Breakfast Cereals.
Production plants from a single source.
Proven cooking and forming processes...
Integral element of the production process.
Cooking and forming of breakfast cereals Forming and cutting
Breakfast cereals have become firmly established on breakfast Cutting can be accomplished directly at the die face or farther
tables almost all over the world. In addition to a wide variety downstream in a separate cutter. Together with the process
of forms, tastes and colours, they are expected today to also conditions prevailing inside the extruder, the suitable die hole
meet stringent nutritional quality requirements. A consistently geometry, the extrusion speed, and the cutting mode determine
high product quality, high operating reliability, and maximum the form and texture of the product. Depending on the require-
efficiency are the most important requirements that state- ments, it is possible to extrude direct-expanded products with
of-the-art production systems must satisfy.To meet them, two- or three-dimensional forms or semi-finished pellets for sub-
Buhler offers its customers a multitude of suitable system sequent indirect expansion. (Co-extruded) cereal pouches filled
components plus the relevant expertise in plant design and by filling mass systems can be neatly formed from the strand of
construction and in process engineering. product in a pillow cutter, producing leak-proof pillows.
Raw materials reception and storage Traditional cooking
Buhler supplies bulk reception and storage systems, Big Bag As a complement to the extrusion process, also traditional
unloading stations, or manual intake hoppers with high-preci- cooking stages can be integrated. Whole grain or coarse grain
sion proportioning elements and reliable conveying systems, fractions can be cooked to the point with the necessary clas-
which offer flexible and hygienic handling of raw materials. sification and involving minimum shearing. Batch cooking offers
the right alternative to the fully continuous process especially for
Raw material blending and mixing corn (maize), wheat or multi-grain products.
Different levels of automation cover functions such as product
retracing or logging of production statistics according to spe- Cold-forming, flaking
cific needs, manpower requirements, or legislation. Beside the cooking process with subsequent forming at the
extruder die face, Buhler also offers two-stage cooking process-
Extrusion processes es. In these, cooking and final forming are separately performed
Extrusion is the most frequently used process for cooking in two machines. Two common representatives for indirect-
and for complete or partial forming of cereal products. As an expanded cereal processes are single-screw extrusion and
HTST (High Temperature Short Time) process, extrusion is a flaking by rolls. Single-screw extrusion with vertical face cutting
comparatively gentle process. As it uses a minimum of water, is applied for making high-precision products and/or when high
it is a low-energy process and therefore ecological as well as throughputs are involved. For rolled breakfast cereals, Buhler
economical. Using steam and water, the premixed solids are offers its tried-and-tested flaking roller mills.
fed into the process. They are partially heated almost to boiling
temperature using an additional preconditioning stage and Thermal treatment
precooked more or less intensively, depending on the water Browning, expansion degree, texture, surface structure, true-
content and the selectable retention (dwell) time. If required, ness of form, storage stability, flavor, and numerous other char-
the taste-imparting substances are also added to the precon- acteristics are essentially controlled by thermal treatment. The
ditioner stage in order to promote aroma reactions as early as functions of hot-air conveying, predrying, tempering, toasting,
during this stage. This allows the raw materials to be cooked puffing, cooling, and final drying offer a multitude of solutions
with the introduction of more or less mechanical energy as a which must be carefully matched.
function of the product. The water content and the tempera-
ture-versus-time profile can be precisely set. This enables Coating
accurately defined and consistent product qualities to be Liquids metering and solids proportioning units allow the ap-
obtained within a broad variation range. Additional colorants, plication of fat- or water-based solutions in combination with
flavouring agents or mineral additives enhance the visual and spices, nut slivers, etc. These systems guarantee a wide variety
taste-related attractiveness of the products as well as of solutions, thanks to heatable or coolable drum types: Even
their nutritional value. critical applications such as high-Brix coating up to 95 Brix are
possible.
BUHLER Pasta & Extruded Products Breakfast Cereals
... for high-value breakfast cereals.
Varied characteristics in shape and color.
Direct-expanded cereals
Widespread traditional products as well as customized shapes. The pro-
cess, for which a patent is pending, also allows simultaneous production
of different colors. If required, products may also be spray-coated.
