Corn Flakes Cereal Production Line
The corn flakes cereal making machine was invented by Will Keith Kellogg, an American Doctor
of Medicine in Michigan, USA. at the end of 19th century when he was
searching a kind of basic food of hygiene vegetarian for fast recovery
in patients. With years of researching and studying the corn flakes cereal making machine technology abroad and invested millions in the R&D of the production technology of the corn flakes cereal making machine, Heshan Machinery Co., Ltd., one of the leading providers of China's corn flakes cereal making machine, has successfully developed the high speed double rolling corn flakes cereal making machine and a serial of Corn Flakes 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 Cornflakes Machine of which the capacity is as high as 1000 kg/h.
Specifications of the Cornflakes Machine - Heshan Cereal Production Line
|
Model
|
BC-150
|
BC-300
|
CFM-600
|
CFM-1200
|
Capacity
|
150 kg/h
|
300 kg/h
|
600 kg/h
|
1200 kg/h
|
Power
|
150 kw
|
220 kw
|
250 kw
|
380 kw
|
Steam Consumption
|
300kg/h
|
400kg/h
|
600kg/h
|
800kg/h
|
Operators
|
4
|
5
|
6
|
7
|
Overall
dimension
|
LXWXH(m)
35X10X6
|
LXWXH(m)
40X10X6
|
LXWXH(m)
45X12X6
|
LXWXH(m)
45X20X6
|
Cornflakes Machine and Corn Flake Production Technology
There are two kinds of raw materials
for producing Corn Flakes with the cornflakes 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 cornflakes 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 cornflakes machine feeder. The mixed raw materials are transported to the feed hopper of the cornflakes 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 cornflakes rolling machine. In this machine the corn particles are pressed into cornflakes. Another air conveyor transports the cornflakes to the oven where the cornflakes are toasted to produce product cornflakes.
Process of cornflakes machine to make classic cornflakes by the Cornflakes 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 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
The high speed rolling machine is a key unit in the system of corn flakes 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 Cornflakes Machine roller, it has high requirements to Cornflakes 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 Cornflakes Machine system for more than ten years. Secondly, it
requires high accuracy requirements. If it can not meet the cornflakes 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 cornflakes 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 Cornflakes Machine roller.
Double Period Conditioner Cornflakes Machine
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.
(GPG mode bottom cleaning)
|
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
|
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
|
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
|
Cornflakes Machine Flaking Rollers
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
|
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
|
|
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
|
Fluid Bed Toasting Cornflakes 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.
|
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