Direct Fried Snack System
Fried Salad & Bugles Production Line
Produce iconic Crispy Bugles, Sala Sticks, and Fried Flour Snacks. A continuous system featuring high-precision Shaping & Cutting technology for double-layer textures.
Continuous Crispy Snacks:
Direct Frying System
The Fried Salad & Bugles Production Line utilizes high-efficiency extrusion to process flour into dough sheets, which are immediately shaped and fried. This rapid “Direct Expansion” method delivers maximum throughput with consistent quality.
The heart of this solution is the Composite Shaping Machine. It pulls the dough sheet, embosses high-definition textures, and cuts it into iconic 3D “Horn” shapes (Bugles) or classic Sala Sticks.
By eliminating the long-tunnel drying process, this line offers a shorter footprint and faster ROI, making it the ideal choice for manufacturers targeting the high-volume ready-to-eat snack market.
Precision Shaping
Engineered for versatility. Swap rollers to produce Bugles, Sala Sticks, or Pizza Rolls with clean, professional edges and uniform size.
Double Layer Tech
Our unique extrusion die can output dual dough sheets, allowing the shaper to create puffed, double-layered “pillow” textures for premium snacks.
High Profit Margin
Primarily utilizing cost-effective wheat flour and starch, this line minimizes raw material volatility and maximizes your bottom line.
Process Flow Chart
A continuous production line from mixing to packaging. High efficiency with minimal manual intervention.
01
Flour Mixing
Wheat flour is mixed with water and additives. Unlike pellet lines, the moisture content here is optimized for direct frying expansion.
02
Extrusion & Sheeting
The Twin Screw Extruder cooks the flour and extrudes it into a continuous, thin dough sheet. The thickness is adjustable.
03
Shaping & Cutting
The Composite Shaping Machine pulls the sheet, embosses patterns, and cuts it into 3D shapes like Bugles (horns) or Sala Sticks.
04
Continuous Frying
Products enter the automatic fryer. Oil temperature (170-180°C) is precisely controlled to ensure golden color and crispy texture without burning.
05
De-oiling & Seasoning
Excess oil is removed via vibration or air knife. Then, seasoning powder is applied in a rotating drum for uniform flavor coating.
06
Cooling & Packing
Fried snacks must be cooled to room temperature to maintain crispiness before being packed by a vertical packaging machine.
Precision Shaping & Frying Technology
From dough sheeting to golden frying, every machine is optimized for wheat flour based snacks.
Step 01: Dough Extrusion
Twin Screw Extruder
The LY-75 Twin Screw Extruder is configured to mix wheat flour and water into a consistent dough. Unlike pellet machines, it is equipped with a special Slot Die to extrude a continuous, flat dough sheet ready for shaping.
Uniform Sheeting
Precise Temp Zones
Alloy Steel Screws
PLC Touch Control
Step 02: 3D Shaping
Composite Shaping Machine
The most critical unit. It features a traction system to pull the dough sheet and a Rotary Cutter to emboss patterns and cut shapes. By changing the roller, you can switch production from Bugles (Horns) to Sala Sticks or Pizza Rolls in minutes.
Interchangeable Rollers
No Burr Cutting
Pattern Embossing
High Speed Output
Step 03: Crispy Frying
Continuous Automatic Fryer
Direct frying creates the crispy texture. Our fryer features a Double Mesh Belt design to keep products submerged in oil, ensuring uniform cooking. The integrated oil filtration system extends oil life and ensures a clean taste.
Double Mesh Belt
Auto Temp Control
Oil Residue Filter
Belt Speed Control
Endless Shapes, One Line
From the classic 3D horn to savory sticks. By simply changing the cutter on the shaping machine, you can produce a wide variety of fried wheat snacks.
Classic 3D Horn
Crispy Bugles
The most popular shape. A hollow cone with ridges, perfect for dipping. Created by our specialized high-speed rotary cutter.
Extruded Stick
Sala Sticks
Crispy, hollow, or solid sticks often flavored with tomato or vegetable seasoning. A favorite finger food for children.
Traditional
Rice Crust (Guoba)
Square, flat chips with a harder crunch. Often made from a rice and wheat flour blend for a traditional Asian snack flavor.
Double Layer
Pizza Rolls / Pillows
Made by sandwiching two dough sheets together. The edges are sealed, creating a puffed “pillow” shape that is airy inside.
Twisted Shape
Fried Twists
Spiral or twisted shapes that hold seasoning powder exceptionally well in their grooves.
Kids Shapes
Animal Shapes
Fun shapes like small fish or bears, achieved with custom-designed cutter rollers. Ideal for the children’s snack market.
