How Sweet Corn is Made

One well-liked and practical method to savor the rich sweetness of corn all year is with canned corn. Nathan Winslow, a cook stove manufacturer, popularized it in the 1830s by developing a safe canning technique that preserved the freshness of the corn kernels.

Sweet corn has become a popular ingredient in pizzas, salads, and tacos. In terms of per capita consumption, it is among the most widely consumed vegetables in the US. However, how is it made? The process of producing canned corn starts with the careful selection of canning-ready corn types. Experts suggest using varieties with soft kernels to achieve the desired taste and texture.

Farmers till the land and apply the required nutrients. After that, farmers plant corn seeds in rows with enough distance between them to promote strong development. Farmers typically seed sweet corn in the United States in March and April of each year.

At 268,000 acres and 2.9 billion pounds harvested annually, the United States currently hosts the world’s greatest sweet corn crop. Corn plants need regular irrigation as they get bigger in order to thrive to their full potential. An acre of high-yielding corn requires, on average, 600,000 gallons of water.

Farmers protect the corn by keeping an eye out for pests and diseases and taking the necessary precautions. When it comes to producing canned corn, harvesting time is everything. Farmers usually pick the sweet corn kernels when they reach the milk stage, which are plump and full of sweet juice.

This time frame spans from mid-August to mid-October. The ear silks should dry and turn brown at harvest. A milky liquid should appear when a thumbnail is pressed into a kernel, signifying that the crop is ready for harvesting.

Sweet corn’s sugars can quickly turn into starch, rendering the grain unattractive, thus, it’s critical to harvest it as soon as possible at the right time. Harvesters that operate mechanically are used to collect the ears. A corn head is a specialized attachment located on the front portion of the harvester.

With the help of rows of snapping rollers or snapping plates, this attachment may gently remove the corn ears from the plants by grasping the stalks. The snapping rollers or plates engage with the cornstalks at the base of the ears as the harvester passes through the cornfield. The rotating rollers snap the plants’ ears off.

After that, gathering chains transports the ears away from the harvester and into a grain or corn transport vehicle that is positioned parallel to it. To keep the truck moving at a steady pace and maintain alignment, the driver communicates with the harvester operator. The harvester operator can adjust the spout or chute of the unloading system.

By pointing this spout toward the truck, you can accurately dump the harvested corn into the truck’s cargo space. After harvesting, the workers quickly take the maize ears to the processing plant. We use efficient transportation techniques to keep the product fresh and reduce delays.

You see, after obtaining as much of the product’s nutritional value as possible, the corn is canned in just four hours. Because of this, the corn farms and corn canning plants are typically close to one another. This is where workers clean and husk the corn ears before canning them.

Every year, about 150,000 tons of corn are canned here. The canning facility equips a conveyor with visual inspection stations to feed the cobs. These are used to detect any flaws or irregularities in the maize that have been canned.

This includes examining the product for color, consistency, and overall quality standard anomalies. After inspecting the product for color, consistency, and overall quality standards anomalies, the workers move the cobs to husking equipment using a conveyor belt system. The outer layers of the husk are carefully removed from the ears by means of rotating rollers or blades.

Integrating brushes or air jets can remove any leftover husk particles. The machine outputs the husked corn ears ready for the following stage. The kernel removed has the cobs lined up and ready to go.

More than 7,000 cobs are stripped of their kernels per hour by the equipment, which consists of rotating knives. The workers pause the machines twice a day for cleaning and sharpening. The cobs themselves migrate to the sides, and the corn kernels fall in the center.

Now, kernels and cobs split off and proceed in different directions. After that, the kernels go through a revolving drum to get rid of any bigger particles. In the process, nothing is lost.

Leaves, cobs, and leftover corn are all marketed as animal feed. After removing the kernels, they blanch the corn by temporarily submerging them in hot water or steam. In order to maintain the integrity of the corn, this step is essential for deactivating enzymes that may cause flavor and color changes.

The making of a brine or syrup solution is the first step in the canning process. The taste, texture, and color of the maize are all preserved by using this solution. Usually, people combine sugar, salt, and water in different amounts to make the brine.

Cans are then filled with the prepared corn kernels. The workers put corn into the cans, leaving a certain amount of headspace to allow for heat expansion during the canning process. This revolving filling machine can fill 300 and 450 cans per minute.

They eventually collect the dropped kernels and add them back to the filling line. After pouring them into the cans, they fully submerge the corn kernels in the brine or syrup solution. The liquid keeps the quality of the maize intact while also acting as a preservative.

There is usually a deaeration phase incorporated to release any trapped air in the cans. In doing so, you can help establish a vacuum seal that keeps the canned corn from spoiling and preserves its integrity. After filling the cans, we seal them using a specialized seaming machine.

In order to keep the freshness of the maize and prevent contamination, the double seaming method guarantees an airtight seal. During certain canning procedures, cans undergo a step called exhausting, where they are briefly heated to remove any remaining air. This process keeps the corn from oxidizing and helps to preserve it.

After that, the sealed cans go through a cooking procedure. This can involve using hot water bath or pressure cooking techniques, depending on the particular needs of the product, which is canned corn. The heat, which also maintains a sterile environment inside the can eliminates any bacteria that are left.

This procedure is essential because it guarantees that the product will stay germ free for 18 months and extends the can’s shelf life. The cans are quickly chilled to room temperature after cooking. By stopping the cooking process, this step preserves the corn’s quality.

Quick cooling guarantees that the corn doesn’t overcook and keeps its freshness. We follow strict quality control procedures during the canning process. To guarantee that the corn meets specific requirements for taste, color, texture, and safety, we carry out testing and inspections.

To find and eliminate any metal pieces that might have unintentionally gotten into the cans during manufacturing, metal detectors are used. In order to safeguard consumer safety and prevent contamination, this procedure is essential. Weighing each can ensures that the right amount of corn, syrup or brine is contained.

Consumers receive vital information from labels that include nutritional content, expiration date, and cooking instructions. This facility can hold an incredible 42 million ears of corn, allowing you to savor the delicious flavor of sweet corn all year long. We have a ton of videos on our channel that are similar to this one, if you liked it.