Matched Screw Profiles — Die geometry and barrel zones are tuned to your exact corn blend, avoiding the density drift that generic builds produce on non-standard grits.
Technical Specifications
| Parameter | Value |
|---|---|
| Model | MT70 |
| Product Type | Corn Flakes Production Line |
| Screw Type | Twin screw |
| Installed Power (MT70) | 160 kW |
| Power Consumption (MT70) | 120 kW |
| Output Capacity (MT70) | 150–200 kg/h (basis not stated in source — confirm raw material / moisture content) |
| Installed Power (MT85) | 190 kW |
| Power Consumption (MT85) | 140 kW |
| Output Capacity (MT85) | 300–400 kg/h (basis not stated in source — confirm raw material / moisture content) |
| Installed Power (MT75) | 210 kW |
| Power Consumption (MT75) | 150 kW |
| Output Capacity (MT75) | 300–500 kg/h (basis not stated in source — confirm raw material / moisture content) |
| Overall Dimensions (MT70) | 41 × 1.5 × 2.2 m |
| Overall Dimensions (MT85) | 43 × 1.5 × 3.2 m |
| Overall Dimensions (MT75) | 45 × 1.5 × 3.5 m |
| Control System | PLC control system |
| Basic Raw Materials | Corn, rice, wheat, oat, barley powder |
| Heating Source (Dryer) | Gas or Electric |
| Flaking Machinery | Hydraulic double-roller system with infrared temperature control |
| Hot Air Roasting Oven | Vibrating pan, conciliation burner, dual circulating fans, cyclone dust removal |
| Coating System | Double tumble sugar melting, elevator, coating drum, spraying nozzle |
| Certification | CE |
Application Suitability
| Application | Material or Output |
|---|---|
| Natural corn flakes | De-germed corn grits, roasted without coating |
| Sugar-coated corn flakes | Corn base with sugar or honey syrup glaze |
| Multi-grain breakfast cereal | Blends of rice, wheat, oat, barley with corn |
| Shaped cereal variants | Ball, tube, ring, star, wheel, flower, heart via die swap |
Why "Rated Capacity" on Corn Flakes Lines Misses the Point
Throughput only holds when the raw material matches the screw and die configuration exactly.
I once watched a corn flakes line lose half its stated output within the first hour. The buyer had supplied standard corn flour for the quote, but the trial used de-germed grits with a completely different gelatinisation behaviour. The barrel temperature profile was wrong from the first zone, expansion collapsed, and flake density climbed outside market tolerance [NEED_CITE: starch gelatinisation thresholds for de-germed vs. whole corn grits]. It took two days of screw reconfiguration and die adjustment to recover. That gap between brochure capacity and actual output is the single most expensive surprise in breakfast cereal projects, and it is why corn flakes extrusion technology specifications must be written against your own raw material, not a generic benchmark.
Barrel Temperature Zones and Gelatinisation Control
Corn starch gelatinises within a narrow moisture-temperature window, and twin-screw extrusion demands that each barrel zone holds within that band. The PLC system on the MT70, MT85, and MT75 allows independent temperature setpoints per zone, so the profile can be stepped to match the specific grit size and moisture of your corn supply. When the feedstock switches from de-germed to whole-grain corn, the profile shifts noticeably — a detail generic builds often ignore.
Screw Element Sequencing for Flake Density
The kneading block arrangement and reverse-element placement determine residence time and shear intensity, both of which govern the expansion ratio entering the flaking rolls. For dense, thin breakfast flakes, the screw sequence favours moderate shear with a longer cooking zone. For lighter puffed cereal variants, the configuration introduces higher-shear elements to promote rapid expansion at the die face. This is the core engineering variable that corn flakes extrusion technology specifications must document before any order is confirmed.
Die Geometry and the Transition to Flaking Rolls
The die orifice shape and land length control the extrudate strand profile before it reaches the hydraulic double-roller flaker. A strand that is too thick will not flatten evenly, producing cracked edges and inconsistent thickness across the batch. The infrared temperature sensor on the flaking rolls keeps surface conditions stable, but the die must deliver a consistent strand first [NEED_CITE: extrudate strand dimensions and flaking roll gap correlation for cereal production]. Die options are swapped to support ball, tube, ring, star, and other cereal shapes without changing the extruder platform.
