Flaking solution for Ranch-Scale Operations | Bellaex

• Applications: Beef and dairy feed programs, integrated feed-mill lines, ranch HIO packages, pre-pelleting or TMR facilities.

• Materials: Corn/maize (primary), plus oats, barley, sorghum and selected oilseeds per recipe and target thickness.
• Types of Raw Materials

1. Corn with Safe Moisture Content: Corn with a moisture content of 12-13.5%.
2. According to the experience of previous customers, if the moisture content of new grain exceeds 20%, it can be directly processed into flakes without water soaking. However, the disadvantage is that the moisture content of the original grain is an average value, with some grains having too high moisture and some having too low moisture. If the flakes are directly processed without soaking, the color of the finished products after drying and cooling will not be uniform, which affects the appearance. Secondly, if the moisture content is too high and needs to reach the standard moisture content, a large amount of steam energy consumption is required for drying, which affects the production capacity. Therefore, it is recommended that customers first pass the corn through a drying tower to dry the moisture content to 17-19%.

• Steam-flaked corn has an aromatic corn smell in terms of sensory perception, without any peculiar smell. It is yellow or golden yellow in color, with a uniform color. There should be no phenomena such as fermentation, mildew, or caking.

• We commonly use three indicators, namely bulk density, thickness, and gelatinization degree, to evaluate flaked corn.

1. The bulk density is between 280-360. Currently, the conventional requirement in pastures is between 320-360.
2. The density of the flakes is closely related to the changes in the content of soluble starch and the enzymatic degradation degree of steam-flaked corn. As the density of the flakes increases, the digestibility of starch shows a downward trend.

• HIO-1 / HIO-2 — 1–2 TPH compact packages for ranch operations

• SFC-5 / 10 / 15 / 20 / 30 — 5–30 TPH feed-mill lines (modular layouts)

• Uniform, low-fines flakes across shifts and seasons
• 24/7 line availability with fast changeovers
• 1–30 TPH scalable, modular layouts
• Recipe-driven thickness targets and interlocks

1. Basic Process:

• Water Spraying via Screw Conveyor: After cleaning, corn is lifted to the top layer by a bucket elevator, evenly sprayed with 40–50°C warm water via a screw conveyor, and then stored in a soaking bin for 8–18 hours to allow surface moisture penetration (soaking time depends on corn moisture content).

2. High-Efficiency Process (Optional):

• German Ultrasonic Moistening Machine: Uses high-frequency vibration to accelerate water penetration through micro-cracks in the corn endosperm, reducing soaking time to 4–12 hours with an internal-external moisture gradient ≤2%.
• Bühler Moistening System

1. Key Process Points:

Water-Material Separation: Soaked corn is transported to a conditioning tower for steam cooking.

2. Parameter Control:

• Cooking time: 45–65 minutes (adjusted based on starch type)
• Temperature gradient: 100–108°C (steam pressure 0.15–0.25 MPa)
• Gelatinization range: 65%–85% (DSC test)
• Moisture change: Initial corn moisture 14% → post-cooking 18±0.5% (critical value for starch gelatinization)

1. Flaking Process

• Continuous Online Flaking: Cooked corn is directly fed into the flaking machine, with roller surface temperature maintained at 80–90°C.

2. Thickness Control:

• Standard feed use: 1.2–1.8 mm (±0.05 mm tolerance)
• Custom needs: Ultra-thin flakes (≤1.0 mm) for high-digestibility formulas; thick flakes (≥2.0 mm) to control rumen degradation rate.

• Drying & cooling – Horizontal dryer 80–100 °C, ~25–28 min to reduce moisture from 18–19% to ≤14%, followed by controlled cooling.

1. Bulk Storage & Transport: Conveyed to vertical silos (humidity monitoring ≤12%), compatible with large-scale feeding systems.

1. Custom Packaging: 15–25 kg woven bags or vacuum-packed ton bags.

• Predictable feed quality — tight thickness control and stable moisture to spec

• High uptime — robust mechanics, stainless contact, quick access for sanitation
  
  
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• Global proof — reliable in Morocco, Dubai, Venezuela and high-humidity, high-steam plants

• Online micro-gap adjustment (select flakers); centralized lubrication; bearing-temperature monitoring; SEW/IE3-IE4 drives; stainless outer covers; recipe presets & thickness lockout; water recirculation loops; SCADA integration; silo and bulk-out options.

Operators Ready in Days, Confidence for Years

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