Industrial Breakfast Cereal System
Corn Flakes & Breakfast Cereal Production Line
Produce premium, Crispy Corn Flakes and varied breakfast cereals with one versatile system. Engineered for perfect Flaking and High-Temp Toasting.
Mastering the Crunch:
Extrusion & High-Temp Toasting
Producing premium corn flakes is more than just flattening dough. The challenge lies in creating the signature “Bubbling Effect” and lasting crispiness that prevents the cereal from getting soggy in milk immediately.
Loyal utilizes a Twin-Screw Extrusion + Flaking process. Unlike traditional batch cooking, this method allows for continuous production and precise moisture control.
The “Soul” of the line is the High-Temperature Toaster. It blasts the flakes with 300°C hot air, instantly expanding the structure to create that golden, crispy texture consumers love.
One Line, Two Products
Maximum ROI.
By simply bypassing the flaking mill, this line transforms into a standard puff snack line, capable
of producing Coco Pops, Froot Loops, and Grain Puffs.
Golden Bubbling Effect
Premium Crispiness.
Our high-temperature toaster utilizes intense airflow to blister the flake surface, creating the
authentic “Kellogg’s-style” texture and caramelized flavor.
Precise Flaking
Uniform Thickness.
The heavy-duty flaking mill features a hydraulic adjustment system and water-cooling rollers to
prevent sticking, ensuring every flake is perfectly thin.
Process Flow Chart
From raw corn flour to golden toasted flakes. A fully automated line ensuring hygiene and consistent texture.
01
Mixing
Corn flour is mixed with water and other ingredients. The moisture content is critical here to ensure proper gelatinization in the extruder.
02
Extrusion & Pelletizing
The twin-screw extruder cooks the flour and forms small, dense spherical pellets (crystals). These pellets are the foundation of the flake.
03
Flaking
The pellets are passed through a heavy-duty Flaking Mill. Two large alloy rollers press the balls into thin, flat flakes.
04
High-Temp Toasting
The raw flakes enter a high-temperature toaster (approx 300°C). The intense heat causes them to blister and bubble, creating the crispy texture.
05
Sugar Coating
(Optional) The toasted flakes are sprayed with sugar syrup, honey, or chocolate in a rotating drum for flavors like “Frosted Flakes”.
06
Drying & Cooling
A final drying step sets the sugar coating, followed by cooling to room temperature before packaging to ensure crunchiness.
Technology for the Perfect Crunch
The difference between premium corn flakes and ordinary cereal lies in the equipment. We use heavy-duty flaking and high-temperature airflow technology.
Step 01: Precision Pressing
Hydraulic Flaking Mill
This massive machine uses two high-hardness alloy rollers to press pellets into thin flakes. Crucially, it features an Internal Water Cooling System to prevent the sticky corn dough from adhering to the rollers, ensuring uniform flake thickness.
Hydraulic Gap Adjustment
Anti-Stick Water Cooling
High-Hardness Alloy Rollers
Non-Stop Operation
Step 02: Creating Texture
High-Temp Jet Air Toaster
Ordinary dryers cannot make corn flakes. Our specialized toaster generates intense heat (up to 300°C) with powerful airflow. This thermal shock instantly expands the flake, creating the signature Bubbled Surface and crispy texture that defines high-quality cereal.
300°C High Temperature
Jet Air Circulation
Bubbling Effect Guarantee
Gas/Diesel/Electric Options
Step 03: Flavor Application
Auto Sugar Coating System
To produce “Frosted Flakes” or “Coco Pops”, this double-drum system sprays high-temperature syrup or chocolate onto the cereal as it tumbles. The integrated Hot Air Feeder ensures the syrup spreads evenly without clumping.
Precision Spray Nozzles
Double-Drum Tumbler
Variable Speed Control
Optional Powder Feeder
Product Versatility
From traditional flakes to extruded puffs. One production line covers the entire breakfast cereal aisle.
Flaking Process
Classic Corn Flakes
The gold standard. Thin, blistered flakes with a toasted corn aroma. Requires the heavy-duty flaking mill.
Sugar Coated
Frosted Flakes
Coated with a crystallized sugar syrup for extra crunch and sweetness. Processed through the coating drum.
Direct Expanded
Coco Cereal Balls
Produced by bypassing the flaking mill. The extruder directly puffs the corn/rice flour into spherical shapes.
Ring Shape
Puffed Corn Squares
Direct expanded into crisp square pillows. Extruded from corn grits, cut and toasted for even crunch.
Custom Mold
Custom Shapes
Stars, moons, or letters. Easily changeable die molds allow you to target the children’s cereal market.
Appetizing
Ready-to-Eat
The final product stays crispy in milk. This high-quality texture is the key to competing with major brands.
