Our twin-screw extrusion lines produce cereal flakes, both plain or coated. The twin-screw extrusion technology is at the core of this very flexible and scalable process. This technology is ideal to meet the market demands and breakfast cereal manufacturing : many raw materials are eligible with coating recipes such as sweet syrups, honey, chocolate and other compositions.
We share our process knowledge to process healthy and balanced products made with wholegrain cereals or including a mix of multi-grains like corn, wheat, oats, rice, barley, rye, Buckwheat or barley … Our automated production lines are used to produce consistently high quality products while keeping the same organoleptic characteristics as traditional flakes.
How does the cereal flakes production line work?
The dry ingredients (premix grains, minerals and vitamins, salt, milk powder, emulsifiers, …) are fed, mixed and conveyed in a preconditioner which hydrates and heats the mixture to start the gelatinization. The partially cooked product is introduced into the twin-screw extruder: the corotating screws mix the pre-moistened powders with a malt syrup, injected directly into the extruder ; the heat generated by viscous dissipation and the controlled shear generated by the screws geometry provide the required thermo-mechanical treatment to the preparation. An advanced cooling system precisely adjusts the temperature in each barrel module. The homogeneous, pasty and cooked product is pushed throughout the die which forms continuous unexpanded strands.
After a short cooling period, the products are tempered, cut and flaked using a flaking device consisting of two thermo-regulated and counter-rotating cylinders. They are then transferred to a dryer / toaster and cooled before being stored and packed. An additional coating operation may be applied to add,- for example, a sweet syrup, before drying and cooling.
Flexible lines that promote product innovation and productivity
The added value of your cereal flakes extrusion lines :
- Quicker process : 15 to 20 minutes against 8 to 10 hours with the traditional batch process
- Flexible promoting product innovation:
- Variety of recipes: diversity of raw materials (cereals, tubers, various ingredients …) and particle size used (from flour to semolina), wide range of coatings
- Possibility to add functional and tasty ingredients : natural color, salt, fiber, vitamins, minerals, emulsifiers,
- Possibility to add particles of grain or seeds that will be visible in the final product.
- Possibility to process multigrain flakes, for example by introducing other grains directly during extrusion.
- Possibility to upgrade the production line to process expanded or coextruded breakfast cereals
- Productive: continuous and automated process, quick start up and stop, fast and easy changeovers and with easy cleaning and maintenance procedures;
- Cost effective : intensified transformation process generating savings in raw materials as well as energy and water, easy maintenance, hygienic design, compact design with less floor space
Coated finished product capacity : from 200kg / h to 1000 kg / h