Producing flaked breakfast cereals from pellets or grits by passing them between contra-rotating rollers is a prime example of a process that is much more complex than it appears. Achieving the consistent high quality demanded by consumers at the high outputs needed by producers requires a great deal more process expertise and precision engineering than might be assumed.

1. Digital Re-print - September | October 2011
Producing Flaked Breakfast Cereals
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2. FEATURE FEATURE
layer of hardened tool steel over a tough ture content of 18 to 20 percent must be rings, alphabet shapes, and cocoa balls
PRODUCING FLAKED
carbon steel interior. As well as long reduced to 3 percent. Discharge options can be extended, through additional units
life – typically 10,000 hours before re- to suit customer preference include a bi- (including the flaking roll), to make a
grinding – there are additional cost ben- directional belt conveyor, a vibratory con- range of flakes, multigrain flakes and filled
efits. The outer layer permits a number veyor, and a vacuum take-off system with pillows.
bREAKFAST CEREALS
of re-grinds, and at the end of natural sampling tray. Baker Perkins provides the process and
life another outer layer can be welded to The choice of standard 780 or 1220mm engineering expertise to reconfigure the
the roll: conventional rolls need replacing roll widths allows a range of outputs to a lines, and works with customers to develop
at this point. The outer layer can also be maximum of 1,500kg/hour. new product ideas, often in the Baker Perkins
repaired in the event of damage by stones Flaking rolls are an essential module in Innovation Centre at Peterborough, where
or other foreign objects. the Baker Perkins Cereal Master TX and a comprehensive range of equipment is
The scraper blades that clean each roll EX expandable lines. These allow manu- available for trials. Each installation is individu-
P
roducing flaked breakfast cereals pellets into a wide range of corn, bran, mul- distribution box is typically used for whole are made of hardened but flexible alloy to facturers to install a basic line for a limited ally specified to match the customer’s exact
from pellets or grits by passing them tigrain and other flakes ready for toasting. grain wheat. ensure uniform contact across the roll width. range of cereals, and then add more units product needs.
between contra-rotating rollers is a Grits and pellets up to 10mm thick are The second challenge is to maintain Two features extend blade life: they are held to increase
prime example of a process that is much reduced to flakes as thin as 0.3mm. a precise and constant gap between the in position by a variable pneumatic pressure the range
more complex than it appears. Achieving With 30 years experience in providing 2-ton contra-rotating flaking rolls: this is system; the blades are also reversible and and value
the consistent high quality demanded by flaking rolls to customers throughout the crucial to achieving consistent product may be reground several times. An optional of products
consumers at the high outputs needed
by producers requires a great deal more
world, Baker Perkins cite the control of three
key process variables as essential to achieving
quality. Any minor variation changes flake
thickness and bulk density, resulting in
oscillating knife increases the effectiveness of
scraper action.
as market
and business
Inline moisture + density
process expertise and precision engineer- the highest flake quality. under- or over-toasting and rejected prod- A major improvement introduced on conditions
ing than might be assumed. The first is achieving an even, regulated uct. Adjustability is also important to the latest generation of machines is the change.
product feed across the full width of the maximise flexibility. substitution of a precision timing belt drive The
Baker Perkins flaking rolls are used by lead- rolls. Uneven feeding causes differential heat A recently upgraded automated hydraulic for the previous torque arm gearbox. With Cereal Master
ing multinational and regional breakfast cereal build up in the rolls and leads to inconsist- system positions each roll via a linear trans- independent drive to each roll, speed can TX includes a
makers, to convert cooked grains ency in flake thickness. Colour, moisture, size ducer: the roll gap is continuously measured be varied to change the nature of the flake flaking roll in
and extrud- ed and texture of the finished product are all and adjusted against a set point. Effective if required. Maintenance is reduced because its standard Our technology based
adversely affected. To avoid compromising sealing against dust ensures reliability and a AC motors and timing belts require no configuration on the 2-Parameter-
quality with excessive ‘dou- low cost of ownership. The system is com- routine work. for making Resonance-Technology,
bles’ it is important that pact and accommodated within the enve- In an environment in which workplace wheat and
the feed be regulated to lope of the machine to minimise footprint, noise is rapidly growing as an issue, the new bran flakes this makes it possible
ensure that pellets and but is readily accessible for maintenance. flaking roll drive features acoustic covers using the tra- to control density
grits are processed The third process variable that must be over the roll drives as standard; there is also ditional steam and moisture in your
individually accurately controlled is roll surface tempera- an option for hinged acoustic covers at each cooking proc- products
To achieve these ture. Consistent roll surface temperature is end of the unit. ess. Other
objectives for dif- essential for optimum flake consistency and These flaking rolls are designed for ease units can be
ferent product is achieved via an effective water cooling of use. There is full PLC control with a added later  fast
types Baker Perkins system. touch-screen HMI providing clear process to extend
 accurate
engineers product- The latest generation of machine visualisation and intuitive operation. The the prod-
specific feed systems. incorporates an advanced roll cool- set-up facility is recipe driven, and there are uct range to  cost effective
Extruded pellets ing and water circulation procedure. comprehensive alarm functions plus a recent include corn,
and multigrains Effectiveness has been refined through a alarm history. multigrain and
are fed by a vibra- contraflow water circulation system, with Simple, open design maximises accessibil- frosted flakes.
tory conveyor water channels close to the surface to ity to the flaking rolls themselves for clean- A stand-
and spreader. For maximise heat removal efficiency. High flow ing and maintenance whilst conforming to ard Cereal
cooked corn grits, rates of up to 10,000 litres per hour control worldwide safety standards; the simple frame Master EX
a grooved roll water temperature within a 0.2ºC tolerance construction allows for easy roll removal. line produc-
feeder is used, with band – water temperature can be varied by The latest machine also has a smaller foot- ing extruded
the flexibility to the operator. print. cereals such
adjust gap height The solid flaking rolls themselves offer On leaving the flaking roll, the product as corn balls, www.doescher.com
and roll speed. A the unique feature of a welded outer is transferred to a toaster where a mois- multigrain
22 | September - october 2011 Grain &feed millinG technoloGy Grain &feed millinG technoloGy September - october 2011 | 23
AD_DoescherDoescher_90x132.indd 1 30/09/2011 11:08

