HIO Steam-Flaked Corn Line | 0.5–2 TPH Ranch/Farm

• Applications: On-farm feed production, feedlot and dairy TMR plants, small commercial mills.
• Materials: Corn (primary), with recipes available for barley and other grains.

Solution Capacity options: 0.5 TPH, 1 TPH, 2 TPH.

• Hole-In-One modular machine—no civil construction; min height ~6 m.
• 5-day installation and start-up; master the system in about 10 minutes.
• Flexible production—steam-flaked corn 50 minutes after warm start.
• Unattended operation—one part-time operator after start-up.
• Uniform flakes with low fines; stainless contact surfaces (SS304).
• Proven components: high-gauss magnet, PLC hydraulic station, easy roll-gap set.

Cleaning – 3-stage line (destoner → vibrating cleaner → magnet) removes stones, fines, and tramp metal; external pre-clean option to reduce dust.

• Removes dust, stones, and ferrous metals to protect rolls and stabilize downstream steam conditioning.
• A typical train includes a vibrating screen, destoner, and a high-gauss magnet to capture hard metal that upstream steps may miss.
• Consistent cleaning reduces fines, prevents roll damage, and improves line uptime in feed mills and ranch operations.

Soaking (optional) – Warm-water spray (40–50 °C), then 8–18 h bin soak for moisture penetration. High-efficiency path: ultrasonic moistening → 4–12 h with moisture gradient ≤2%. For new crop, dry to 17–19% before soak to improve color uniformity and energy balance.

Steam Conditioning (50–60 min)

• Grain is tempered in the steam chest for 50–60 minutes to soften the endosperm and initiate starch gelatinization.
• Counter-flow steam distribution helps the kernel reach target moisture and temperature for controlled flaking (commonly ~18–20% moisture and ~100 °C where specified).
• Stable conditioning delivers predictable flake density and thickness across seasons and grain lots.

Flaking (1.5–2.5 mm)

• Conditioned grain passes through the flaking mill, where online roll-gap control sets thickness at 1.5–2.5 mm according to the recipe.
• Alloy chill-cast rolls and SS304 scrapers keep the roll surface clean, reducing buildup and motor overload risk.
• The result is uniform steam-flaked corn with low fines, optimized for rumen availability and TMR handling.

Optional Drying & Cooling

• A horizontal dryer and cooler reduces flake temperature and brings moisture to storage or feeding targets.
• One-piece stamped ventilation plates and balanced airflow help dry evenly without leakage or dead zones.
• Proper drying and cooling improve shelf life, prevent caking, and protect flake integrity in bins and bags.

TMR Mixing

• Finished flakes are conveyed to the TMR mixer and blended with forage, protein meals, minerals, and additives per your formulation.
• Uniform particle size and moisture support consistent ration density and reliable bunk management.
• Accurate inclusion of steam-flaked corn helps stabilize intake and supports performance in dairy and feedlot programs.

Fifteen years of manufacturing experience combined with European technique have gone into this patented, uniquely designed unit with independent intellectual property rights.

• Material quality: Fully using SS304 stainless steel with a thickness of 4 mm (left–right) and 3 mm (front–back), ensuring a 10-year product lifespan.
• Steam jet: Four steam nozzles feed steam into the silo from multiple directions to make sure the grain is cooked uniformly.
• Modular design: Modular architecture facilitates future yield upgrades or switching to different pastures—just like LEGO.

Ensures the material’s cooking quality and transfers it to the flaking mill.

• Reducer: Guomao gearbox with a 5-year extended warranty; free repair or replacement for any issues within five years.
• Conveyor blade: Genuine SKF bearings with a 3-year extended warranty.
• Bracket unit: Welded structural-steel base with annealing to ensure stability and durability.
• Tool box module: Full SS304 stainless-steel toolbox for common tools and parts, resistant to rust and corrosion.
• Water tank module: SS304 stainless-steel container with an integrated modular design to save space.

Global proof — reliable in Morocco, Dubai, Venezuela and high-humidity, high-steam plants

Used with external steam generators or boiler steam; stable operation with no leak points or steam loss.

• Connector: 304 stainless steel connectors for steam-pipeline connection. Control accessories: Reputable local brands.

Special design for the HIO flaking mill, leveraging Bellaex’s 27 years of grain-mill manufacturing experience.

• Equipment base: Designed for easy roll replacement.
• Rolls: 500 mm × 450 mm nickel-chromium-molybdenum composite rolls with a uniform hard layer (20–25 mm); patented wire-drawing design to meet material-pressing needs.

• Electrical components: Frequency converter by Siemens, with other electrical components by Schneider; supports manual or automatic control for flexible, convenient operation.

1–10 TPH expandable flaking process. Flexible combinations; single-machine capacity up to 10 TPH depending on model and utilities.

Steam Generators: Diesel-fired, natural-gas-fired, biomass-fired, or coal-fired.

• Water Treatment System: Makeup water for steam generators; supports consistent conditioning quality.

Practical, outcome-focused training led by senior flaking and feed-process engineers.

With 15+ years in steam flaking and compound feed operations, our trainers focus on what matters on your floor: safety, routines, and repeatable quality. The goal is simple—within the first week after handover, your team is producing to the agreed quality targets for thickness, moisture, and flake integrity.

Structured curriculum tailored to your formulas and utilities.

We combine classroom and hands-on modules: startup/shutdown, roll-gap setting, scraper adjustment, steam quality and conditioning time, dryer/cooler settings, sanitation and allergen control, and changeovers. Maintenance teams receive dedicated sessions on bearings, hydraulics, lubrication, and wear-part inspection to prevent unplanned stops.

Standard deliverables you can rely on.

We provide SOPs, quick-reference checklists, and parameter sheets aligned to your species/formulations. Acceptance criteria and data-logging templates help your QC team verify moisture, density, and temperature. A recommended spares kit and PM calendar keep your store and planners aligned.

Ongoing support, as your team and product mix evolve.

Refresher training is available on site or remotely when you add SKUs, staff, or capacity. We can also audit your line seasonally to keep conditioning, flaking/pelleting, and cooling tuned to incoming grain quality.

Training focus areas (typical):

Safety & EHS • Utilities & steam quality • Conditioning time/temperature • Roll-gap/roll care • Dryer/cooler tuning • QC checks (moisture, bulk density) • Cleaning & sanitation • Changeover discipline • Preventive maintenance

Typical steam consumption is 400–500 kg/h; electrical load ≈19.4 kW/h for the flaker system; steam generator and water treatment are included as options.

50–60 minutes is the typical range before flaking to 1.5–2.5 mm.

After start-up, the line can be run unattended with one part-time operator for checks and replenishment.

Yes. Barley and selected grains are supported with recipe-specific conditioning and roll-gap settings.