This presentation deals with the Definition, Background and the Manufacturing process of Cornflakes, Oats and Whole Wheat Shredded Grain.

1. BREAKFAST
CEREALS

2. DEFINITION
Breakfast cereal is a food made fromprocessedgrains that is often eaten as the
first meal of the day. It is eaten hot or cold, usually mixed withmilk, yoghurt or
fruit. Some breakfast cereals require brief cooking, but these hot cereals are less
popular than cold ready-to-eat cereals.

3. BACKGROUND
 Pre-historic people ground whole grains and cooked them with water to form gruels and porridges
similar. Cold cereals dint not develop until the second half of the 19th century.
 Ready-to-eat were in vented because of religious beliefs. An American clergyman, Sylvester Graham,
who advocated a vegetarian diet. He made the first “ Quarter Oats” in 1829 .
 Influenced by Graham, Seventh-Day Adventists, who also believed in vegetarianism, founded the
Western Health Reform Institute in Battle Creek, Michigan, in the 1860s. At this institute, later
known as the Battle Creek Sanitarium, physician John Harvey Kellogg invented several grain-based
meat substitutes.

4.  In 1876 or 1877, Kellogg invented a food he called granola from wheat, oats, and corn that had been mixed, baked, and
coarsely ground. In 1894, Kellogg and his brother W. K. Kellogg invented the first precooked flaked cereal. They cooked
ground wheat into a dough, then flattened it between metal rollers and scraped it off with a knife. The resulting flakes
were then cooked again and allowed to stand for several hours. This product was sold by mail order as Granose for 15
cents per 10-ounce (284 g) package.
 Both W. K. Kellogg and C. W. Post, a patient at the sanitarium, founded businesses to sell such products as health foods.
Their success led dozens of imitators to open factories in Battle Creek between 1900 and 1905. These businesses quickly
failed, while Kellogg and Post still survive as thriving manufacturers of breakfast cereals.
 Kellogg and Post both manufactured corn flakes, which turned out to be much more popular than wheat flakes.

6. Manufacturing of corn flakes

7. Raw Materials
 Most important raw material – Grain, which in this case is corn.
 Sweeteners used- Malt ( obtained from barley), white sugar, brown sugar and corn syrup. Some are
natural sweetened by concentrated fruit juice.
 Flavours- chocolate, strawberry, cinnamon and other spices and fruit flavours can be added.
 Other ingredients include nuts, dried fruits and marshmallow etc..
 Vitamins and minerals are often added to replace those lost during cooking.
 Antioxidants such as BHA and BHT are the preservatives most often added to breakfast cereals to
prevent the cereals from going rancid and stale.

8. Preparing the Grain:
 Grain is received at the cereal factory, inspected, and cleaned. Whole grains or partially ground
grains or flour can be used.
 They are then mixed with flavouring agents, vitamins, minerals, sweeteners, salt, and water in a
large rotating pressure cooker.
 The cooked grain is moved to a conveyor belt, which passes through a drying oven. Enough of the
water remains in the cooked grain to result in a soft, solid mass which can be shaped as needed. If
flour is used instead of grains, it is cooked in a cooking extruder.
 At the end of the extruder, the cooked dough emerges as a ribbon. A rotating knife cuts the ribbon
into pellets. These pellets are then processed in much the same way as cooked grains.

10. Making Flaked Cereals:
 The cooked grains are allowed to cool for several hours, stabilizing the moisture content of each
grain. This process is known as tempering. The tempered grains are flattened between large metal
rollers under tons of pressure. The resulting flakes are conveyed to ovens where they are tossed in a
blast of very hot air to remove remaining moisture and to toast them to a desirable colour and
flavour.
Making Other Cereals:
 Cereals can be made in a wide variety of special shapes (circles, letters of the alphabet, etc.) with a
cooking extruder. A die is added to the end of the extruder which forms a ribbon of cooked dough
with the desired cross-section shape. A rotating knife cuts the ribbon into small pieces with the
proper shape. These shaped pieces of dough are processed in a manner similar to puffing. Instead of
completely puffing, however, the pieces expand only partially in order to maintain the special shape.

