Product Description
# How to Make Breakfast Cereal Corn Flakes Using a Twin - Screw Extruder ## 1. Raw Material Preparation - **Corn**: Select high - quality corn grains. Clean the corn thoroughly to remove any dirt, debris, or damaged kernels. Then, the corn is usually milled to a suitable particle size. Coarsely ground corn is often preferred as it can contribute to the texture of the final corn flakes. - **Additives**: Commonly used additives include sugar, salt, malt flavoring, and vitamins. These additives are measured accurately according to the desired taste and nutritional profile of the corn flakes. For example, sugar can enhance the sweetness, salt can balance the flavor, and malt flavoring can add a rich, characteristic taste. Vitamins can be added to increase the nutritional value of the product. ## 2. Mixing the Ingredients - Combine the milled corn, sugar, salt, malt flavoring, and vitamins (if any) in a large mixing container. Use a mechanical mixer to ensure thorough and homogeneous mixing. The goal is to distribute all the ingredients evenly so that each batch of corn flakes has a consistent taste and quality. This mixing process usually takes about 10 - 15 minutes at a moderate speed. ## 3. Conditioning the Mixture - Add an appropriate amount of water to the mixed ingredients. The water content is crucial as it affects the texture and processing properties of the mixture. Generally, the water content should be around 18% - 25% of the total weight of the dry mixture. - Stir the mixture well to ensure that the water is evenly absorbed. Let the mixture stand for about 30 minutes. This conditioning process allows the water to penetrate the corn particles and hydrate the ingredients, making the mixture more plastic and easier to process in the extruder. ## 4. Setting Up the Twin - Screw Extruder - Clean the twin - screw extruder thoroughly to remove any residues from previous use. Check all the components, including the screws, barrels, and die, to ensure they are in good working condition. - Install a suitable die at the end of the extruder. The die should be designed to produce a flat, ribbon - like shape that is suitable for further processing into corn flakes. The dimensions of the die opening can be adjusted according to the desired thickness and width of the corn flake ribbons. ## 5. Extrusion Process - Feed the conditioned mixture into the hopper of the twin - screw extruder. The hopper supplies the mixture to the screws, which rotate and convey the mixture through the barrels. - As the mixture moves through the barrels, it is subjected to high pressure and temperature. The temperature in the extruder can be set in the range of 120 - 150°C. The heat and pressure cause the corn starch to gelatinize, and the ingredients to fuse together. This forms a continuous, cooked mass that is extruded through the die as a flat ribbon. - The screw speed can also be adjusted to control the flow rate of the mixture and the residence time in the extruder. A higher screw speed generally results in a faster production rate but may require careful adjustment to ensure proper cooking and shaping of the product. ## 6. Cutting the Extruded Ribbons - The freshly extruded flat ribbons are still hot and soft. Use a cutting device to cut the ribbons into small, manageable pieces. The size of the cut pieces can be adjusted according to the desired size of the final corn flakes. For example, the pieces can be cut into rectangles or squares with dimensions of about 1 - 2 cm. ## 7. Drying the Cut Pieces - The cut pieces are then transferred to a drying oven. The drying process is important to remove the excess moisture from the pieces and to harden them. The drying temperature can be set in the range of 60 - 80°C, and the drying time usually takes about 30 - 60 minutes, depending on the moisture content and the size of the pieces. - During drying, the pieces should be turned or agitated gently to ensure even drying. This helps to prevent the pieces from sticking together and to achieve a consistent texture throughout. ## 8. Toasting the Corn Flakes - After drying, the corn flakes are ready for toasting. Toasting is a crucial step that gives the corn flakes their characteristic crunch and flavor. The corn flakes are placed in a toaster or an oven set at a relatively high temperature, around 180 - 200°C. - The toasting time is short, usually about 2 - 5 minutes. During this time, the surface of the corn flakes turns golden brown, and the interior becomes crispy. Careful monitoring is required during toasting to prevent over - toasting, which can result in a burnt taste. ## 9. Cooling and Packaging - Once the corn flakes are toasted, they are allowed to cool to room temperature. Cooling helps to stabilize the texture and flavor of the corn flakes. - After cooling, the corn flakes are ready for packaging. They can be packaged in various types of packaging materials, such as cardboard boxes with plastic liners or plastic bags. The packaging should be air - tight to maintain the freshness and crunchiness of the corn flakes. Quality control checks are also carried out during the packaging process to ensure that only high - quality corn flakes are packaged and sold.
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Company Profile
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.
Product Parameters
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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