Stainless Steel Large Capacity Corn Flakes Plant

The large capacity corn flakes plant is a manufacturing facility designed to produce corn flakes in bulk using an extrusion process. Corn flakes are a popular breakfast cereal made from corn, sugar, and various flavorings. The extrusion process is a key step in producing corn flakes, as it involves cooking, shaping, and drying the cereal mixture.

Breakfast cereals production line flow chart.

Mixer machine—conveyor machine—extruder machine—dryer machine—suger sprayer machine—dryer machine—cooling machine.

Corn flakes plant flow chart.

Mixer machine—conveyor machine—extruder machine—Vibrate cooler—dum cooling machine—flake presser machine—dryer machine—vibrate distributor machine—Baking machine—suger sprayer machine—dryer machine—cooling machine.

Here are the key components and steps involved in a large capacity corn flakes extrusion plant:

1. Raw Material Handling: The primary raw material for corn flakes production is maize (corn), which is typically purchased in bulk. The maize is cleaned, de-germed, and ground into cornmeal to create the base ingredient for the cereal.

2. Mixing and Preconditioning: The cornmeal is mixed with water and other ingredients, such as sugar, salt, and flavorings, to create a uniform cereal mixture. Preconditioning involves heating the mixture to soften the starches and prepare it for extrusion.

3. Extrusion: Extrusion is the heart of the corn flakes manufacturing process. The preconditioned cereal mixture is fed into an extruder, which is a machine with a screw or auger that compresses and heats the mixture. As the mixture passes through the extruder, it expands and cooks, forming the characteristic corn flake shape. The extruder typically operates at high pressure and temperature.

4. Shaping and Cutting: After extrusion, the cereal mixture is shaped into flakes using shaping rollers and then cut into the desired flake size. This step determines the final size and thickness of the corn flakes.

5. Drying: The freshly formed corn flakes contain a high moisture content. To achieve the desired shelf-stable cereal, the flakes are conveyed through a drying system, such as a multi-pass oven or a conveyor dryer, where hot air is used to remove moisture and crisp up the flakes.

6. Toasting: Toasting is an optional step that adds flavor and color to the corn flakes. The flakes are typically passed through a toasting oven, where they are baked to achieve the desired texture and taste.

7. Coating and Flavoring: Some corn flakes may be coated with additional sugar, vitamins, or flavorings at this stage to enhance their taste and nutritional content.

8. Cooling and Packaging: After toasting, the corn flakes are cooled to room temperature to prevent moisture buildup, and they are then packaged in various-sized containers, such as boxes, bags, or bulk containers. Packaging may also involve adding labels and branding.

9. Quality Control: Throughout the production process, quality control measures are in place to ensure the corn flakes meet safety and quality standards. This includes regular testing for taste, texture, moisture content, and shelf stability.

10. Storage and Distribution: The finished corn flakes are stored in warehouses and distributed to retailers and wholesalers for sale to consumers.

Corn flakes plant capacity.

AVN65 machine line has capacity 120-150 kg per hour.
AVN70 machine line has capacity 200-250 kg per hour.
AVN85 machine line has capacity 400-500 kg per hour.

Extrusion Machine Line Advantage:

1.Feeding System: Raw materials are fed into the extruder through a feeding system. This system includes hoppers, feeders, and conveyors to ensure a steady supply of ingredients to the extruder.

2.Extruder: The heart of the system is the extruder, which is responsible for the cooking and shaping of the snack. It usually consists of a barrel, screws, and a die. The raw ingredients, such as grains or starches, are fed into the extruder where they are cooked, pressurized, and pushed through a die to give the snack its final shape.

3.Cutting System: Once the extruded snack has been formed, a cutting system is used to cut it into the desired shape and size. This can include rotary cutting systems, knives, or other cutting mechanisms depending on the specific snack being produced.

4.Drying Chamber Design: The design of the drying chamber is important for efficient moisture removal. It should allow for even airflow around the snacks to ensure uniform drying.

5.Cooling System: After the snacks are dryed, they may pass through a cooling system to bring down the temperature and set the final texture. This helps in the solidification of the product and ensures it is ready for packaging.

6.Flavoring and Seasoning System: Many extrusion snacks machines have a system for applying flavors and seasonings to the finished snacks. This can be done through a drum coating system or other methods to ensure an even distribution of flavors.

7.Conveyor System: A conveyor system is used to transport the snacks from one part of the machine to another. This is essential for maintaining a continuous and efficient production process.

8.Control Panel: Modern extrusion snacks machines come with a user-friendly control panel. This panel allows operators to monitor and control various parameters such as temperature, pressure, and speed. It ensures precise control over the extrusion process, leading to consistent product quality.

9.Safety Features: Extrusion snacks machine lines are equipped with safety features to protect operators and prevent accidents. Emergency stop buttons, safety interlocks, and protective covers are commonly incorporated.

10.Hygienic Design: The equipment is often designed to meet strict hygiene standards in the food industry. This includes easy-to-clean surfaces, sanitary construction materials, and accessibility for cleaning and maintenance.

11.Capacity and Flexibility: Extrusion snacks machine lines come in various sizes and capacities to meet the production needs of different manufacturers. Some machines also offer flexibility in terms of producing different types of snacks by adjusting parameters.

12.Energy Efficiency: Manufacturers often design these machines with energy-efficient features to reduce operational costs and environmental impact.

Details Picture of Machines

Customer & Service
We shipped the machinery to numerous countries globally, including Italy, Germany, Russia, Turkey, Australia, Indonesia, India, etc. Our machines and service have received commendations from nearly every customer, fostering repeat business.

1.Twelve months following installation (Within 13 months of delivery).
2.Complimentary advisory service prior to, during, and post-sales.
3.Supply fundamental production methods and formulations.
4.International on-site setup and personalized training for machine maintenance and operation.
5.Calibration and examination of the machinery until all components are operational before departing the manufacturing facility.

Packaging & Shipping
1.Daub coal oil on the surface of the machines.
2.Plastic film as the inner packing.
3.Train, ship of depend on clients’ requirement.

FAQ

Q: What is the duration of your warranty period?
A: Our guarantee spans one year from the commencement of operations.

Q: Can you describe the installation process?
A: We will deploy our skilled technicians to your facility to oversee the installation and commissioning tasks, providing training for your operators.

Q: If we share our factory layout, can you assist in designing the entire production line?
A: Certainly, our seasoned engineers and technical staff can aid in organizing the layout and overseeing the installation of the entire production line, tailored to your specific circumstances.

Q: What is the timeframe for your delivery?
A: Typically, it takes 7 – 10 days for stocked items, and 20 – 25 days for non-stock items, depending on the quantity.

Q: Will you provide support if issues arise during future production?
A: Absolutely, we are committed to being at your service. You can reach me through mobile, WhatsApp, Skype, Viber, WeChat, and more. I will promptly address and resolve any problems you encounter.

A large capacity corn flakes extrusion plant is equipped with industrial-scale machinery to produce corn flakes in high volumes to meet consumer demand. The specific equipment used may vary depending on the manufacturer’s production capacity and processes, but it typically includes large extruders, drying ovens, toasting equipment, and packaging lines. The plant may also have quality control and testing facilities to ensure consistent product quality.

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