11.  Hot cereals are made by processing the grain as necessary (rolling or cutting oats, cracking wheat,
or milling corn into grits) and partly cooking it so the consumer can cook it quickly in hot water.
Salt, sweeteners, flavors, and other ingredients may or may not be added to the partly cooked
mixture.
Adding Coatings:
 After shaping, the cereal may be coated with vitamins, minerals, sweeteners, flavors such as fruit
juices, food colors, or preservatives. Frosting is applied by spraying a thick, hot syrup of sugar on the
cereal in a rotating drum. As it cools the syrup dries into a white layer of frosting.

13. Packaging:
 Some cereals, such as shredded wheat, are fairly resistant to damage from moisture. They may be
placed directly into cardboard boxes or in cardboard boxes lined with plastic. Most cereals must be
packaged in airtight, waterproof plastic bags within cardboard boxes to protect them from spoiling.
 An automated machine packages the cereal at a rate of about 40 boxes per minute. The box is
assembled from a flat sheet of cardboard, which has been previously printed with the desired
pattern for the outside of the box. The bottom and sides of the box are sealed with a strong glue. The
bag is formed from moisture-proof plastic and inserted into the box. The cereal fills the bag and the
bag is tightly sealed by heat. The top of the box is sealed with a weak glue which allows the consumer
to open it easily. The completed boxes of cereal are packed into cartons which usually hold 12, 24, or
36 boxes and shipped to the retailer.

14. Quality Control:
 Every step is carefully monitored for quality. Sanitation is necessary. Machines- Stainless Steel,
thoroughly cleaned and sterilized with hot steam.
 Grain is inspected for any foreign material when it arrives, and when it is cooked and when it is
shaped.
 To ensure the proper cooking and shaping, the temperature and moisture content of vitamins and
minerals is measured to ensure the accurate nutrition information. Filled packages are weighed to
ensure that the contents of each box is consistent.
 In order to label boxes with an accurate shelf life, the quality of stored cereal is tested over time. In
order to be able to monitor freshness over a reasonable period of time, the cereals are subjected to
higher than normal temperature and humidity in order to speed up the spoiling process.

16. Manufacturing of Oats

17. Background
 Wild oats were eaten as early as the Neolithic and Bronze Ages. The Romans cultivated it. The
Teutons and the Gauls used it to make gruel.
 Often growing weed-like amongst wheat and barley, oats thrive in cold climates with a short
growing season, hence its prevalence in Scotland, Ireland, Scandinavia, and Germany. In those
countries it became a basic foodstuff well into the nineteenth century.
 Haggis—a blend of oatmeal, goat organs, onions, and spices that are roasted in pieces of goat
stomach—is still enjoyed as a traditional Scottish meal.
 In the United States, however, oats were viewed as nothing more than horse feed until a German
grocer named Ferdinand Schumacher emigrated to the United States in the mid-1800s and saw a
ready market for oatmeal in the growing immigrant population.

18.  In 1854, Schumacher began grinding oats in his Akron, Ohio, store, using a hand mill similar that
used to grind coffee beans. Within two years he opened the German Mills American Oatmeal
Company. Using a water wheel to generate power and rotate two large millstones, Schumacher's
business was able to fill twenty 180 lb (81.7 kg) barrels with oatmeal daily.
 One of Schumacher's employees, Asmus J. Ehrrichsen had the idea to replace the millstones with
rotating knife blades. This substantially reduced the amount of residue and produced a meal of
uniform taste and flakiness. However, one-quarter of Schumacher's oats were still ending up as
residue, a product that he could not sell. Therefore, in 1878 Schumacher purchased a set
of porcelain rollers from England. By rolling the groats, the residue was virtually eliminated and the
cooking time was decreased to one hour.
 In nearby Ravenna, another mill, owned by Henry Parsons Crowell, William Heston, and Henry
Seymour, was also selling steel-cut oats. Instead of selling them in bulk out of an open barrel,
Crowell measured out two pounds and placed them in clean paper boxes with the cooking directions
printed on the outside. They called their product Quaker Oats.

