Corn Flakes Machine, Production Line
- Breakfast Cereal Machines

There are two kinds of raw materials for producing corn flakes with the corn flakes making machine. One is Maize (Corn) Meal, the other is 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.

When the cornflour is used as feed material, firstly, the feed material is process in the corn flakes making machine mixer: Add corn flour or corn residue to nutritional additives and mix evenly with a certain proportion of water. And then the mixture is fed into the corn flakes making machine feeder. The mixed raw materials are transported to the feed hopper of the corn flakes making machine extruder. Extruder processes the raw material in the feeding hopper enters the extrusion system to be extruded and cut into small particles. These particles and then screened by a vibrating screen. disperse the particles. The air conveyor is used to transfer granular corn particles to the tablet cornflake rolling machine. In this machine the corn particles are pressed into corn flakes. Another air conveyor transports the corn flakes to the oven where the corn flakes are toasted to produce product corn flakes.

Process of corn flakes making machine to make classic corn flakes by the Corn Flakes Making Machine

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 Corn Flakes Making Machine Is Shown As Follows:

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

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

The high speed rolling machine is a key unit in the system of corn flakes making 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 corn flakes making machine roller, it has high requirements to corn flakes making machine 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 corn flakes making machine system for more than ten years. Secondly, it requires high accuracy requirements. If it can not meet the corn flakes making machine 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 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 corn flakes making machine roller operation. 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 corn flakes making machine roller.

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.


Double Period Conditioner GPG Mode Bottom Cleaning

(Table Horizontally scrollable on Mobile Device)

Model	HDC-150	HDC-300	HDC-600	HDC-1500
Power （kW）	4	6.5	12.5	16.5
Capacity （kg/h）	200	400	800	1500
Modification time（s）	120～180	120～180	120～180	120～180
Max.water added	30%	30%	30%	30%
Pressure	0.2Mpa	0.2Mpa	0.2Mpa	0.2Mpa

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.

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





(Table Horizontally scrollable on Mobile Device)

MODLE	HEATING MOD	HEATING AREA     m 2	POWER (kw)	WORKING TEMPERATURE ( ℃ )	CAPACITY  (kg/h)
HPD-S150	STEAM	1.5	0.55	60∽180	300
HPD-S250	STEAM	2.5	0.75	60∽180	600
HPD-S360	STEAM	3.6	1.1	60∽180	1200
HPD-L150	LPG(GAS)	1.5	0.55	60∽180	300
HPD-L250	LPG(GAS)	2.5	0.75	60∽180	600
HPD-L360	LPG(GAS)	3.6	1.1	60∽180	1200

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.

 
Flaking Roller


Precise gap control


Contraflow water circulation



(Table Horizontally scrollable on Mobile Device)

Mode	HFR-300*400	HFR-400*600	HFR-600*800	HFR-800*1000
Power	40 kw	50 kw	60 kw	70kw
Roller Size Φ*L	300*400	400*600	600*800	800*1000
Gap force	640 kN	640 kN	800 kN	800 kN
Safe Gap	0.2mm	0.2mm	0.2mm	0.2mm
Circumferential Speed	3.8-6.5 m/sec	3.8-6.5 kw	3.8-6.5 kw	3.8-6.5 kw
Hydraulic pressure	6.3MPa	6.3MPa	6.3MPa	6.3MPa



(Table Horizontally scrollable on Mobile Device)

Modle	HSE-50	HSE-72	HSE-92	HSE-133
Extruder Dia (mm)	50.5	71.7	92.4	133
Depth of the tank (mm)	9	12.6	15.5	23.5
Ratio of length and dia L/D	32-52	32-52	32-52	32-48
Power kw	45	110	250	480
Capacity kg/h	150	300	600	1200

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.

(Table Horizontally scrollable on Mobile Device)

CONVEYOR WIDTH (m)	CEREAL PROCESS CAPACITY (kg/h)	DIMENSION, L.W.H (mm)
0.4	400	7800x1500x3300
0.6	700	8800x1750x3500
1.0	1250	8800x2150x3600
1.3	1500	8800x2450x3700

Pictures of the machine


Toasted corn flakes and rice flakes