Low-cost Steam-flaked Maize (Corn) Grain for Cattle
10.22 - Low-cost steam-flaked maize (corn) grain for cattle
Beth McDade, University of Guelph, Canada
Figure 1: Examples of round bales (left) and square bales (right) (Brar & Sharma, 2021).
Suggested citation for this chapter.
McDade, B. (2026) Low-cost steam-flaked maize (corn) grain for cattle. In Farmpedia, The Encyclopedia for Small Scale Farmers. Editor, M.N. Raizada, University of Guelph, Canada. farmpedia.org
1. Why steam flaking is better than high moisture maize
Steam-flaking maize is the process of steaming maize grain to a moisture level of 18-20% and then grinding the steamed maize through heated rollers to a density of 0.31 g/L. Figure 1 shows what maize looks like after steam flaking.
Figure 1: Steam-flaked maize (Source: Lorimor, 2022)
“Steam processing (flaking or rolling) increases ruminal digestibility of starch (percentage of intake)… from 75 to 85% for corn [maize].” (Huntington, 1997, p. 852) This increases starch digestibility in the rumen, allowing the cattle to create more volatile fatty acids and have less starch to digest in their small intestine, and therefore, absorb more energy and consume less energy during digestion. Steam-flaked maize is also about half the density of high-moisture (full grains) of maize, meaning that feedlot cattle will eat less steam-flaked maize than high-moisture or ground maize. Feedlot cattle are cattle that are killed for meat, while dairy cattle are cows that produce milk to be harvested. Below are some easily-quantifiable examples of the benefits of steam-flaked maize for feedlot and dairy cattle:
Benefits for feedlot (meat) cattle (Gonzalez-Vizcarra et al., 2017)
- Higher weight gain per day
- Steam-flaked maize-fed cattle: 1.34 kg/day
- Dry rolled maize-fed cattle: 1.19 kg/day
- Higher weight gain to feed proportion
- Steam-flaked maize-fed cattle: 0.221
- Dry rolled maize-fed cattle: 0.2
- Less total maize consumption
- Steam-flaked maize-fed cattle: 6.1 kg/day
- Dry rolled maize-fed cattle: 5.99 kg/day
- 17% higher net energy calorie content than dry-rolled maize (Zinn et al., 2002)
Benefits for dairy (milk) cattle (Theurer et al., 1999)
- Increased daily milk production
- Steam-flaked maize-fed cattle: 37.4 kg/day
- Dry rolled maize-fed cattle: 35.6 kg/day
- Higher protein content in milk
- Steam-flaked maize-fed cattle: 3.02%
- Dry rolled maize-fed cattle: 2.95%
The starch in steam-flaked maize is also more digestible, meaning that the cattle are able to get more energy from a single grain of maize if it is steam-flaked than if it is dry-rolled or whole; steam-flaking increases ruminal digestibility of starch and produces higher protein and higher digestible fiber than dry-rolled maize (Huntington, 1997). It is easier on their digestive system by increasing rumen microbes, leading to healthier cattle (Theurer et al., 1999).
2. How-to steam flake maize
Step 1. Remove maize grains from cobs directly before steam-flaking
Figure 2: Removing maize grain from the cob by hand (Source: Link)
- Maize should be high-moisture, not dried.
- Freshly harvested maize is a good idea, as shown in Figure 2 above.
- Professional machinery cleans and separates maize, but if it is freshly harvested, normal crop cleaning methods will be sufficient.
- If using dried maize, soak the grain in water for 1 hour or until the grain moisture meter reads 15%.
- To use the grain moisture meter, take a handful of maize grains and place them in a bowl or a bag. Then, stick the ends of the prongs into the maize, and the screen will display a percentage. This is what you base the maize moisture on and how you will know if the maize is ready to be steamed. An example of using a grain moisture meter (hydrometer) is shown below in Figure 3:
Figure 3: Use of a grain moisture meter with rice (Source: Link)
Step 2. Steam the loose maize grains until a grain moisture meter reads 18-20%
Shipping containers (Figure 4a) are a fantastic option for a community to share, allowing for in-bulk steaming of maize. This would reduce steaming prices by spreading it between community members, and mean less time required for more maize as it has a larger capacity, so each batch can be larger, meaning less frequent replacement of maize grains once they have finished steaming.
