Production Line/Process of Corn Flakes up to 200 kg/h (possibility to propose from 100 kg/h up to 800 kg/h)

1. Screw feeding conveyor
2. Sifter
3. Mixer
4. Screw conveyor
5. Extruder
6. Vibrating conveyor
7. Pneumatic transport
8. Flatting machine
9. Vibrating conveyor
10. Thermal dryer
11. Feeding conveyor
12. Additive imputing machine
13. Digester
14. Vibrating conveyor
15. Roasting furnace
16. Feeding conveyor with air cooling of the product
17. Automatic packing machine
18. Outflowing conveyor
19. Cartoon packer
20. Horizontal conveyor

Brief technology description of production corn flakes

The main raw material for production of corn flakes is cereals is the corn flour. It is discharged from the transport container into the screw feeding conveyor (1) that loads the raw into continuous sifter (2). The sifter uploads the sifted flour into the mixer (3). The mixer is used while adding into the formulation the cocoa, starch, etc.

The raw using the screw conveyor (4) is fed from the mixer into the feeding hopper of the extruder (5). Twin screw extrusion installation carries out the thermal-chemical treatment of initial raw, coming after the preparation stage. At the exit from the extruder we get the semi-finished product in form of balls, which are discharged on vibrating conveyor (6) to prevent the gluing. The semi-finished product is fed from vibrating conveyor into the flatting machine (8) with pneumatic conveyor (7), where the semi-finished product is flatted using two shafts,  moving in different directions.

Then the product comes on vibrating conveyor (0) for consequent loading into thermal dryer (10), which is designed for continuous drying of the products, coming out from the extruder. During the process of transferring products along conveying system, the moisture is evaporates out of them. Then the product with the feeding conveyor (11) comes to the additive imputing machine (12), in which from the digesters (13) it is fed the syrup with dry bulk ingredients and flavor additives. For continuous line operation it is recommended to install two digesters for alternately work.

The product at the exit using vibrating conveyor (14) comes into the roasting furnace (15) for the final stage of production flakes. Here the product loses the residual moisture and gets the golden crust.

The next stage is packing of the finished product in packs. For this the flakes are loaded into the automatic packing machine (17) from the cooling drum of the roasting furnace through the feeding conveyor (16). Then the packed product through the outflowing conveyor (18) comes into the cartoon packer (19), from where it is outflowed through the horizontal conveyor (20).

The initial raw is loaded into the sifter.

Productivity is up to 500 kg/hour

Power up to 1.5 kW

 

Sifter. Centrifugal sifter GCB sifts the bulk foods, removing impurities from them.

The principle of operation of the sifter is based on continuous centrifugal bursting of the bulk raw material through cylindrical sieve of pre-assigned flow section. The power of 1.5 kW.

 

Mixer. Mixing of food bulk components. Productivity up to 1000 kg / hour. The installed capacity of 4 kW. Form of a working body - belt, spiral blades (screw-type). All parts in contact with product are made of stainless steel of food marks

Advantage of the mixer:

Uniformity, homogeneous mixing of the product (96-98%).

There is no “dead zones” in the mixing chamber

The tightness of the mixer.

No dust in the mixing process.

Programming of the mixing process, etc.

 

Extruder. It is designed for production of semi-finished product. Productivity 200 kg/hour.

Power of the main drive 90 kW

Power of heaters minimum 2x6 kW. Number od cases - 6.

The extruder is equipped with a microprocessor control system with micro-touch-screen panel of the operator and startup function, which greatly improves the reliability of the product and makes the process of management the extruder simple and understandable. The extruder is also equipped with self-cleaning screws high hardness, which excludes the presence of carcinogens and solids in the final product, and also allow not to disassemble and clean the extrusion zone at shutdown. The extruder is equipped with the necessary units (dies, hung cutters, storage bins).

 

Installation for roasting corn flakes is intended to improve the food properties of processed product due to its thermal treatment. Infrared radiation, penetrating into the product, causes its rapid internal heating.

Productivity 200 kg / hour

Type of infrared emitters - halogen lamp

Installed capacity: infrared emitters - 48 kW

electric drive - 1.0 kW

 

Additive input machine  is designred for adding dry and (or) liquid flavour sepplements and consequent distribution of them along the product. Productivity up to 300 kg/hour.

Power consumption 1 kW/hour

Dimensions (LхWхH): 2600х950х1610 mm

 

Roasting furnace.  This equipment is intended for roasting flakes. Four heating zones are provided, the temperature adjustment of each of which occurs separately. This system is designed to prevent product drying and to make product frying gradually at higher temperatures without loss of taste qualities

Performance up to 300 kg / hour.

Power consumption 10 kW.

Dimensions (LxWxH): 4050x2200x2050 mm

 

It is designed for organization of continuous filling cycle by means of weight batching. Consists of automatic packing machine and weight batcher.

Supply voltage 380 V

Supply current frequency of 50 Hz

Power consumption of 1 kW / hour

Air consumption at an average pressure of 100 l / min

 

Moving of packages from automatic packaging machine (film) into the machine for packing in a cartoon box (cartoon packer).

Supply voltage 380 V

Supply current frequency of 50 Hz

Power consumption 0.25 kW / hour

 

The line is designed for packaging of ready packs with product into cartoon boxes.

Power supply 380V, 50Hz,

Installed capacity of not more than 2.5 kW

Consumption of compressed air of not more than 1000 l / min. Dimensions 4100x850x950

 

Moving packaged products on the packaging table for packing in wholesale packaging (boxes).

Supply voltage 380 V

Supply current frequency of 50 Hz

Power consumption 0.25 kW / hour

 

No Name QTY 1 Screw conveyor 1 2 Sifter 1 3 Mixer 1 4 Extruder 1 5 Pneumatic conveyor 1 6 Flatting machine 1 7 Vibrating conveyor 3 8 Thermal dryer 1 9 Feeding conveyor 2 10 Additive imput machine 1 11 Digester 2 12 Roasting furnace 1 13 Automatic packing machine 1 14 Outflowing conveyor 1 15 Cartoon packer 1 16 Horizontal conveyor 1

 

Period of production 120 working days from the deposit payment.