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International corn shellers, also known as corn shuckers or huskers, are devices used to detach the corn kernels from the cob. There are several types of corn shellers, each with its own unique mechanism and usability.
Handheld Corn Sheller
The handheld corn sheller is the most common type of corn sheller available. It is manufactured from cast metal and is suitable for shelling small volumes of corn. The device is corn-shaped and is usually painted in bright colors to appeal to consumers. Using the handheld corn sheller is simple; the operator puts the corn on the holder and turns the handle to turn the drum. As the drum rotates, the corn kernels detach from the cob and fall into the container placed below.
Bench Corn Sheller
Like the handheld corn sheller, the bench corn sheller is operated manually. However, it is a suitable option for people who want to shell large quantities of corn quickly. The corn sheller is mounted on a bench or table. It is massive and has a crank handle that the operator turns to turn the drum and discharge the corn kernels. Some bench corn shellers have a separator that distinguishes the shelled corn from cob pieces.
The main drawback of the bench corn sheller is that it requires physical labor to turn the handle. This can be tedious and tiresome, especially when shelling a large quantity of corn.
Power Corn Sheller
The power corn sheller, also referred to as the electric corn sheller, is a popular option among farmers because it is fast and efficient. It is powered by electricity and comes in various styles and sizes to match different capacity requirements. The drum's rotating speed is high, making it simple to shell a large amount of corn within a short time. Kernel and cob separation is also easier and faster.
The drawback of the power corn sheller is that it is bulky due to the added motor power. It can also be more costly than the manual options.
Walk-Behind Corn Sheller
It is also known as a push corn sheller. It is powered by a gasoline engine that provides mobility and makes it convenient to shell corn in different locations. The operator walks behind the corn sheller and pushes it in front to propel the corn cob into the drum for separation. Walk-behind corn shellers are useful for operations where the corn harvest is spread out over a large area.
Commercial-Grade Corn Sheller
This type of corn sheller is designed for heavy-duty use and maximum efficiency in commercial farming operations, including large-scale corn production and feed processing facilities. A key characteristic of commercial-grade corn shellers is their large size and specialized features designed for high-capacity corn shelling. The corn sheller may have automated mechanisms that streamlines the shelling process and enhances productivity. For example, it may be equipped with a conveyor belt system that feeds the corn cob into the shelling mechanism continuously, minimizing manual intervention and ensuring a smooth, uninterrupted shelling process. This is in addition to their powerful motors, lengthy drums, and specialized kernel retrieval systems. Some commercial corn shellers may also have adjustable settings to accommodate different varieties of corn and customize the shelling process to meet specific requirements.
International corn sheller specifications vary depending on the specific type of sheller being referred to. Typical corn shellers have the following key specifications:
Material
A corn sheller is mostly manufactured from cast iron, stainless steel or alloy. Alloy materials are typically made to be resistant to rust and lightweight. Durable materials like stainless steel can withstand damage from wet corn.
Sized grains
A corn cob sheller will be designed to shell a certain size of corn cob. Some shellers can shell small to medium maturity. However, large-sized cobs may break or not fit. Appliance manufacturers or dealers can provide guidance on which sheller can be used based on the age of farm equipment.
Efficiency
Efficiency refers to how fast the machine can shell corn. Generally, corn shellers can efficiently shelled corn at a specific speed or rate. Efficiency may vary depending on the type of corn, moisture content, operator skill, and other factors.
Capacity
This refers to the amount of corn (usually measured in bushels) that the sheller can process per hour. International corn shellers' capacity may vary depending on size and power. For example, a large capacity corn sheller may process 20 to 30 bushels per hour. Smaller shellers may process between 5 to 10 bushels per hour.
Power source
A sheller can be human-powered, animal-powered, or electric-powered. Animal-powered shellers used in earlier centuries must have a pulley installed to connect to an animal, like a donkey or ox. Modern-powered corn shellers are electricity powered, and they have motors of varied horse powers. A 4kw motor power, for instance, can shell corn powerfully and efficiently.
Noise
The noise level of an electric corn sheller is measured in decibels (dB). Different shellers produce different noise levels. A 7.5kw corn sheller motor produces about 94dB. The noise can be reduced to 87dB with good silencing techniques and safety guards. A corn sheller would be fitted with safety guards to silence the noise and protect the user.
Proper maintenance of the corn sheller allows it to remain in good working condition for many years. Periodic inspection and routine cleaning are always part of the maintenance routine. Pay attention to critical parts of the sheller, and do not overlook seam areas and corners where residue tends to build up. Remove debris carefully without damaging any parts of the corn sheller and clean with warm, soapy water. Specific parts like filters need to be replaced instead of cleaned.
Handling the corn sheller carefully with both hands and tipping it to remove excess water are additional maintenance tips. Let it dry before putting it away. Regular oiling of the parts that move, run, or rub against each other will prevent the corn ear sheller from getting stuck or seized up. Allow the corn sheller to fully dry before storing it in a dry place away from rust and water damage.