Technical Specifications
Industrial-grade systems featuring heavy-duty flaking mills and high-capacity roasting ovens.
| Model | Output Capacity | Main Motor Power | Total Installed Power | Line Dimensions (L*W*H) |
|---|---|---|---|---|
| LY-65 | 120 – 150 kg/h | 30 kW | 120 kW (Approx) | 38 x 1.5 x 2.2 m |
| LY-70 | 200 – 250 kg/h | 45 kW | 160 kW (Approx) | 45 x 1.5 x 3.0 m |
| LY-85 | 400 – 500 kg/h | 132 kW | 280 kW (Approx) | 56 x 2.0 x 3.5 m |
* Important Energy Note: The “Total Installed Power” listed is for fully electric heating.
By choosing Gas or Diesel for the High-Temp Toaster and Dryer, you can reduce the
electricity load by up to 70%.
Hydraulic Roller Adjustment
Siemens/Schneider Electrics
Full Stainless Steel 304
Need a factory layout? Because this line is long, we offer customized layout design to fit your L-shape or U-shape workshop.
Get Custom LayoutWhy Switch to Extrusion?
Traditional batch boiling is energy-intensive and slow. Loyal’s Twin-Screw Extrusion technology offers a continuous, efficient, and versatile alternative for modern cereal production.
Traditional Method
Batch Steam Cooking
- High Energy Cost: Requires massive boilers and steam consumption.
- Slow Process: Requires hours of “Curing/Tempering” for moisture equilibrium.
- Limited Shapes: Only produces basic flakes; cannot make complex puffed shapes.
- Large Footprint: Requires huge curing silos and space.
Loyal Technology
Twin-Screw Extrusion
- Energy Efficient: Uses friction heat and precise electrical heating.
- Continuous Flow: Raw material to finished product in 45 minutes. No curing needed.
- High Versatility: Makes Flakes, Loops, Balls, Stars on the same line.
- Compact Design: Integrated process saves up to 40% floor space.
Premium Pricing
Corn flakes command a retail price 2-3x higher than standard puffed snacks, offering significantly higher profit margins per ton.
High Repeat Purchase
Breakfast cereal is a daily staple in many households. Brand loyalty leads to consistent, recession-proof sales volume.
Product Diversification
Target adults with healthy corn flakes and children with sweet, colorful froot loops using the Same Equipment.
Live Factory Gallery
Real on-site photos of our corn flakes production line and breakfast cereal equipment.
What Our Clients Say
Reliability and craftsmanship are why cereal manufacturers choose Loyal.
“
The quality and craftsmanship of the equipment are excellent. It exceeded my expectations and it was a perfect transaction.
“
It has been a very pleasant experience working with Loyal Company. They provided excellent machines and service. Although we have a 7-hour time difference, Loyal Company’s after-sales support was always able to respond to any questions we had while we were working. I believe we will cooperate in the future.
Why Choose Loyal?
Corn flakes production is technically demanding. We address the common issues of sticking rollers, uneven thickness, and soggy textures with precision engineering.
Anti-Stick Rollers
Sticky corn dough is a production nightmare. Our rollers feature an internal Water Cooling System and specialized scrapers to prevent adhesion, ensuring continuous operation.
0.05mm Precision
Uniform thickness equals uniform baking. Our flaking mill uses a Hydraulic Adjustment System to control the roller gap with 0.05mm accuracy, guaranteeing consistent flakes.
Long-Lasting Crunch
To stop cereal from getting soggy, our High-Temp Toaster creates blisters (bubbles) on the flake surface. This structure resists milk absorption for a longer crunch.
No Clumping
Our coating drum integrates a Hot Air Feeder. This dries the syrup spray instantly upon contact, ensuring flakes are coated individually and don’t stick together in lumps.
Frequently Asked Questions
Expert answers on raw materials, dual-functionality, and energy costs.
What raw material should I use: Corn Grits or Corn Flour?
For our twin-screw extrusion line, we recommend using Corn Flour (60-80 mesh). Unlike traditional batch cooking which uses large grits, flour allows for faster gelatinization and a more uniform texture in the extruder.
Can this line also produce Coco Pops or Froot Loops?
Yes. This is a major advantage. We install a “Bypass Conveyor” next to the Flaking Mill. When you want to make puffed cereals (balls, rings, stars), the product skips the flaker and goes directly to the dryer/coater. One line, two functions.
How do I adjust the thickness of the corn flakes?
The Flaking Mill is equipped with a Hydraulic Adjustment System. You can precisely control the gap between the two rollers (e.g., from 0.1mm to 1.0mm) via the control panel or handwheel to change the flake thickness instantly.
The High-Temp Toaster consumes a lot of power. How can I save costs?
High-temperature toasting (300°C) is energy-intensive but necessary for quality. To reduce operational costs, we strongly recommend choosing Natural Gas or Diesel Burners instead of electricity, especially if your local electricity rates are high.
Why are my flakes hard and not crispy?
Hard flakes usually mean the “Bubbling” (blistering) didn’t happen. This is caused by insufficient heat in the toaster. Ensure your High-Temp Toaster reaches the target temperature (approx 300°C) to create the thermal shock that expands the flake surface.
Planning a Cereal Factory?
We can provide a detailed ROI analysis comparing “Flake Production” vs “Puff Production” costs.
Request Analysis