Expanded flakes
Cornflakes or wheat, rice, and multigrain flakes etc. produced by the
same processes: extrusion or traditional cooking. Spray-coating is also
possible, e.g. with sugar syrup or dry ingredients such as nut slivers.
Indirect-expanded cereals Co-extruded cereals
Puffed products made from extruded pellets or whole grain Water- or fat-based fillings in direct-expanded cereal
such as corn (maize), wheat, or rice. Spray-coating and envelope. Very wide variety of shapes, surface structures,
coloring are also possible. colors, and textures.
BUHLER Pasta & Extruded Products Breakfast Cereals
Integral customer solutions.
From intake to shipping.
Storage Mixing Predryer Toasting Coating
Maintenance Extrusion Flaking Drying
Weighing Cooking Packaging
Shaping
Extensive range of services.
From engineering to training.
Extrusion pilot plant Training of customer personnel
The functional extrusion pilot plant supports practical develop On your request Buhler offers you a personnel training on site
ment of new products, processes, and equipment, comple- also the opportunity to perform the training in our pilot plant.
menting scientific approaches to problem solutions. You take profit of the highly diversified program, executed by
Various process stages can be simulated here either in isola- our specialists.
tion or in a wide variety of combinations.
Customer service
Engineering Our engineers and service specialists are available for onsite
Our project engineers will ensure smooth handling of your consulting, ensuring troublefree operation of our equipment
order, making sure our systems are seamlessly integrated in throughout its service life. This concept is supported by a
your production environment. worldwide, efficient spare parts service.
Installation and start-up
The installation and startup specialists of the “Pasta and
Extruded Products” business unit guarantee competent
installation and construction site management and a smooth
commissioning to startup.
Core elements from Buhler.
The crucial process operations.
Batch Cooker BSTC
The BSTC is applied to processes including traditional (discontinuous) cooking
of whole grain or coarse fractions. The compact rotary drum cooker is an all
stainless steel construction. Its 1,700 l pressurized vessel is designed to receive
batches of up to 800 kg. The component is installed as a complete module
with fittings and a separate operator’s panel. A PLC control system ensures ac-
curate and stable process conditions over the entire automated cooking cycle.
Preconditioner BCTC
The preconditioning concept is based on a separation of the overall process
into two stages: A highly efficient raw component mixing-steaming-heating unit
and a retention unit with an adjustable residence time. Available in 6 sizes, the
pre-conditioner can cover a wide range of process requirements with respect
to residence time and throughput. Thus, the BCTC is especially suitable for
indirect expanded products.
Twin-Screw Extruder BCTA
The modular twin-screw extrusion system offers highest flexibility for continuous
mixing, cooking and forming steps. Fine mechanical engineering and an inte-
grated PLC control system allow for stable process conditions. Moreover, the
elaborate construction ensures easy adaptation to different products and pro-
cesses. All together the BCTA series is an effective tool to meet today’s but also
future quality and production needs.
Single-Screw Former BCXA/BCXO
A century of experience in pasta process technology stands behind the latest
single-screw former design. Dedicated to the production of sophisticated break-
fast cereals, this tool combines the features of the successful BCTA twin-screw
cooking extruder with those of the cold extrusion technology applied to pasta
processing. Sanitary design, careful material selection for the components and
optimized screw and die geometries result in optimum product quality and
operational reliability.
Flaking Roller Mill BCFA
A steady and focused further development has created the latest Buhler flaking
tool. While adding modular functions onto the platform as requested an optimum
match of the equipment to the customer’s needs is guaranteed. Improved ef-
ficiency, reduced maintenance time, sanitary design and a number of features
to control product quality ensure a safe and economic production of flaked
products.
Coating Drum TNBB
The coating drum adds a sweet, savoury or coloured finish to the product in an
ultimate step prior to drying/packaging. It is suitable for breakfast cereals such
as flakes and extruded products. Paired with the liquid preparation and dosing
system, various water and fat based solutions are applicable. An added-on solid
dosing system may refine your product further. Sanitary design and stainless
steel construction allow for wet cleaning.
BUHLER Pasta & Extruded Products Breakfast Cereals
PE 55026 en 1106 2000 DF
Bühler AG
CH-9240 Uzwil, Switzerland
T + 41 71 955 11 11
F + 41 71 955 33 88
E-Mail: extrusion@buhlergroup.com
www.buhlergroup.com
