Product Description
Here are the steps to make corn flakes using a twin - screw extruder: ### 1. Raw material preparation - **Corn grits**: Select high - quality corn grits as the main raw material. Corn grits are coarsely ground corn kernels. You may need to clean them thoroughly to remove any impurities such as dirt, stones, or broken pieces. - **Additives**: - **Sugar**: Adds sweetness to the corn flakes. The amount can vary depending on the desired taste, usually around 5 - 15% of the total dry ingredients. - **Salt**: Enhances the flavor. About 1 - 3% of the total dry ingredients is a common amount. - **Milk powder (optional)**: Can improve the nutritional value and flavor. It can be added in an amount of 3 - 8% of the total dry ingredients. - **Water**: Required to hydrate the dry ingredients and enable the extrusion process. The amount of water added is typically around 20 - 30% of the total weight of the dry ingredients. ### 2. Mixing the ingredients - Use a large mixer to combine the corn grits, sugar, salt, milk powder (if using), and water. Mix them thoroughly until a homogeneous mixture is formed. The mixture should have a dough - like consistency, not too dry or too wet. This step helps to evenly distribute the additives throughout the corn grits. ### 3. Twin - screw extruder setup - **Temperature settings**: - **Feed zone**: Set the temperature in the feed zone relatively low, around 40 - 60°C. This is to ensure smooth feeding of the mixture into the extruder without premature cooking. - **Compression and mixing zones**: As the materials move through these zones, the temperature gradually increases. Temperatures in these zones can range from 60 - 100°C. The heat helps to start the gelatinization of starches in the corn grits and the interaction of the ingredients. - **Die zone**: The temperature at the die is usually set at 120 - 150°C. This high temperature fully cooks the corn mixture and gives it the proper structure as it exits the die. - **Screw speed**: Adjust the screw speed according to the viscosity of the mixture. A screw speed of 100 - 300 revolutions per minute (RPM) is commonly used. A slower speed (100 - 150 RPM) is suitable for a more viscous mixture, allowing for better mixing and shaping. A faster speed (200 - 300 RPM) can be used for a less viscous mixture to increase the production rate. ### 4. Extrusion process - **Feeding the mixture**: Feed the prepared corn mixture into the hopper of the twin - screw extruder. The twin - screws will convey, mix, and shear the materials as they move through the barrel. - **Extrusion through the die**: The cooked mixture is extruded through a die at the end of the extruder. The die is designed to produce long, ribbon - like strands of the corn mixture. The shape and size of the die can be adjusted according to the desired final product dimensions. - **Cutting**: After extrusion, the continuous strands are cut into small pieces using a cutter attached to the extruder. The cutting speed can be adjusted to control the length of the pieces, which will eventually become the corn flakes. ### 5. Flaking process - **Rolling**: The cut pieces are passed through a set of rollers. The rollers flatten the pieces into thin flakes. The pressure and gap between the rollers can be adjusted to control the thickness of the corn flakes. A typical thickness for corn flakes is around 0.5 - 1.5 mm. ### 6. Drying - Place the freshly formed corn flakes in a drying oven. Set the oven temperature at around 80 - 100°C. The drying process helps to remove the remaining moisture from the corn flakes, making them crispy. The drying time can range from 15 - 30 minutes, depending on the thickness of the flakes and the initial moisture content. ### 7. Toasting (optional but recommended) - After drying, the corn flakes can be toasted to enhance their flavor and crispness. Toast the flakes in a toaster oven or a baking oven at a temperature of 120 - 150°C for about 5 - 10 minutes. Monitor the toasting process closely to prevent over - toasting, which can make the flakes bitter. ### 8. Coating (optional) - If desired, the corn flakes can be coated with additional ingredients. For example, they can be coated with a sugar - syrup solution to make them sweeter or with a flavored powder to add different tastes. The coating process can be done by spraying or dipping the corn flakes in the coating material. ### 9. Packaging - Once the corn flakes have reached the desired flavor, texture, and moisture content, they are ready for packaging. Use appropriate packaging materials, such as plastic bags, boxes, or cartons, to protect the corn flakes from moisture, air, and light. Label the packaging with product information, including ingredients, nutritional facts, and storage instructions.
Company Profile
corn flake machine breakfast machine corn flakes extruder breakfast cereal machine
Jinan Sunward Machinery Co., Ltd is an industry and trade integrated enterprise. The company is committed to R & D extrusion machinery and related ancillary equipments. It is covering mainly machinery and equipment for corn meal milling system, corn flakes/breakfast cereal system, baby food system, corn puff snacks system, pellets system, artificial rice system,soy nuggets system; as well as pet food/fish food system.Jinan Sunward Machinery Company's workshop was founded in 2009. All machines were exported to all over the world by export agent. Company begin to have Independent import and export rights in 2014. For supplying best service, technology department, Sales department, producing department , after- sales department are always available for you.
SPECIFICATIONS
| Model |
Main motor |
Output |
| TSE65 |
22kw |
100kg/h-150kg/h |
| TSE70 |
30kw |
200kg/h-250kg/h |
| TSE85 |
55kw |
300kg/h-500kg/h |
| TSE90 |
75kw |
800kg/h-1000kg/h |
Certification
Package
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