CEREAL PRODUCTION

AMORIN : In 1863, James Caleb Jackson, a religiously conservative vegetarian who ran a
medical sanitarium in western New York, created a breakfast cereal from graham flour dough
that was dried and broken into shapes so hard they needed to be soaked in milk overnight.

But nowadays how Cereals are made in the factories?

Lets find out!
(note save in audio file. File name Part 1_Amorin)

PRECILDA: In the first step of corn flakes manufacturing, the corn is thoroughly sorted and
cleaned. This process ensures that high quality kernels. The cord kernels arrived at the factory
undergo quality control then ensure quality standard size and meet the company standard.
Selected corn kernels are stored in a controlled condition such as cool and dry areas to
preserve quality.

(note save in audio file. File name Part 2_Precilda)

ACOL:Next process, corn kernels undergo a controlled wetting process which helps to soften
and facilitates the extraction of flakes later on. Prior to milling the corn kernels undergo initial
cleaning stage to remove impurities such as sand, dust and debris. The kernels are subjected
to a series of vibrating sieves and screens that separates the corn particles. After the initial
cleaning the corn kernels undergo a more detailed secondary cleaning. Gravity Separators and
vacuum cleaners are used to remove finer impurities.

(note save in audio file. File name Part 3_Acol)

MALAKI:Clean high Quality corn kernels are sorted according to size and density. Specialized
sorters and separation equipment are used to ensure that only suitable kernels are used in the
production. Once the corn sorting and cleaning step is complete, the kernels are ready to move
to the next stage

(note save in audio file. File name Part 4_Malaki)

ACOL: Selected corn kernels undergo soaking and conditioning process, this step is essential
to soften the kernel and prepare properly for milling stage. After Cleaning again, the corn
kernels are transferred to large soaking tanks, this tanks is filled with hot water. During this
stage,hot water penetrates the kernels which helps to soften the husk and facilitate the ball
milling process. A ball mill is a type of grinder used to grind or blend materials as it works on
the principle of impact and attrition: size reduction is done by impact as the balls drop from near
the top of the shell. Rotation per Minute or RPM in ball mills is calculated through a working
formula of:

76.65
N=
√ D −d
Where:
N= revolution per minute
D= diamter of the mill
d= average diamter of the ball.
(note save in audio file. File name Part 5_Acol)

PRECILDA:Additional condition will be applied before milling, this will help to achieve better
separation of the husk during the milling stage and produce a more uniform corn flakes.
Soaked and Conditioned corn kernels go through a grinding and separation process. This is
done to convert kernels to a fine homogeneous mass that will be transformed into corn flakes

(note save in audio file. File name Part 6_Precilda)

MALAKI: Next Stage, the kernels are fed between two great giant steel that rotates in opposite
directions. One slightly faster than the other. The mills are specialized equipment designed to
grind the kernels into a fine uniform mass of corn kernels. The product of this stage turns into a
dough called “Masa de Maiz”.

(note save in audio file. File name Part 7_Malaki)

AMORIN: The resulting dough will now undergo a separation process to remove husk and
unwanted interference. This is now the base material that will be used to form corn flakes in
later stages of the manufacturing process. Once done the stages of cooking and flake
formation will be the next step. This step helps to give the corn flakes its crispy characteristics
including texture and shape. Addition of sugar, honey and any other ingredients will be added
depending on the recipe.

After, the cereal will undergo freeze cooling to eliminate moisture and maintain the freshness of
the product. Then finally quality control and packaging for product distribution and selling.

(note save in audio file. File name Part 8_Amorin)