3. Built by feed millers for feed millers. Equipped with the industry‘s most efficient
drive system, the new Bühler pellet mill Kubex™ T saves up to 20% of energy –
while boosting line capacity to up to 80 tons per hour. With the Kubex™ T
you save costs, reduce your carbon footprint and make your operation even
more productive. Gaining competitive advantages has never been easier.
For more information please visit www.buhlergroup.com/kubex-t
Bühler AG, Feed & Biomass, CH-9240 Uzwil, Switzerland, T +41 71 955 11 11, F +41 71 955 28 96
fu.buz@buhlergroup.com, www.buhlergroup.com
Kubex™ T pellet mill.
Developed in close cooperation
with leading feed millers.
Direct drive concept. Saves up to
20% of energy compared to
conventional drive systems.
Variable die speed. Formulation-
specific optimization of production
process and pellet quality.
Up to 585 kW motor power. Boosts
line capacity to up to 80 t/h.
Belt- and gearless drive system.
For minimum maintenance and
ultimate machine availability.
ABS control for press rolls.
Prevents roll slippage and protects
machine against blockages.
360° accessibility. Wide-opening
sliding doors on both sides.
The world’s most compact design.
Fits anywhere and everywhere.
Almost double capacity with same
footprint as conventional pellet mills.
Innovations for a better world.

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an archive of individual features on the docstoc website.
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October 2011
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• Producing Flaked
breakfast Cereals
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Redefined
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