Figure 4a: Shipping container (Source: CC0 Open Access)
Other options for steaming include empty oil barrels (Figure 4b) or tin cans (Figure 4c).
Figure 4b: Oil barrel (Source: CC BY-SA 2.5 Open Access)
Figure 4c: Tin cans (Source: CC0 Open Access)
Wooden containers can be used but will warp over time due to the steam and will have to be replaced. It is important to not use plastic, as plastic conducts heat and steams maize less efficiently than metals (Berry & Bush, 1988, p. 1878). The steam can damage the container by bending the plastic, and the steaming process can potentially leach plastics into the grain which could be dangerous for cattle health (Liu et al., 2025, p. 8). For this stage, a steaming machine will be needed, such as the low-cost example of a wallpaper steamer (~$25 USD) shown below in Figure 5:
Figure 5: A wallpaper steamer (Source: Link)
In a metal or glass closed container, spread maize out so that the grains do not touch each other. Multiple layers can be steamed at once using racks or other kitchen utensils to create levels inside the steaming container. Turn the steaming machine on and seal it inside or connect to the container with as little space around the steam output as possible. Run the steamer, checking the moisture every 20 minutes to determine the rate of gelatinization which varies depending on the weather and density of maize grain relative to the size of the container used. Continue steaming the maize until the grain moisture meter (hydrometer) reads 18-20%. Instructions on hydrometer use can be found in the previous step.
Step 3. Roll hot maize through the flaking machine
Conventional steam-flaking is done with heated rollers. If it is possible to remove the rollers from the flaking machine and leave them in the sun to heat, the results will be better. An example of an inexpensive flaking machine (~$300 USD) is shown below in Figure 6:
Figure 6: A rolling machine for flaking maize (Source: Link)
Place a bag or bowl below the spout on the bottom of the machine to catch the maize flakes as they process. Next, collect the freshly-steamed maize, do not allow it to cool, and feed it through the flaking machine from the top. The steam coming off of the maize will further heat the rollers. After rolling, you should get around half the amount of bushel density as before.
Step 4. Leave the flaked grain to dry out in the sun or in a hot, dry room.
Grind the steamed maize grains until one bushel (~35 liter bucket) weighs around 15.5-18 kilograms. Or fill a 1L soda bottle with the steam-flaked maize; it should weigh around 315-330 grams (A regular plastic 1L bottle weighs 15 grams). If the steam-flaked maize is allowed to dry completely after processing, steam-flaked maize can last multiple days in a dark, dry area. It should be used as soon as possible, though, as storage can degrade the starch availability of the steam-flaked maize from 76-80% to 21% in just 3 days of being stored at 55° Celsius (Trotta et al., 2021, p. 5). They have a shorter storage duration than dried maize due to their higher moisture content.
3. Cost-benefit analysis
The largest inputs to this process are maize grains and oil, as the steaming process usually takes about 1 hour with the best technology and may take longer with the methods described in this article. The capital costs for the equipment can be as low as $350 USD, a mid-end do-it-yourself package for $428 USD, or with professional equipment, upwards of $5,000 USD. There are examples of products that farmers can purchase to begin steam-flaking maize at the end of this article.
In the United States, steam-flaked maize is used frequently to feed their cattle. If professional equipment is used, there are opportunities for export-oriented steam-flaked maize production. Professional equipment is needed in this case because there are specific criteria for maize to be considered steam-flaked in North American markets.
Last year, the average maize commodity prices ranged from 5.90-6.90 USD per pound (Grain Farmers of Ontario, n.d.). The average price for a kWh of electricity in Sub-Saharan Africa is $0.161 USD per kWh and across Asia, $0.105 USD per kWh (Best Broadband Deals, 2021). Using the wallpaper steamer method, this process will need 2 kWh of electricity which will cost 20-30 cents per hour for small-scale farmers. Depending on outside temperature, outside relative humidity, and the size of the container selected to steam the maize grain, it will take a variable amount of time. For the least cost of steaming, some strategies can be used to optimize the process:
- Steam during hottest time of day
- Steam while it is raining or during times of high humidity
- Steam in a metal container
- Steam in a small container/fill container with as much spaced-out maize as possible
Depending on current energy prices, it may cost more to produce steam-flaked maize than the benefit it produces to cattle product yields. If it takes more than 1.95 hours to steam one pound of maize to 18-20% moisture, the electricity cost will be higher than the benefit; using whole-grain high moisture maize or dry-rolled maize would be advisable. To reduce the electricity cost, solar-powered batteries for the steaming process are the best option; although it has a high initial capital cost, it will greatly reduce the costs of steam-flaking in the long run.
