Extruded flakes differ from those made by the traditional process, in that grit for flaking is formed by extruding the mixed ingredients through die hole.
Then the cutting off pellets of dough to desired size.
Water is to be added sufficiently for pellet formation and cooking.
The flakes of desirable texture density, size and shape are obtained.
Corn flakes:
The size required for corn flakes is one half to one third of the whole kernel. It is produced by dry milling process. Grits should be free from germ and bran
It is mixed with flavor ingredients and cooked at 15-18 psi pressure for 2 hours.
Cooked mass is dampened, delumped, dried, cooled and tempered.
Flaked and toasted
After cooling the flakes may be sprayed with solutions of vitamins and minerals before packing.
Wheat flakes
The steamed wheat is passed between flaking rollers, it flattens the grain and makes it permeable to moisture.
Flattened kernels are transferred to pressure cooker and sugar, salt, malt and other colouring substances are added.
They are cooked at 20 psi steam pressure for 90 minutes.
Grains are gelatinized
They are dried to 28-31% moisture.
Then further drying to get 21 per cent moisture and a spray of B complex vitamins is done.
Bran flakes
The dry wheat and bran are combined with flavoring syrup consisting of sugar, corn syrup, malt and salt and cooked until the starch is fully gelatinized.
The cooked particles are partially dried, tempered, flaked
Finally toasted to give flakes.
Extruded flakes
These are made from wheat or maize. They are cooked in extrusion cooker and are made from fine meal or flour.
The dry material is fed into extrusion cooker and is joined by a liquid solution of flavoring material, sugar, malt, salt etc.
These are mixed together by rotation of screw and conveyed through the heated barrel and there by cooked.
The material is extruded through the die in the form of ribbons which are cut to pellet size.
Pellets are dried, tempered, flaked, toasted and packed.
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