Extruded Bran, Wheat & Corn Flakes

Extruded Bran, Wheat & Corn Flakes schematic

1. SBX Master™ Extruder

Ingredients are texturized and cooked through a combination of heat, mechanical shear and moisture addition.

2. Forming Extruder

A second extruder forms the product.

3. Pellet Conditioner

Conditions the product for handling.

4. FlakeMaster™ Flaking Roll

Consistent flake quality is achieved using the Baker Perkins FlakeMaster™ flaking rolls.

5. Thermoglide2™ Toaster

Controlled toasting and drying of the flakes takes place in the Baker Perkins Thermoglide2™ toaster where the fluidized bed process minimizes product damage.

6. Syrup Coating System

Cereals are glazed or coated by atomized spraying systems and rotating drum before the product is dried.

7. Dryer

A final dryer is specified to dry the coated products.

  • Extruded Flakes

    Twin-screw extrusion brings flexibility and low production costs to the product of breakfast cereal flakes.

    Extruded flakes are made from flours and other powdered ingredients that require no preparation or pre-conditioning on site. Instead, they are fed directly to a twin-screw extruder with a barrel extension for cooking

    The ingredients are fed into one end of the enclosed extruder barrel. At the same time, the liquid feed system meters process liquids into the barrel. These ingredients are conveyed along the extruder barrel by the forwarding action of the screw elements. During this process they are subjected to a combination of heating, cooling, mixing and shearing.

    There are then two process options. A new technique involving an extended extruder barrel with a super-cooled final section enables pellets to be formed using a single extruder. This provides a compact system suitable for the majority of extruded flakes.

    For high output and some multigrain products, separate cooking and forming extruders will continue to be the preferred option. The cooked mass is discharged through a pipe die to a second extruder for forming and discharged through a plate die where it is cut into pellets.

    In both processes, each pellet will eventually become an individual flake. The pellets are conveyed by pneumatic line to a conditioner where they are held for a short time to allow their moisture content to equalize.

    The pellets are fed into the Flake Master™ Flaking Roll Unit at a controlled rate, via a vibratory feeder. The rate is carefully controlled and matched to the roll speed to ensure that the pellets are well spaced as they are flaked to avoid forming doubles.

    The thickness of the flakes is determined by the gap between the flaking rolls. Too thick and they will not have the characteristic crunch of a good flake: too thin and they are likely to burn during toasting. The gap is set and maintained by a high-speed monitoring and control system that uses hydraulic actuators to ensure that they rolls are neither forced apart by the pellets passing through nor move together if there is a gap.

    The flakes are toasted and dried in a Thermoglide2™ Toaster. A bed of flakes is built up on a vibratory conveyor that passes beneath a bank of nozzles through which air is blown at high speed. This fluidizes the bed of flakes and gently lifts and tumbles them to remove excess moisture and toast the surface to enhance the flavour and colour.

    If flakes are to be frosted or glazed they are conveyed to a revolving coating drum that keeps them gently turning in a sugar syrup spray. The final process is drying and cooling.

  • Required Equipment
    Extrusion & Co-Extrusion  








    SBX Master™ Extruder



    Cereal Forming  





    FlakeMaster™ Flaking Roll


    Cereal Toasting  







    Thermoglide2™ Toaster

    Syrup Coating  







    Preparation & Coating Systems


Brochure: Breakfast Cereals

Brochure: Breakfast Cereals

Extruded Flake Products

Extruded Flake Products

View some of the extruded flake products that can be made on Baker Perkins' cereal process lines.

Cereal Master EX™

Cereal Master EX™

Expandable modular process lines for a wide variety of extruded and co-extruded breakfast cereals.

Cereal Innovation Centres

Cereal Innovation Centres

Baker Perkins offers all its customers facilities to develop new products and processes, produce samples for test marketing, and conduct feasibility trials.