Digital Re-print - September | October 2011

Producing Flaked Breakfast Cereals

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FEATURE

FEATURE

PRODUCING FLAKED bREAKFAST CEREALS

roducing 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. Baker Perkins flaking rolls are used by leading multinational and regional breakfast cereal makers, to convert cooked grains and extruded

pellets into a wide range of corn, bran, multigrain and other flakes ready for toasting. Grits and pellets up to 10mm thick are reduced to flakes as thin as 0.3mm. With 30 years experience in providing flaking rolls to customers throughout the world, Baker Perkins cite the control of three key process variables as essential to achieving the highest flake quality. The first is achieving an even, regulated product feed across the full width of the rolls. Uneven feeding causes differential heat build up in the rolls and leads to inconsistency in flake thickness. Colour, moisture, size and texture of the finished product are all adversely affected. To avoid compromising quality with excessive doubles it is important that the feed be regulated to ensure that pellets and grits are processed individually To achieve these objectives for different product types Baker Perkins engineers productspecific feed systems. Extruded pellets and multigrains are fed by a vibratory conveyor and spreader. For cooked corn grits, a grooved roll feeder is used, with the flexibility to adjust gap height and roll speed. A

distribution box is typically used for whole grain wheat. The second challenge is to maintain a precise and constant gap between the 2-ton contra-rotating flaking rolls: this is crucial to achieving consistent product quality. Any minor variation changes flake thickness and bulk density, resulting in under- or over-toasting and rejected product. Adjustability is also important to maximise flexibility. A recently upgraded automated hydraulic system positions each roll via a linear transducer: the roll gap is continuously measured and adjusted against a set point. Effective sealing against dust ensures reliability and a low cost of ownership. The system is compact and accommodated within the envelope of the machine to minimise footprint, but is readily accessible for maintenance. The third process variable that must be accurately controlled is roll surface temperature. Consistent roll surface temperature is essential for optimum flake consistency and is achieved via an effective water cooling system. The latest generation of machine incorporates an advanced roll cooling and water circulation procedure. Effectiveness has been refined through a contraflow water circulation system, with water channels close to the surface to maximise heat removal efficiency. High flow rates of up to 10,000 litres per hour control water temperature within a 0.2C tolerance band water temperature can be varied by the operator. The solid flaking rolls themselves offer the unique feature of a welded outer
Grain

layer of hardened tool steel over a tough carbon steel interior. As well as long life typically 10,000 hours before regrinding there are additional cost benefits. The outer layer permits a number of re-grinds, and at the end of natural life another outer layer can be welded to the roll: conventional rolls need replacing at this point. The outer layer can also be repaired in the event of damage by stones or other foreign objects. The scraper blades that clean each roll are made of hardened but flexible alloy to ensure uniform contact across the roll width. Two features extend blade life: they are held in position by a variable pneumatic pressure system; the blades are also reversible and may be reground several times. An optional oscillating knife increases the effectiveness of scraper action. A major improvement introduced on the latest generation of machines is the substitution of a precision timing belt drive for the previous torque arm gearbox. With independent drive to each roll, speed can be varied to change the nature of the flake if required. Maintenance is reduced because AC motors and timing belts require no routine work. In an environment in which workplace noise is rapidly growing as an issue, the new flaking roll drive features acoustic covers over the roll drives as standard; there is also an option for hinged acoustic covers at each end of the unit. These flaking rolls are designed for ease of use. There is full PLC control with a touch-screen HMI providing clear process visualisation and intuitive operation. The set-up facility is recipe driven, and there are comprehensive alarm functions plus a recent alarm history. Simple, open design maximises accessibility to the flaking rolls themselves for cleaning and maintenance whilst conforming to worldwide safety standards; the simple frame construction allows for easy roll removal. The latest machine also has a smaller footprint. On leaving the flaking roll, the product is transferred to a toaster where a moisGrain

ture content of 18 to 20 percent must be rings, alphabet shapes, and cocoa balls reduced to 3 percent. Discharge options can be extended, through additional units to suit customer preference include a bi- (including the flaking roll), to make a directional belt conveyor, a vibratory con- range of flakes, multigrain flakes and filled veyor, and a vacuum take-off system with pillows. Baker Perkins provides the process and sampling tray. The choice of standard 780 or 1220mm engineering expertise to reconfigure the roll widths allows a range of outputs to a lines, and works with customers to develop new product ideas, often in the Baker Perkins maximum of 1,500kg/hour. Flaking rolls are an essential module in Innovation Centre at Peterborough, where the Baker Perkins Cereal Master TX and a comprehensive range of equipment is EX expandable lines. These allow manu- available for trials. Each installation is individufacturers to install a basic line for a limited ally specified to match the customers exact range of cereals, and then add more units product needs. to increase the range and value of products as market and business conditions change. The Cereal Master TX includes a flaking roll in Our technology based its standard configuration on the 2-Parameterfor making Resonance-Technology, wheat and this makes it possible bran flakes to control density using the traditional steam and moisture in your cooking procproducts ess. Other units can be added later fast to extend accurate the prod cost effective uct range to include corn, multigrain and frosted flakes. A standard Cereal Master EX line producing extruded cereals such as corn balls, multigrain

Inline

moisture + density

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Built by feed millers for feed millers. Equipped with the industrys most efficient drive system, the new Bhler 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

Bhler 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. Formulationspecific 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 worlds most compact design. Fits anywhere and everywhere. Almost double capacity with same footprint as conventional pellet mills.

Innovations for a better world.

This digital Re-print is part of the September | October 2011 edition of Grain & Feed Milling Technology magazine. Content from the magazine is available to view free-of-charge, both as a full online magazine on our website, and as an archive of individual features on the docstoc website. Please click here to view our other publications on www.docstoc.com.

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October

2011

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In this issue:
Sample preparation of feeds and forage for NIR analysis 15-Year Celebration: Fortifying with folic acid prevents 22,000 birth defects annually Global Feed Markets: Wheat supply grows and grows as corn crop shrinks

Producing Flaked breakfast Cereals

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