I. Introduction of Corn Flakes

Extrusion technology is a method commonly used to process cornflakes. Specific steps are as follows:

Cornmeal is mixed with water and other ingredients such as sugar, salt, spices, etc. to make corn syrup. Put the corn syrup into the twin screw extruder, and extrude it into flakes or other shapes through the high temperature, pressure and shear of the extruder. Then the extruded corn flakes are dried and roasted to obtain crunchy texture and better taste. Finally, the corn flakes are packed.

Corn or maize flakes processed by extrusion technology do not need to add a lot of oil like traditional baking or frying process, which is more healthy and environmentally friendly in the production. In addition, the extruded corn flakes making machine solution includes the most complete equipment items, so other healthy breakfast cereals in different designs and shapes can also be manufactured easily. For example, the extruder machine can deal with single or combined cereal materials, including wheat, bran, rice. Shapes include rings, granules, balls, flakes and others. All of these enrich the variety of breakfast cereal products.

II. Parameters 

III. Features

• Finished food quality ensured: Optimal extrusion solution, premium equipment design, and equipment processing ensure high-level and stable production.
• High output: High designed capacity; minimal material loss;
• Less energy: High mechanical coordination, low wear; optimized heating, thermal transfer& insulation details, low heat loss
• Low production cost: Flow production, precise control of each process
• Simple and low cost maintenance: Modular structure, easy operation. Lifetime after-sales service
• Material: High-quality food-safe materials for all food contact part
• Failure rate:  Nearly zero failure as long as preventive maintenance

IV. The General Flow Chart for Corn/Maize Flakes

• Step 1: Mixing of wholewheat Flour & wheat bran with water
• Step 2: Extruded to pellets
• Step 3: Pellets cooling
• Step 4: Pellets flaking
• Step 5: Flakes pre-drying
• Step 6: Flakes baking
• Step 7: Flakes seasoning
• Step 8: Flakes drying after seasoning
• Step 10: Cooling before packing
• Step 11: Packing’

V. Components of Corn Flakes Making Machinery

1. Mixer
2. Screw conveyor
3. Twin-screw extruder
4. Chiller
5. Cooling vibrator
6. Flake rolling machine
7. Belt pre dryer (Electric/natural gas/diesel heating options)
8. Roaster (Electric/natural gas/diesel heating options)
9. Seasoning machine
10. Two-Tank syrup sprayer (Optional)
11. Belt dryer (Electric/natural gas/diesel heating options)
12. Cooling machine
13. Automatic packing machine
14. Controlling system (PLC/or instrument control options)
15. Complete conveyors
16. Steam boiler (Optional)
17. Burner (Optional)