Zero-Waste Direct Expansion Technology
High-Efficiency Extruded Breadcrumb Production Line
Transform raw flour into American-Style Granular Crumbs instantly. No fermentation, zero crust waste, and full color customization (Golden/Orange) via our twin-screw extrusion system.
From Flour to Crumb
in Minutes, Not Hours
Traditional breadcrumb production is slow: mixing, fermenting, baking, and removing crusts. It wastes time and up to 15% of your raw material.
Loyal’s Extruded Breadcrumb Line replaces the entire bakery section with a single Twin-Screw Extruder. By using high temperature and pressure, it instantly cooks and puffs the flour mixture.
The result is a highly consistent, American-Style Granular Crumb that is perfect for coating chicken nuggets, onion rings, and fish fillets—with absolutely zero waste.
Zero Waste Production
No crusts to cut off. No bad batches from failed fermentation. Every gram of flour you put in comes out as high-quality breadcrumb. 100% material utilization.
No Fermentation Needed
Skip the 4-8 hour fermentation and baking process. The twin-screw extruder cooks the dough in seconds using High Shear & Heat, drastically reducing energy costs.
Instant Color Control
Easily produce Golden, Orange, or White crumbs by adding natural pigments (like Paprika or Turmeric) directly into the mixer. The color is locked in during extrusion.
Continuous Automatic Workflow
From raw flour to finished breadcrumb in one seamless line. No manual handling, no fermentation time.
Extruded Breadcrumb Process
01
Mixing
Wheat flour is mixed with water and optional additives (salt, natural pigments) in a high-speed mixer to ensure uniformity.
02
Extruding (Cooking)
The Twin-Screw Extruder cooks and puffs the material under high temperature/pressure, replacing traditional baking.
03
Cutting
The extruded puffs are cut into manageable pieces by a rotary cutter before entering the drying system.
04
Drying
A multi-layer oven removes moisture to make the product crispy and extend shelf life (target moisture < 5%).
05
Crushing & Sifting
The dried puffs are milled into granules. A Vibrating Sifter separates them into different sizes (Fine, Medium, Coarse).
Engineered for Consistency
Every stage of the line is synchronized. From the high-pressure cooking in the extruder to the precise granulation in the miller, we ensure uniform crumb size and texture.
Step 1: Cooking & Puffing
Twin-Screw Extruder
The heart of the line. It replaces the traditional mixer, fermentation room, and baking oven. Utilizing High-Temperature Short-Time (HTST) technology, it gelatinizes the flour and extrudes it into porous puffed balls or sheets instantly.
Alloy Steel Screws
PID Temp Control
Self-Cleaning Function
Direct Expansion
Step 2: Moisture Removal
Multi-Layer Mesh Belt Dryer
To achieve that signature “crunch,” moisture must be removed uniformly. Our dryer uses a hot air circulation system that penetrates the breadcrumb layer from both top and bottom. The multi-pass design saves floor space while maximizing drying area.
3 / 5 / 7 Layers
Gas / Electric / Steam
SS304 Mesh Belt
Uniform Drying
Step 3: Granulation
High-Efficiency Miller
This is not a standard flour mill. Our Breadcrumb Miller is designed to shatter the dried puffed material into granules rather than grinding it into dust. It preserves the porous structure of the crumb, ensuring good oil absorption control during frying.
Adjustable Granularity
Low Dust Generation
High Throughput
Easy Screen Change
Step 4: Grading
Vibrating Sifter
Consistency is key for industrial coating lines. The sifter separates the output into Target Size, Oversize (returned to miller), and Fine Powder. This ensures that every bag of breadcrumbs you sell performs exactly the same for your customers.
Multi-Deck Design
Stainless Steel 304
Low Noise Operation
Precise Separation
More Than Just Crumbs
From classic granular coatings to novelty shapes. Our extruder dies allow you to produce a wide variety of breading styles with Vibrant Colors instantly.
American Granular
The industry standard. Small, round, porous balls that provide a hard, crunchy bite. Excellent for coating chicken nuggets and fish fillets.
Puffed Flakes
Thin, flat discs similar to cornflakes. These provide a lighter, crispier texture and cover more surface area with less weight.
Geometric Shapes
Unique to extrusion technology. Create Stars, Triangles, or Rings to make fun, visually appealing coated snacks for children.
