis and competitive assessment are performed
- Comprehensive financial feasibility and return on investment calculations are presented
Following feasibility approval, comprehensive engineering studies begin:
- Detailed facility layout plan is created
- Process flow diagrams and P&IDs are prepared
- Machine layout plans and realistic 3D modeling are developed
- Optimum solutions for energy, water, and auxiliary facilities are planned
- Electrical, automation, and control systems are designed in detail
- Storage and logistics systems for raw materials and final products are projected
After design approval, the production and procurement process begins:
- Production of main corn processing machines is carried out
- Auxiliary equipment and systems are procured
- Comprehensive quality control and factory tests are applied for each equipment
- Automation and control systems integration is provided
- Transportation planning and shipment organization is performed
- Site logistics and storage needs are arranged
The assembly process begins when equipment reaches the site:
- Site preparation and infrastructure work are coordinated
- Equipment installation and placement are carried out by expert teams
- Process lines, pipe and cable systems are assembled
- Electrical, automation, and control systems are installed
- All assembly processes are subject to quality control procedures
- Full compliance with occupational safety standards and legal requirements is ensured
After assembly completion, the gradual commissioning process of systems begins:
- Cold and hot tests are systematically applied
- Process parameters are optimized
- Equipment performances are tested and adjustments are made
- Product quality tests are performed
- Capacity and efficiency performance is verified
- Performance guarantees specified in the contract are proven
In the final phase of the project, comprehensive training and support services are provided:
- Detailed theoretical and practical training is given to operator and maintenance personnel
- Comprehensive operation and maintenance documents are delivered
- Process optimization techniques are transferred
- Quality control procedures and laboratory techniques are taught
- Troubleshooting and fault management training is provided
- Continuous improvement and optimization support is offered
Main Product Lines of Our Corn Processing Facilities
Corn Flour Production Lines
Tanış A.Ş. corn flour production lines are of critical importance for the food industry:
- Different corn flour varieties with fine, medium, and coarse grinding options
- Special formulations for tortilla, bread, snack, and other food applications
- Capacity options ranging from 50-500 tons/day
- Consistent quality with online moisture and color control
- Ability to adapt to special customer specifications
- 99.5% purity and stability guarantee
Corn Grits Production Facilities
Specially designed grits lines for chips, breakfast cereals, and brewing industry:
- Precise granulometry control between 300-1500 microns
- Special quality standards for chips, brewing, breakfast cereal industry
- High-efficiency dehulling (hull separation) systems
- State-of-the-art foreign matter separation and cleaning systems
- Full compliance with FDA, EFSA, and other international standards
- Consistent quality guarantee from batch to batch
High value-added starch and by-product processing facilities:
- Modern wet milling and starch extraction technologies
- Separate processing and evaluation lines for gluten, corn germ, and corn bran
- Optional starch modification and derivative production options
- Energy-efficient drying systems
- Fully automatic packaging and palletizing solutions
- Sustainable waste management and environmentally friendly production model
Integrated facility solutions combining multiple product lines:
- Ability to produce different corn products in a single facility
- Up to 25% optimization in raw material and resource use
- Investment savings with common infrastructure and auxiliary systems
- Flexibility to adjust product balance according to market conditions
- Operational efficiency with centralized management
- Competitive production costs with economies of scale
Modern Technology and Innovation
Tanış A.Ş. corn processing facilities incorporate the latest technological innovations in the sector:
- Advanced cleaning systems working with optical, gravimetric, and magnetic principles
- Patented dehulling and degerming (hull and germ separation) technologies
- Grinding systems consuming 15% less energy per ton
- Screening technologies performing classification with micron precision
- Full automation with minimum operator intervention
- Industry 4.0 compatible equipment and IoT integration
Our facilities are designed for maximum operational efficiency:
- 3-5% higher product extraction rates compared to competitor systems
- Up to 20% energy savings per ton
- Up to 30% reduction in water consumption
- Up to 50% labor savings
- 95%+ capacity utilization rate and minimum downtime
- Product changeover capability in less than 30 minutes
Tanış A.Ş. corn processing facilities offer superior and consistent product quality:
- 99.5% consistency rate from batch to batch
- Full compliance with GFSI-defined food safety standards
- Precise color, moisture, and granulation control
- Full traceability and quality assurance systems
- Ability to develop customer-specific product specifications
- Design compliant with FSSC 22000, BRC, IFS, and other certification requirements
Environmentally friendly and sustainable facility design:
- 20-30% reduction in energy consumption per ton
- Up to 40% savings in water use with circular systems
- Zero waste targeted by-product evaluation systems
- Energy-efficient equipment minimizing carbon footprint
- Low emission and noise level reduced systems
- Facility design fully compliant with green production standards
Small and Medium Scale Facilities
Ideal solutions for local markets and entrepreneurs:
- 50-150 tons/day corn processing capacity
- Compact facility design with 1,500-3,000 m² area requirement
- 18-30 months return on investment
- Easy operation with 3-5 personnel per shift
- Competitive production capacity for local and regional markets
- Future expansion possibility with modular design
Optimum solutions for medium and large-scale producers:
- 200-500 tons/day capacity corn processing systems
