Bühler has completed construction of a corn flour production plant for PV Sons Corn Milling in India. The plant will consume 84% less water and 52% less energy compared to a traditional nixtamalisation process, the company claims, and will produce 96% less waste. 

Tortillas and tortilla chips have long been appreciated and consumed in Latin and North America but are reportedly gaining popularity in other regions, including India. India is one of the top 10 maize producers in the world, contributing 2-3% of the total maize produced globally. 

Bühler’s Prime Masa Nixtamal process uses steam technology, instead of cooking and soaking, and therefore uses around 84% less water, enabling the production of tortilla flour with its typical flavour, as well as quality and yield. The process uses only 150 litres of water, instead of 1,500 L traditionally used to process 1,000 Kg of corn into nixtamalised corn flour. The steaming process is also shorter than the traditional cooking process, leading to energy savings. Through this process, the company says, wastewater is eliminated, and the flour produced has a higher nutritional value. 

Parag Chheda, Managing Director of PV Sons, says: “Our association with Bühler is since the inception of PV Sons in 2006. At that time, we chose Bühler as it was the best equipment manufacturer for grain milling, perhaps holding the No. 1 rank. Over time, Bühler has proved its mettle. Their machines have proven extremely reliable – work long hours without breaking down.” 

After trials at the company’s Grain Innovation centre in Uzwil, PV Sons chose to integrate the line in its plant. The Nixtamal line was commissioned entirely in July 2021. 

Parag Chheda, MD of PV Sons, said: “Prime Masa is a product of the future. We foresee huge potential for Prime Masa. And it is the next progression for us – to offer a new and relevant product to our clients. We are extremely happy with the Prime Masa output. Its quality surpassed everything available on the local market. We knew we had a winner on hand, and we could place our bets on it.” 

Tino Böhm, Bühler’s Head of Business Segment Maize, said: “once the commissioning was completed, we visited PV Sons in Pune and were inspired by their dedication. We could literally feel their satisfaction with the new line. We are convinced that PV Sons will establish itself well in the market and develop new and innovative products. Our greatest reward is a customer who is excited to see the performance of its plant and is happy with our work.”