Technical Specifications
Choose the model based on your capacity requirements. We use high-efficiency twin-screw extruders to maximize output while minimizing energy consumption.
| Model | Screw Dia. | Output Capacity | Main Power | Installed Power | Line Dimensions (L*W*H) |
|---|---|---|---|---|---|
| LY-65 | 65 mm | 100 – 150 kg/h | 22 kW | 70 kW | 21 x 1.5 x 2.2 m |
| LY-70 | 70 mm | 200 – 260 kg/h | 30 kW | 95 kW | 24 x 1.5 x 2.2 m |
| LY-85 | 85 mm | 400 – 500 kg/h | 75 kW | 140 kW | 28 x 2.5 x 3.0 m |
| LY-95 | 95 mm | 800 – 1000 kg/h | 90 kW | 190 kW | 32 x 3.0 x 3.5 m |
Factory Length Constraints?
These dimensions represent a straight line. If your factory is short, we can design a U-Shape or L-Shape Layout to fit the equipment into your space.
Extrusion vs. Fermentation
Choosing the right line depends on your final product texture and cost structure. Do you need Low-Cost Efficiency or Premium Needle Texture?
This Machine (Extruded)
American Granular Line
Best for Nuggets, Patties, and Fillers. Focuses on speed and zero waste.
Material Utilization
100% (Zero Waste)
Process Speed
Very Fast (Instant Puffing)
Crumb Texture
Hard / Crunchy
Zero crust waste (Huge savings)
Easy color customization
Cannot produce needle shape
Alternative Technology
Electrode Panko Line
Best for Premium Tempura and Shrimp. Focuses on light, airy needle texture.
Material Utilization
85% (Crust Removal)
Process Speed
Slow (Requires Fermentation)
Crumb Texture
Light / Airy / Needle
Premium needle shape
Less oil absorption
Higher OpEx (Waste & Energy)
Live Production Gallery
From instant extrusion puffing to the final golden crunch. See our machines in action.
Trusted by Food Processors
Precise granulation and technical expertise are why clients switch to our extrusion lines.
“
Almost the same size as my calculations, it was nice working with you. The machine output matched our specific granulation requirements perfectly.
“
Your explanation was more complete than all the companies, even Fava and Pawan. I appreciate the detailed technical breakdown of the extrusion process.
Why Choose Loyal?
Breadcrumb extrusion is high-intensity work. We build our machines with reinforced alloys and smart designs to ensure you get consistent golden crumbs, shift after shift.
Wear-Resistant Core
Extruding flour creates high friction. We use Bimetallic Alloy Screws and Nitrided Barrels that last 3x longer than standard steel, reducing your maintenance downtime.
Golden Recipe
Struggling with color? We provide proven formulations for Golden, Orange, and White crumbs. We teach you exactly how much pigment and water to add for that perfect American-style finish.
Energy Efficient
By eliminating the traditional baking oven and utilizing Direct Expansion, our line consumes up to 40% less energy compared to electrode baking lines of similar capacity.
Modular Maintenance
Our barrels use a Modular Design. If one section wears out, you only replace that specific segment, not the whole barrel. This significantly lowers your long-term spare parts cost.
Frequently Asked Questions
Answers about texture, ingredients, and machine capabilities.
Can this machine make Japanese Panko (Needle Shape)?
No. This extruder line produces American Style (Granular) breadcrumbs, which are hard and crunchy. If you need light, needle-shaped Panko, you need our Electrode Baking Line. The technology is completely different.
Can I use leftover bread or bread crusts as raw material?
No. This line is designed to process raw Wheat Flour, Corn Starch, or Rice Flour. It is a “Direct Expansion” process, meaning it cooks the raw flour instantly. It is not a grinder for old bread.
How do I make Golden or Orange breadcrumbs?
It’s very simple. You just add natural pigments (like Paprika extract or Turmeric) into the Mixer along with the flour and water. The extruder mixes and locks the color into the dough, ensuring a uniform, vibrant finish without post-dyeing.
How do I change the crumb size (Mesh)?
You can change the output size by changing the screen mesh on the Miller and Sifter. We provide various screen sizes (e.g., 2mm, 4mm, 6mm) so you can produce fine coating or coarse crunchy crumbs with the same machine.
How do I clean the extruder barrel?
The twin-screw extruder has a Self-Cleaning Function. Because the two screws mesh closely together, they scrape each other clean as they rotate. You don’t need to disassemble the barrel for daily cleaning, saving huge labor time.
Ready to start production?
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