Case Note — 2021 Collaboration (BellaEx × Chengkai Group)
In 2024, BellaEx partnered with Modern Dairy to design, build, and commission a 10 TPH steam-flaked corn line for Chenkai Group (Changchun, Jilin).
The line is organic-ready and winterized to −22 °F (−30 °C), integrating inline moisture measurement, sealed steam conditioning, continuous roller flaking, and a single-deck dryer-cooler with rotary spreader. Outcome: uniform, market-ready flakes with predictable moisture and starch gelatinization for stable ADG and lower cost per cwt of gain.
Project Highlights
- Capacity: 10 TPH continuous
- Application: Organic cattle feed — steam-flaked corn
- Scope: Receiving → Cleaning → Soaking/Tempering → Steam Conditioning → Flaking → Drying & Cooling → Finished Handling
- Compliance: Hygienic contact surfaces, enclosed conveying, dust/foreign-matter control
- Value: Tight moisture control, reduced variability, shorter building/CapEx, cold-climate uptime
Chenkai Group (formerly Changchun Construction Investment Company, founded 1991) is a state-owned enterprise under Changchun SASAC. Reorganized in 2001 and again in October 2020 as Changchun City Development Agricultural Investment & Development Group Co., Ltd., the group operates across urban-rural infrastructure, asset operation, finance/investment, and modern agriculture. As of end-2020, total assets reached RMB 50.5B with an AAA credit rating, supported by 8 HQ departments and 17 subsidiaries/branches—positioning the client to scale integrated agri-projects from genetics and feed through slaughter and cold-chain.
Equipment configuration: a three-stage line—stone remover, vibrating screen, and magnetic separator—to remove impurities, gravel, and metal debris.
We use Bühler’s three-piece water-addition suite—an inline moisture sensor, a dosing controller, and a sanitary injection manifold—to monitor corn moisture in real time and meter make-up water precisely.
Process Flow
- Inline Measurement & Water Dosing: As whole corn enters tempering, the inline sensor reads kernel moisture continuously. The controller drives the dosing valve/pump so the actual moisture tracks the target setpoint in real time.
- Soaking (Tempering) in the Soak Bin: Condition the grain in a dedicated Soak Bin for 10–18 hours (adjust by raw-material condition and target kernel moisture). This step equalizes moisture across the endosperm and pericarp for downstream stability.
- Steam Conditioning (Steam Chest): Convey tempered corn to the Steam Conditioner. Here we recycle the soak water as process water for conditioning to reduce utility cost and waste. We recommend purified water at approximately 122–140 °F (50–60 °C) for consistent results and clean operation.
Soaking, Steam-Seal, and No-Surge Flow—Built for Clean, Low-Capex Operation
Soaking (Tempering). We temper whole corn in a controlled Soaking step to equalize kernel moisture before cooking. The temper is set to the target moisture for downstream stability; residence time is adjusted to the raw corn condition and the flaking spec.
Zero Steam Carryover by Design. To keep the Steam Conditioner tight and efficient, we install a stainless-steel rotary airlock at the outlet. The airlock locks steam inside the conditioner, maintaining temperature and moisture where they matter, and prevents backflow of vapor into the upstream water-addition screw conveyor. Result: cleaner dosing, steadier cook, and less condensate where you don’t want it.
No Buffer Bins—Lower Roof, Lower Budget. We eliminate all intermediate buffer/surge bins between tempering and conditioning. This brand-new flow scheme saves at least 1.5 m (≈5 ft) of building height, reduces civil works and steel, and simplifies layout and maintenance. The solution is BellaEx proprietary, proven in 80+ customer installations over long-term operation.
What you gain: tighter moisture control, zero fugitive steam upstream, fewer hold-ups, and a shorter, lower-capex line that still delivers stable flakes and repeatable performance.
Flaking: cooked corn discharges directly into the flaking mill for continuous online flaking; roller surface temperature is held at 80–90 °C (176–194 °F). Thickness control: standard feed use is 1.1–1.5 mm with ±0.05 mm tolerance. Custom options include ultra-thin flakes ≤1.0 mm for high-digestibility formulas and thicker flakes ≥2.0 mm to moderate rumen degradation rate.
Single-Deck Dryer-Cooler with Rotary Spreader — Even Bed, Consistent Finish
This project adopts a single-deck Dryer-Cooler to finish steam-flaked corn. Between the Flaking Mill and the Dryer-Cooler, we install a rotary spreader to distribute product uniformly across the deck. The spreader eliminates uneven bed depth, preventing hot spots, channeling, and localized over- or under-drying. Airflow becomes predictable, residence time stays on spec, and outlet moisture and temperature are tighter—run after run.
The selected Dryer-Cooler is built with an SS304 stainless-steel housing for hygiene, corrosion resistance, and long service life in warm, wet environments. The single-deck configuration simplifies access, reduces headroom, and cuts maintenance time, while still delivering the bed stability needed for clean flake handling and reliable storage downstream.
What this achieves: uniform bed formation at the inlet, stable thermal profile through the deck, fewer fines and clumps, and a consistent, market-ready flake at discharge—with a compact footprint and sanitary construction.
Packaging and logistics: bulk storage in vertical silos with moisture monitoring (typical setpoint ≤12%) and compatibility with large-scale feeding systems. Custom packaging is available, including 25 kg woven bags and vacuum-packed one-ton bags.