Technical Specifications
Standard configurations for our Fried Salad & Bugles lines. All contact parts are made of food-grade Stainless Steel 304.
| Model | Extruder Type | Capacity | Total Power (Electric) | Line Dimensions (L*W*H) |
|---|---|---|---|---|
| LY-65 | Twin Screw | 120 – 150 kg/h | 95 kW | 22 x 1.2 x 2.2 m |
| LY-70 | Twin Screw | 200 – 260 kg/h | 145 kW | 25 x 1.5 x 2.2 m |
| LY-85 | Twin Screw | 400 – 500 kg/h | 210 kW | 30 x 1.5 x 2.5 m |
Energy Saving Tip:
Frying requires significant heat energy. The “Total Power” listed above assumes electric heating. To reduce operational costs by up to 40%, we highly recommend configuring the fryer with a Natural Gas or Diesel Burner system.
Not sure which capacity fits your market? We can provide a detailed ROI Calculation comparing electric vs. gas frying costs.
Request Cost AnalysisProfit Stability vs. Volatility
Investing in a fried flour snack line offers a predictable cost structure compared to fresh potato processing, ensuring stable margins year-round.
Fresh Potato Processing
High Volatility
- Price Fluctuations: Raw potato prices change seasonally, impacting your profit margins unpredictably.
- Storage Issues: Fresh potatoes rot quickly and require expensive climate-controlled warehousing.
- Water Waste: Washing and peeling consume massive amounts of water, increasing environmental costs.
Bugles / Flour Snack Line
Stable & Efficient
- Stable Cost: Wheat flour and starch prices are globally stable. You can calculate your profit 12 months in advance.
- Easy Storage: Flour has a long shelf life and requires only basic dry storage. Zero spoilage loss.
- No Water Waste: It’s a dry mixing process. No washing or peeling required, making it eco-friendly.
20-Minute Cycle
Flour to Bag in 20 Minutes. This is a continuous, high-speed line. Fast production cycles mean faster cash flow turnover compared to fermentation processes.
Product Versatility
One extruder + interchangeable cutters = Multiple Products (Bugles, Sticks, Pizza Rolls). You can adapt to market trends without buying new machines.
Space Saving
Unlike pellet lines that need 30-meter drying tunnels, this line is compact (approx 25m total). It fits easily into smaller workshops, reducing rental costs.
Live Factory Gallery
Real on-site photos of our fried salad and bugles production lines installed worldwide.
What Our Clients Say
Real feedback from snack manufacturers who have successfully installed our frying lines.
“
I must thank Shandong Loyal for sending technicians to help teach us how to use the machine. Anyone interested in doing business about food, whether it is instant noodles, snacks, or frying machines, can contact this company for advice. They have a skilled team and warm hospitality.
“
Your company’s machine is very good, best service. I have recommended it to my friend, and you will receive his order soon.
Why Choose Loyal?
In fried snack production, the difference between “premium” and “low-end” lies in oil control and shaping precision. We master both.
Crispy, Not Greasy
Excess oil kills the taste. Our line integrates a powerful Vibration De-oiling System immediately after the fryer to remove surface oil, keeping snacks light and crunchy.
Burr-Free Cutting
A rough edge makes snacks look cheap. Our Composite Shaping Machine uses high-hardness alloy rollers to ensure every Bugle and Sala Stick has a Clean, Sharp Cut.
Oil Cost Saving
Frying oil degrades quickly. We equip our fryers with an Automatic Oil Filtration System that continuously removes residue, extending oil life and reducing waste.
PID Temp Control
Fluctuating temperatures lead to inconsistent color. Our PID control system maintains oil temperature within ±2°C accuracy, ensuring uniform golden color for every batch.
Frequently Asked Questions
Common questions about producing fried wheat flour snacks.
What creates the best texture: Wheat Flour or Corn Flour?
For Bugles and Sala Sticks, Wheat Flour is the primary ingredient. It creates a smooth, elastic dough sheet that puffs nicely when fried. Corn flour can be added (10-20%) for flavor, but wheat flour provides the necessary structure for 3D shaping.
How do I change the product shape from Bugles to Sticks?
The shape is determined by the Roller Cutter on the Shaping Machine. We provide different rollers (Horn, Stick, Fish, Chip). Changing a roller takes about 20-30 minutes, allowing you to produce multiple products on one line.
How are “Double Layer” snacks (Pizza Rolls) made?
The Twin Screw Extruder is equipped with a special die that extrudes two parallel sheets of dough. These sheets meet at the Shaping Machine, where the roller crimps the edges together, trapping air inside to create a hollow “pillow” shape.
How often do I need to change the frying oil?
With our Continuous Oil Filtration System, you rarely need to discard oil completely. The system filters out crumbs and residue in real-time. You only need to top up fresh oil to replace what is absorbed by the product.
Which heating source is most cost-effective for the fryer?
We strongly recommend Natural Gas or Diesel burners for the fryer. Electric heating consumes significant power for large-capacity lines. Gas burners can reduce your operational energy costs by 30-50% depending on local utility rates.
Want to see the Roller Options?
Download our accessory catalog to see the full range of shapes available for the Composite Shaping Machine.
Download Shape Catalog