Water- and energy-saving systems and methods for producing lime-cooked masa

A method comprising:

• (a) moisturizing a maize kernel to produce a moisturized maize kernel, wherein the step (a) comprises spraying the maize kernel with a lime solution;
• (b) tempering the moisturized maize kernel, using a conditioner, to produce a tempered maize kernel;
• (c) after the step (b), receiving, by a cooker and from the conditioner, the tempered maize kernel;
• (d) steaming, using the cooker, the tempered maize kernel;
• (e) tempering the steamed maize kernel produced by the step (d);
• (f) grinding a first portion of the tempered maize kernel produced by the step (e) into a fine-ground dough material using a first mill;
• (g) grinding a second portion of the tempered steamed maize kernel produced by the step (e) into a coarse-ground dough material using a second mill,
• wherein the first mill is different from the second mill;
• (h) cooling the fine-ground dough material produced by the step (f) and the coarse-ground dough material produced by the step (g);
• and
• (i) mixing the cooled fine-ground dough material and the cooled coarse-ground dough material to form lime-cooked masa;
• wherein the lime-cooked masa comprises the coarse-ground dough and the fine-ground dough.