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Cereal Making By Cornflakes Machine - Process Description

We do turnkey projects of cereal cornflakes plants, cornflakes machines, and wheat and rice breakfast cereal machines. With years of researching and studying the cornflakes cereal making machine technology abroad and invested millions in the R&D of the production technology of the cornflakes cereal making machine, Heshan Machinery Co., Ltd., one of the leading providers of China's cornflakes cereal making machine, has successfully developed the high speed double rolling cornflakes cereal making machine and a serial of cornflakes Cereal Making Machines that are compatible to the cereal making machine used by the major cereal producers; after we produced a high speed twin-screw extruder of which the capacity is as high as 1000 kg/h.

There are two kinds of raw materials for producing cornflakes with cornflakes machine. One is Maize (Corn) Meal or maize (corn) flour, it can be mixed the corn starch or in fixed proportion. The other is degermed maize grits, it also can mix some spices during the producing process.

I. Raw Material: The best material is hard dent corn, because of its transparency after gelatinization and good looking of the products.
II. Adopting the drying-degerming method. First, to regulate the moisture with the hot steam and hot water exceeding 90℃. And then to pre-grind the corn without germ. The mixture would separate out grits after evenly sieving.
III. Ingredients: To add the salt, malt and the other ingredients with the water during cooking the grits, it can make the water content up to 20%~35%, then to cook the grits with steam of 1.47X105P until gelatinized to semi-transparent.
IV. Drying: to dry and extrude the grits at 66℃ until the moisture is 19%~20%, cool it down to 30~40℃. Then to press the flake to  0.7~1mm with steel roller. Before pressing, the corns should be made dispersedly to ensure the chips evenly distributed.
VI. Roasting: Temperature: 250~350℃, Time: 20~150 seconds. to make the moisture down to 10%. To fry the chips with the temperature not exceed 200℃,the corn chips would be crispy.
VII. Spraying enhancer: To spray with nutrient substance to make it intensified corn chips or spread on sugar, flavor if necessary. 

The process of cornflakes machine is shown as follows:

Corn →Cleaning →Peeling and Degerming →Classifying →Cooking →Drying & Rlending →Rolling, Flaking or Extruding →Toasting →Cooling →Packing →Finished Products

Modern Process to Make Bran Flakes, Wheat Flakes, Multigrain Flakes, Frosted Flakes, Direct Expanded Cereals

Mixing →Conditioning → Extruding →Pulse Drying →Vibrate Feeding → Rolling, Flaking or Extruding →Fluid Bed Toasting→ Cooling → Packing → Finished Products

Cornflakes Machine Unit Operation


The high speed rolling cornflakes machine

The high speed rolling machine is a key unit in the system of cornflakes machine. It is composed of a pair of alloyed steel roll which rotate on opposite directions, high strength frame, hydraulic controlling system, auto adjusting roll seam system, cooling constant temperature system of the rolling, transmission system and control system. For the rolling machine, it has high requirements to rolling technology, First, it requires high hardness of roller surface. If it can not meet the standard, the surface , not smooth as that, would be damaged after a period of using to effect the rolling. We can make the hardness of the surface more than 65 degrees with special technology. It allows you to use them in cornflakes machine system for more than ten years. Secondly, it requires high accuracy requirements. If it can not meet the standard, you may find that the rolling can not evenly, it would be serious vibrating and noisy. Thus it requires us to control the processing procedure strictly, it has to make sure that the cylindricity of rolling is on 3μm.

The rolling cornflakes machine adopts hydraulic pressure control system, the roller can be adjusted the pressure to perfect situation according to the product characters to ensure the product quality. The servo regulating system of the roller allows you to adjust the gag in the range of 0-2mm. It is number display; you can read them easily and accurately. We design the cooling water tunnel inside the roller, so it can avoid the rolling gap changing occurred by expand with heat and contract with cold during working, as it would impact the rolling quality .To ensure the rolling can work in a constant temperature condition we design a circulating cooling water & constant temperature control system which has the high pressure water pump for the cooling water tunnel inside the roller .

Double period conditioner design features

Designed to separate the mixing part and aging part, to ensure the aging time.

The inlet is designed to be right above the outlet, be easy to assemble it with the extruder;

It has many inlets to feed kinds of material to the Conditioner;

It is designed to have an easy opened door to clean the inner of Conditioner easily;

The material can be pre-processing with the double-screw extruder ;

The powder material is used for continuous feeding and mixing liquid material such as the vapour,water,syrup and etc.

Twin screw extruder design features

It is circulation layer design for the middle layer of the tank ,it can be heating and cooling circularly

The tank is made of anti-corrosion and wear-resistance material. Each model can be assembled and extended the length if required.

The extruder is corwood structure, it can be flexible assembled and disassemble.

Unique design of the cutter, accurate positioning, stable cutting and high precision cutting .

PLC automatic control system, easy operation.

Pulse dryer design features

It can be flexible adjusted the flow air and pulse frequency, to ensure the dried material can be flew evenly.

The material would be leap itself by the to enlarge the contact area between the material and hot air .

It can propagates heat rapidly and shorten the drying and cooling time.

It can economize the energy, the consumption can be saved about 30-50% .

It can keep the grain separated

It can reduce the pollutants and shorten the cleaning time

Flaking dollers design features

It is designed to be a Peripheral cooling system ,it can keep balance of the roller temperature and avoid the flake stick to the roller;

It is equipped with hydraulic pressure and electronic surveillance;

The speed of roller feeder can be adjustable to ensure separate the flake grain separated;

There is the buffer unit to protect the roller efficiently.
The falking roller is covered by the nicochrome alloy steel .The hardness is HS74~78, with highest resistance to hight temperature and tear and ware.

Fluid bed toasting machine design features

The flakes are crispy and good taste after baking at 280℃ high temperature

It is impingement hot air toasting to ensure the products be heated evenly

It is hot-air recycle system to save energy .

It is automatic intelligent control by PLC to ensure the product to be heated and dehumidify accordingly.

Optional choice for direct heating or indirect heating.



Specifications of the Heshan Automatic Cereal Cornflakes Machines


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