There is no standard among the steam-flaking industry that formalizes how long maize needs to be steamed to reach 40-60% gelatinization (Google Patents, 2002). The process usually entails steaming maize grain for 45-65 minutes in a vertical steam chamber at 100-109 degrees Celsius. When maize reaches 18-20% moisture after being steamed at 99° steam temperature, it should be properly gelatinized. Poorly gelatinized maize of less than 35% gelatinized starch has about a 5% yield increase in terms of dairy cows, compared to 5-16% yield increase with properly gelatinized steam-flaked maize (Google Patents, 2002).
In a North American study with professional steam-flaking equipment on a feedlot with 5,000 cattle, the efficiency of food given to cattle had to be 1.7% higher to absorb the weekly costs of producing steam-flaked maize. Steam-flaking maize, in reality, was found to increase food efficiency by 7.4-12.1% (Macken et al., 2006).
If the process for steaming maize is more than a 5% increase in price per unit of maize (pound, kilogram, etc.) this is not economically feasible, and other processes should be considered. This is because the minimum feed efficiency gain from poorly steamed flaked maize is 5% (Google Patents, 2002).
Additional Critical Analysis
Due to the products used to create the makeshift steam-flaking system described in this article being all mechanical, any worker or member of the household can operate the machinery. The greatest operating risk is the high heat of the steam, and the dangers of the mechanical mill. Farmers must be careful when unsealing the steaming chamber once the maize is fully steamed, as they can be burned if too close to the steam. Equally important is keeping extremities such as hands and arms, as well as children, away from the flaking mill. They use large rollers to flatten the maize and have a lot of mechanical power, therefore able to severely injure people if it is used improperly. Frequent cleaning of machinery is also needed as the maize has a high starch and moisture content, potentially attracting mold or pests. Cleaning the machinery also helps with maintenance, as it is difficult to find replacement parts for cheap roller mills. It is important to keep them unclogged and free of debris.
It is useful to have a basic understanding of economics and math, as farmers will have to frequently compare the margin of improvement in sales against the prices of maize and electricity or fuel. Fuel and maize costs vary, and if they rise above the profit gained from steam-flaking maize (feeding it to cattle or selling it to the local community), it is a bad idea to continue producing steam-flaked maize. The high initial capital cost means this can be risky for a single family or farm to invest in, however, the mills and steaming equipment can be shared between a cooperative or within the community. The cattle can be brought to the site of the maize-flaking operation to reduce transport costs and efforts, as cattle eat multiple kilograms of this feed per day. Due to the high value addition of steam-flaked maize, production can also be set up for sale. As mentioned earlier, it has a steady demand in the USA and other western markets, so with professional machinery, export-oriented production could be considered. With a truck, wheelbarrow, or other high-capacity vehicle, steam-flaked maize could also be sold within the local community to other farmers. This can help utilize excess maize, fetch higher prices than selling unprocessed maize, and improve profits for the entire community.
Helpful links to get started
Additional equipment recommendations
- Grain-rolling machine: any machine that flattens or rolls grain instead of fine-grinding it is sufficient. If the rollers from the machine can be removed to be heated, the machine will make more effective steam-flaked maize:
- Link ($242 USD)
- Link ($228 USD)
- Grain moisture meter (hydrometer): This is needed to measure the rate of gelatinization (steaming) of your maize with your specific operation:
- Link ($11.40 USD)
- You will also need a weighing scale and a metal container to steam the maize inside. Lowest cost: $265.50 USD including grain roller, wallpaper steamer, and hydrometer
- Wallpaper or carpet steamer: This will be used to create steam. Connect it to your closed container to steam the maize.