- Minimum personnel requirement with fully automatic operation
- Advanced SCADA systems and central control
- Low operating cost per ton and economies of scale
- Market flexibility with wide product portfolio
- Ideal capacity for export-oriented production
High capacity solutions for industrial leaders:
- 500+ tons/day capacity large-scale facilities
- Integrated production lines for corn flour, grits, starch, and derivatives
- Maximum automation and digitalization
- Industry-leading extraction rates and efficiency
- Fully integrated logistics and storage solutions
- Operating costs optimized for global competition
Raw Material Reception and Preparation Systems
Systems containing critical first steps for quality final products:
- Corn reception and conveying units sized according to capacity
- Multi-stage cleaning and stone separation systems
- Controlled drying and tempering units
- Precise magnetic protection and metal detector systems
- Automatic moisture measurement and dosing units
- Optical sorting systems for separating rotten and damaged grains
Main process equipment that is the heart of facilities:
- High-efficiency dehulling (hull separation) systems
- Patented degerming (corn germ separation) technology
- Precisely adjustable roller and grinding systems
- Multi-stage screening and classification equipment
- Air classification systems providing precise separation
- Advanced separation and purification units
For smart and efficient facility management:
- Siemens or Allen Bradley PLC-based central control systems
- User-friendly SCADA interface and visualization
- Digital recipe management software
- Online quality parameter monitoring systems
- Integrated reporting and analysis tools
- Remote access and technical support infrastructure
Auxiliary equipment supporting main systems:
- Low-pressure pneumatic conveying systems preserving product quality
- Dust collection and filtration units in ATEX standards
- Energy-efficient drying and moisture removal systems
- Fully automatic packaging and palletizing units
- Comprehensive laboratory equipment and quality control systems
- Wastewater treatment systems compliant with environmental standards
Corn processing facility investment is a strategic and profitable venture:
- Opportunity to transform raw materials into high value-added products
- Supplying raw materials to industries such as food, feed, paper, and bioethanol
- Wide product range with corn flour, grits, starch, and derivatives
- Additional income from by-products such as corn germ, gluten, and bran
- Profit margins varying between 15-25% of sector average
- Export potential to international markets
- 20-30% cost advantage with integrated facility
- Opportunity to become a strategic player in the food sector
Here are the factors that make Tanış A.Ş. an ideal partner for your corn processing facility investment:
- More than 60 years of grain processing technology experience
- Full service approach from concept to turnkey delivery
- Minimized project risks with single point of responsibility
- Written performance guarantees on quality and efficiency
- Optimum investment cost and competitive pricing
- Early return on investment with 12-18 month rapid installation periods
- Comprehensive training and continuous technical support for operating personnel
- Spare parts and service guarantee extending up to 10 years
The systematic process we follow for your corn processing facility investment:
- Initial meeting and detailed needs analysis (1-2 weeks)
- Feasibility study and investment evaluation (3-4 weeks)
- Concept design and proposal phase (2-3 weeks)
- Contract and detailed project planning (2 weeks)
- Comprehensive engineering and design studies (8-12 weeks)
- Equipment manufacturing and procurement process (16-24 weeks)
- Transportation and site organization (3-4 weeks)
- Assembly and installation (12-16 weeks)
- Commissioning and personnel training (4-6 weeks)
- Test production and final acceptance (2-3 weeks)
Take Action for Your Corn Processing Facility Investment
To realize your corn processing facility investment:
- Free feasibility study: Let us provide detailed feasibility analysis for your investment plan
- Visit our reference facilities: See our successfully operating facilities on-site
- Detailed project catalog: Request our catalog containing different capacity options and technical details
- Investment consultancy: Evaluate all aspects of your investment with our expert team
- Special offer: Contact us for a project-specific, competitive offer
Frequently Asked Questions
A modern corn processing facility project generally takes 12-18 months from contract signing to commissioning, depending on capacity. Small capacity facilities can be completed in about 12 months, while facilities over 300 tons/day can be completed within 16-18 months.
For a 100 tons/day capacity facility, approximately 2,000-2,500 m² of covered area is required. Infrastructure requirements include 600-800 kVA electrical connection, 25-30 m³ daily water capacity, and natural gas/steam source.
The minimum capacity for an economically sustainable investment is generally accepted as 50-75 tons/day. This level is the lowest capacity that can cover fixed costs and offer competitive operating costs.
While the average payback period depends on market conditions, a modern and efficient corn processing facility investment generally pays for itself within 24-36 months. In integrated facilities, this period can decrease to 20-30 months.
Our facilities have the flexibility to process different corn varieties such as white corn and flint corn in addition to standard yellow corn. Process parameters can be optimized according to the type of corn to be processed.
Yes, our modern corn processing facilities are designed to make rapid transitions between different product types. Thanks to automatic recipe management systems, product changes can generally be completed within 30-45 minutes.
Yes, we offer comprehensive solutions for modernization of existing facilities. We have modular modernization packages for objectives such as capacity increase, efficiency improvement, energy optimization, or quality enhancement.
In our modern corn processing facilities, energy consumption per ton is 60-80 kWh, while water consumption is between 0.5-0.8 m³. These values are 20-30% below the sector average and may vary according to the specific technologies used.