Reading the Power and Footprint Numbers
Installed power ranges from 160 kW on the MT70 to 210 kW on the MT75, while actual consumption sits lower — between 120 kW and 150 kW — because not every heater and motor runs at peak simultaneously. The overall line length spans 41 m to 45 m depending on model, which means the dryer, roasting oven, and coating drum are sized to match extruder throughput rather than added as afterthoughts. The hot air roasting oven uses a conciliation burner with two separate circulating fans, giving even heat distribution across the vibrating pan and preventing scorched edges on thin flakes.
When the Extruder and Dryer Fall Out of Sync
A corn flakes extruder running at full screw speed feeds a dryer that was quoted for a smaller model. The result is wet, under-dried flakes entering the coating drum, where sugar syrup will not adhere properly and the final moisture specification is missed [NEED_CITE: moisture content tolerances for packaged breakfast cereals]. The coating drum tumbles product that is still too warm, causing sugar to clump instead of forming an even glaze. Every station on this line is specified as a matched set, so the dryer capacity, roasting oven throughput, and coating drum volume track the extruder output without bottleneck or idle time.
Why Buyers Choose This Line Configuration
The screw configuration and die design are specified against your raw material report, not copied from a generic template. Trial runs happen in an in-house testing workshop using your actual corn blend before the line ships, so expansion and density are verified early. The PLC control system stores batch recipes, allowing operators to switch between natural and sugar-coated corn flakes without manual recalibration. Complete line throughput is matched from mixing through packing under one supplier, eliminating the finger-pointing that occurs when separate vendors supply mismatched stations. Electrical schematics and voltage confirmation are completed before production begins, preventing commissioning delays on site.
Documentation & Verification
- Line layout drawing with throughput calculation for your target cereal output
- Screw and die configuration record matched to your corn or multi-grain blend
- Trial run report on your raw material documenting expansion and flake density
- Electrical schematic with voltage and frequency confirmation for your market
- CE declaration of conformity for the complete line
- Operation and maintenance manual with wear parts list for screws, dies, and flaking rollers
Installation, Commissioning & Support
- Foundation must support 41–45 m line length with level tolerance across extruder and flaking stations
- Dedicated power circuit required for 160–210 kW installed load depending on model selected
- Gas or electric dryer option confirmed before installation to match local utility availability
- PLC control system programmed with your recipe parameters during on-site commissioning
- Hydraulic flaking rollers calibrated to your target flake thickness on first production run
- Wear parts stock including screw elements, die inserts, and flaking roller sleeves available at dispatch
What to Include in Your Enquiry
To build a line layout that actually holds its output, share your raw material specification — corn variety, particle size, moisture content — along with your target daily production volume and the cereal shapes you plan to run. Confirm the voltage and frequency standard at your facility, and note whether gas or electric heating is preferred for the dryer and roasting oven. If you have existing upstream mixing or downstream packing equipment, include model details so the interface points can be matched.
Frequently Asked Questions
Q: How is screw configuration adjusted for different corn or multi-grain raw materials?
A: The kneading block sequence, reverse-element placement, and barrel zone lengths are rearranged based on your raw material report. De-germed corn grits require a different gelatinisation profile than whole-grain corn or oat blends, so the screw build is specified per formulation and verified in trial runs before the extruder ships.
Q: What barrel temperature profile produces the correct flake expansion and density?
A: Each barrel zone is independently controlled through the PLC system, with setpoints stepped to match your grain blend and moisture content. The profile is established during the in-house trial run on your raw material, documented in the configuration record, and stored as a repeatable batch recipe.
Q: How do you confirm throughput matching between the extruder, dryer, and coating stations?
A: The line layout includes a capacity calculation for every station. Dryer belt area, roasting oven volume, and coating drum dimensions are sized so none of them throttle or idle relative to the extruder output. This calculation is shared with the buyer before the quotation is finalised.
Q: Can trial runs be done on my specific corn blend before the line ships?
A: Yes. The in-house testing workshop runs your raw material through the configured screw and die set, documenting expansion ratio, strand dimensions, and flake density. The trial run report is provided before shipment so product development begins with verified parameters rather than starting from scratch after installation.