19. Raw Materials
 Oat grain is the only ingredient in oatmeal. The seeds of the Avena grasses are harvested in the fall.
The thinner-skinned grains are preferable as they have a high protein content without being overly
starchy.
 Additionally, the thin-skinned oats will yield 60% oatmeal, while the yield of thick-skinned oats is
50%. Oatmeal millers develop close relationships with their farmer-suppliers in order to insure that
they receive the finest quality grain.
 The grains should be milled as soon as possible thereafter to prevent spoilage or infestation of boll
weevils. Rancidity is a major concern in the milling of oats. With a higher fat content than other
cereal grains, the lipase enzyme can create a soapy taste. This is controlled by steaming the oats.

21. Cleaning and Sifting:
 The oats are loaded onto moving trays and washed under a high-intensity water spray. Often the
trays are perforated so that foreign material is discarded underneath.
Steaming:
 The cleaned oats then move to a large steamer where they are subjected to moist heat for
a predetermined length of time.
Rolling or Cutting:
 Standard oats are those that have been steel-cut. The oats are run through a machine with razor-
sharp knife blades. Quick-cooking oats are rolled between cylinders to produce a flatter, lighter
flake. These processes are usually repeated several times to produce the type of oat flake that is
desired. In both processes, the hull is separated from the grain. The hulls are sifted out and used for
other purposes.

22. Roasting:
 The hulled oats are then placed into a roaster where they are toasted at a pre-set temperature for a
pre-determined amount of time.
Packaging:
 Pre-printed containers are filled with pre-measured amounts of oatmeal. A lid is vacuum-packed
onto the top of the container. The containers are then loaded into cartons for shipment.
By-Products and Waste:
 The oat hulls that have been removed from the grain are often used for livestock feed and as fuel.
The most common by-product of the hulls is furfural, a liquid aldehyde (dehydrogenated alcohol)
that is used as a phenolic resin or as a solvent. The list of products that contain furfural include
nylon, synthetic rubber, lubricating oils, pharmaceuticals, antifreeze, charcoals, textiles, plastic
bottle caps, buttons, glue, and antiseptics.

24. Manufacturing Of Whole Wheat
Shredded Grain

25. Background
 Wheat was generally used to produce shredded whole wheat. It contains 6 gms of dietary fibre, 0
gms of sugar, 0 gms of cholesterol and 3 gms of sodium and 155 calories per 46 gms.
 Henry perky invented shredded wheat cereals in Denver, Colorado in 1890. he developed a method
of processing wheat into strips that were formed into pillow like biscuits.
 He first sold his cereal to vegetarian restaurants in 1892, distributing it from a factory in Niagara
falls, New York. A health oriented publication, recommended his product as use as soup croutons.

26. Cooking:
 Usually performed in batches with excess water at temperatures slightly below the boiling point at
atmospheric pressure. They have large horizontal baskets. Steam is directly injected directly into the
water to heat the grain. After the cooking cycle is completed, the water is drained and the cooked
wheat is dumped and conveyed to cooling units.
Cooling:
 The wheat is surface dried and the temperature is reduced to ambient levels, thus stopping the
cooking process. After this, they are placed in large holding bins and allowed to temper.
Shredding:
 Here, the wheat kernels are squeezed between one roll with a smooth surface and another roll with a
grooved surface. A comb is positioned against the grooved roll and comb teeth pick the wheat shred
from the groove. There are many variations in the grooved roll.

27.  After shreds are produced, they fall in layers onto a conveyor moving under the rolls. After shreds
are produced, they fall in layers onto a a conveyor moving under the rolls.
 After the web of many layers of shreds reaches the end of the shredder, it is fed through a cutting
device to form the individual biscuits.
Cutting:
 The edges of the cutting devices are dull rather than sharp, so that the cutting action compresses
the edges of the biscuit together to form a crimped joint, which holds the shread together on a
biscuit form.
Baking and Drying:
 After the individual biscuits are formed, they are baked in a batch or a continuous conveyor belt
oven. After the are baked and dried, they are ready for packaging.

28. Packaging:
 The packaging of these biscuits are done in an aluminium bags which is the primary packaging and
then they are put in the cartoon boxes with all the data printed on them.