Corn shellers find application in various scenarios due to the widespread production and consumption of maize worldwide. Here are some common usage scenarios of corn shellers:
Farm Operations:
Farmers with large-scale maize production rely on both manual and automated corn shellers to efficiently shell maize cobs and prepare the maize kernels for other processing and marketing.
Maize Processing Plants:
Corn shellers play a vital role in the maize processing industry. After farmers harvest the maize, maize cobs are sent to processing plants, which have high-capacity corn shellers that can process large volumes to shell maize kernels quickly and efficiently. The shelled maize will further be processed into maize flour, maize starch, corn syrup, and other products.
Livestock Farms:
Livestock farms often raise animals like cattle, goats, sheep, and chickens. These animals consume maize as one of their staple foods. Hence, they use corn shellers to shell the maize and feed the maize directly into the animal's diets or process it further into other animal feeds to enhance the livestock's growth and health.
Agricultural Cooperatives:
Agricultural cooperatives usually collect maize from multiple farmers for bulk processing or marketing. Corn shellers help the cooperatives efficiently process large volumes of maize to increase the value of the products, thereby benefiting the cooperative and the individual farmers.
Research and Laboratory:
Agricultural research institutions or laboratories may require maize kernels for various studies, tests, or the development of new maize varieties. High-precision corn shellers are used in such cases to ensure minimum damage to the maize kernels to maintain their integrity for subsequent analysis.
Food and Snack Companies:
Food companies producing maize-based products or snacks, such as popcorn, cornflakes, and tortillas, require large quantities of shelled maize. Industrial corn shellers are used to support their production lines, ensuring a stable supply of maize kernels.
Community Events and Festivals:
In some communities, especially during the harvest season, there may be activities or festivals centered around maize, such as maize shelling competitions or demonstrations. These events not only foster community spirit and culture but also serve as an opportunity for local farmers to showcase their harvest and use of technology.
On-line Shelling Service:
In some regions, maize shelling service providers offer on-the-spot maize shelling services at pay-per-bushel rates. This enables smallholder farmers to shell their maize without having to invest in purchasing a corn sheller. It also provides convenience and accessibility for maize shelling.
When buying a corn sheller machine for commercial purposes, there are several factors one's need to consider to ensure they are getting the appropriate corn sheller for given needs. There is a myriad of corn shellers with different specifications suited to various types of maize and shelling requirements. As a result, it is imperative to take time and carefully assess the intended corn sheller before making a purchase.
As earlier highlighted, different types of corn shellers are designed for use under certain conditions to achieve specific end results. Identify the type of corn sheller that suits the local shelling conditions. Focus on the effectiveness, efficiency, and ease of use of the corn sheller selected. The corn sheller selected should help achieve desired shelling results with minimal effort and time investment.
The selected corn sheller should align well with given shelling capacity requirements. When it is all said and done, it is worth noting that corn shellers are available in varying capacities, ranging from small-scale to large-scale shelling. To meet corn shelling demands, it is important to select a capacity that corresponds well to the set shelling capacity requirements. Furthermore, the efficiency and productivity of the corn shelling process will be greatly affected by selecting the appropriate capacity.
Given the diverse varieties available in the corn-sheller marketplace, it is advisable to read through customer reviews to get insight into the performance of a certain corn sheller. By doing so, one is able to learn from the experiences of those that chose to work with a particular type or model of corn sheller. This will make it easier to make an informed decision when the time to purchase the corn sheller finally comes.
Remember to factor in the maintenance and operating costs associated with the corn sheller being considered for purchase. Some corn shellers may demand high maintenance costs, while others may require frequent operating costs due to their high energy consumption.
Q1: Where should corn shellers be lubricated?
A1: The corn sheller feed roller and its bearings, output auger and its bearings, cutter discharge chutes, and cable driving ropes are some of the corn sheller parts that require regular lubrication. Corn shellers have grease fittings on some of their moving parts. Additionally, lubrication can be done using graphite or any other oil on the friction sites.
Q2: What are the Corn Sheller parts diagram?
A2: A typical corn sheller machine will have the following parts. The feed chute is where ear corn is loaded into the machine. The feeding roller pushes the corn cobs against the shelling blades. The shelling blades then cut the kernels from the corn cob. The kernel drop is where the shelled corn falls. The cleaned corn cob then drops into the cleaned corn cob exit.
Q3: What are the adjustments on a corn sheller?
A3: A corn sheller like the IH 22 has several adjustments. Among them is the feed roll clamp that adjusts the feed roll clamp to vary the clam pressure and the shelling plate that adjusts the shelling plate to vary the clearance between the shelling plate and the corn cob. Also, there is the kernel drop chutes that adjust the kernel drop chutes to vary the kernel drop opening size.
Q4: How can someone get a service manual for a corn sheller?
A4: Some manufacturers like New Idea and IH may have service manuals available in their libraries. An authorized dealer may assist in locating the manuals. Alternatively, one can contact the manufacturer directly to request the service manual.