- Link ($28.25 USD)
Mid-range, good for sharing among the community: $313.40 USD including grain roller, steam generator, and hydrometer:
- Steam generator (boiler):
- Link ($76 USD)
- Link ($149.25 USD)
Mid-range, smaller capacity but useful if metal containers are unavailable: $340 USD including grain roller, cabinet rice steamer, and hydrometer.
- Cabinet rice steamer: Link ($103 USD)
Professional equipment: The machines listed are all-inclusive, but a weighing scale could be necessary to confirm bushel density.
- Link ($3,327.75 USD)
- Link ($10,386.60 USD)
Solar-powered battery: ensure that the kW of the machine you purchase is higher than the kW of the steamer you are using or it will not be able to power the steamer.
- Link ($221.90 USD)
Further reading and Youtube videos:
Detailed description of industrial steam-flaking: Link
Video of industrial steam-flaking: Link
How to make a wooden steaming box: Link
How to use a grain moisture meter: Link
References
Berry, M.R. & Bush, R.C. (1988). Thermal Processing Retortable Plastic Containers with Metal Lids in Steam and Water with Comparisons to Metal Cans. Journal of Food Science, 53(6), 1877-1879. Link
Best Broadband Deals. (2021). The price of electricity per KWh in 230 countries. BestBroadbandDeals. Link
Brown, D. R. (2002). Method for steam flaking grain. Google Patents. Link
Gonzalez-Vizcarra, V.M., Plascencia, A., Ramos-Avina, D., & Zinn, R.A. (2017). Influence of Substituting Steam-Flaked Corn for Dry Rolled Corn on Feedlot Cattle Growth Performance When Cattle Are Allowed Either Ad Libitum or Restricted Access to the Finishing Diet. Asian-Australasian Journal of Animal Sciences, 30(11), 1563-1567. Link
Grain Farmers of Ontario. (n.d.). Daily Commodity Report. Grain Farmers of Ontario. Link
Huntington, G.B. (1997) Starch Utilization by Ruminants: From Basics to the Bunk. Journal of Animal Science, 75, 852–886. Link
Liu, H., Li, P., Zhou, T., Yu, Z., Zhang, W., Zhu, Y., Xu, J., Wu, X., Li, J., Zhang, C., Chen, L. & Weng, D. (2025). Exposure to Leachates of Plastic Food Containers Disturbs Glucose and Lipid Metabolism: Insights From Models Mimicking Real-Life Exposure Scenarios. Ecotoxicology and Environmental Safety, 289, 117498. Link
Lorimor, A. (2022). Starch Availability of Steam-Flaked Corn in Commercial Feedlots Evaluating Roll Size and Flake Density [Photograph]. Feedlot Magazine. Link
Lykos, T. & G.A. Varga. (1995) Effects of Processing Method on Degradation Characteristics of Protein and Carbohydrate Sources In Situ. Journal of Dairy Science, 78(8), 1789-1801. Link
Macken, C.N., Erickson, G.E., & Klopfenstein, T.J. (2006). The Cost of Corn Processing for Finishing Cattle. The Professional Animal Scientist, 22(1), 23-32. Link
Owens, F.N., Secrist, D.S., Hill, W.J., & Gill, D.R. (1997). The Effect of Grain Source and Grain Processing on Performance of Feedlot Cattle. Journal of Animal Science, 75(3) 868–879. Link
Romiter Group. (n.d.). Automatic Steam Flaked Corn Feed Production Line. Corn Process. Link
Theurer, C.B, Huber, J.T., Delgado-Elorduy, A & Wanderley, R. (1999). Invited Review: Summary of Steam-Flaking Corn or Sorghum Grain for Lactating Dairy Cows. Journal of Dairy Science, 82(9) 1950-1959. Link
Trotta, R.J., Kreikemeier, K.K., Royle, R.F., Milton, T. & Harmon, D.L. (2021). Flake Density and Starch Retrogradation in Influence In Situ Ruminal Degradability Characteristics of Steam-Flaked Corn and Predicted Starch Digestibility and Energetic Efficiency. Journal of Animal Science, 99(11), skab298. Link
Zinn, R.A., Owens, F.N., & Ware, R.A. (2002). Flaking Corn: Processing Mechanics, Quality Standards, and Impacts on Energy Availability and Performance of Feedlot Cattle. Journal of Animal Science, 80(5), 1145–1156. Link