Corn flakes production is a capital intensive and lucrative venture. The chips are regarded as nutritious healthy food because of the added nutrients. It is a popular breakfast cereal eaten worldwide in developed and developing countries.
Highly commercial the billion dollar industry is highly competitive. Common raw material in flakes production is corn, blended flavor, salt, sugar. Corn flakes is eaten raw, added to milk or sugar and eaten for breakfast.
Raw materials in corn flakes production
It is important for a manufacturer to locate the business close to huge supply of corn (maize). Alternately factor transportation from farm and situate the factory in commercial district.
Raw material in the production process are corn flour (maize flour), corn (maize) corn starch, de-germed corn grits mixed spices. Other commonly used raw material are oats barley, wheat or rice. More are colorants, minerals, vitamins, flavoring agents, preservatives. Sweeteres in the production process are corn syrup, white sugar spices, different flavors, brown sugar.
- corn flour (maize flour)
- corn starch
- degermed corn grits
- mixed spices
Things to Consider
Startup considerations involves funding, writing a business plan and competitive analysis. Others are labor requirements, location of factory, type of equipment, where to purchhase raw materials. more challenges include marketing, bramding, incorporation and tax.
- writing a business plan
- competitive analysis
- labor requirements
- location of factory
- type of equipment
- where to buy raw materials
- incorporation and tax
The cost of manufacturing machinery is no cheap and requires adequate funding. There are major manufacturers of corn flakes making machinery in China. Funds are needed to purchase, build or lease factory, buy equipment, secure operational license, purchase raw materials.
A small, medium or large enterprise requires from 2 to 7 people to operate the machinery. Other labor requirements are sales representatives, factory manager, receptionist, marketers, accountant, managing director and driver.
- Machine operator
- Sales representatives
- Factory manager
- managing director
There are two viable locations for food and beverage companies. Locate the factory close to the market base or farmers. Make sure the choice of location as good utilities, labor, road network and security.
To compete favorably with existing brands funds are used for marketing and market penetration. Secure funds from commercial or trade bank loans or venture capitalists. Other funding sources are crowdfunding, partnership, sale of part equity of the company.
Regarding licensing register a business name and as a limited liability company. There is tax identification number, insurance, operational license, certification/ inspection from National Agency for Food and Drug.
It is important to join the national association of manufacturers. There are also land use and local government laws guiding the enterprise.
Corn flakes extruding line
In order to produce corn flakes the investor needs to invest in high speed extruding line. Corn flakes production is capital intensive because the line is both automated and manual. A small/medium sized extrude line operation requires 2-4-7 workers.
Capacity requirements are 150kg/hr – 320kg/hr-1200kg/hr, power 97.52kw-170.14kw-250KW-380kw. Dimensions 45x5x3m-56x5x3m.standard configuration popular brand name Siemens or WEG motor, electric parts Schneider or Delixi,
Touch screen Siemens materials is stainless steel. High speed corn flakes systems are alloy steel roll, hydraulic control system and high strength frame. Others include cooling constant temperature system, auto adjust roll system, transmission systems.
Machines needed are the twin-screw extruder, vacuum transporter, mixer, fluid-bed dryer pre-drying. Others are flaker distributor, double period conditioner, flaker and flaking roller. More are a fluid bed toaster, coating final dry systems, transfer storehouse and transportation after flaking.
Corn flakes production machines
- Touch screen
- Stainless steel
- Alloy steel roll
- Hydraulic control system
- High strength frame
- Cooling constant temperature system
- Auto adjust roll system
- Transmission systems
- twin-screw extruder
- vacuum transporter
- fluid-bed dryer
- flaker distributor
- double period conditioner
- flaking roller
- fluid bed toaster
- coating final dry systems
- automated packaging machine
- transfer storehouse
- transportation after flaking
The Manufacturing process
The manufacturing process starts with grain preparation, making flaked cereals/shredded cereals/puffed cereals/other types of cereals.
How to make corn flakes
To produce corn flakes it goes through eight processes. It starts with the mixing of the raw materials then extruding process before drying. Next stage is the toasting, coating sugar, drying and cooling. To achieve quality product use hard dent corn.
The drying degermed method of production involves regulating moisture content with hot water not exceeding 90C and hot steam. Degermed corn is then pre-ground to separate grits add malt, salt. Other ingredients during cooking stage.
Make water content 35% cook steam till gelatinized material is transparent. Dry extruded grits 66C moisture 20% cool at 40C press flakes 0.7-1mm.
Disperse chips evenly for better results and roast 250-350C for 20-150 seconds to attain moisture content of 10%. then fry chips at temperatures not exceeding 200C. Use spraying enhancer with nutrient substance to intensify flavor, sugar or spread.
How to Make Shredded cereals
Shredded cereal is produced from wheat cooked in boiling water. Once moisture has penetrated the grain it is cooled and tempered. Then it proceeds to metal rollers for shredding then shredded wheat is cut, baked.
How to Make puffed cereal
Puffed cereal is made from rice or wheat that iis cooked, cooled and dried. The rollers are used to partially flatten the flaked cereal. After bumping the rice is dried then introduced to an oven.if wheat is the main ingredient they go through a pretreatment process to partially remove outer layer oof bran. To puff the grain they are placed in a small vessel with hot steam at very high pressure. A pressure is released technique causes the grain to assume a puffed cereal.
The type of coating added depends on the recipe and manufacturers choice. Added coatings include vitamins, flavors, fruit juice, preservatives sweeteners or colorants. Spraying thick syrup of sugar in a rotating drum is a standard practice for white layer frosting.
It is mandatory to abide by NAFDACs guidelines on food for human consumption. The factory is inspected by the regulatory body including raw materials, manufacturing process and health certificate for workers. The product undergoes quality control throughout the production stage till packaging and storage.
The packaging should be moisture proof highly resistant to environmental conditions. Most companies use cardboards lined with plastic in airtight water proof containment. Packaging is automated to reduce contact with workers and assure good quality control.
Corn flakes industry is very competitive and challenging. A small/medium enterprise will compete with industrial giants. Marketing considerations include unique branding, quality product and advertisement. Use television advertisement, radio, social media, website and print media.