Specifications
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Summary
Steam flaking increases the net energy (NE) of corn by an average of 18%, far surpassing traditional tabular estimates (e.g., 4–11% in NRC standards).
Digestibility Mechanisms:
- Starch digestibility improves by 10% (99% vs. 90% for dry-rolled corn).
- Non-starch organic matter (e.g., protein) digestibility rises by 10% (80.6% vs. 73%).
Flow chart
Cleaning → Moisture Addition/Soaking → Steam Conditioning → Metered Feeding → Flaking → Drying → Cooling → Screening → Storage/Packaging → Data & QA (bulk density, thickness)
Cleaning
- Equipment Configuration: Three-stage operation (stone remover → vibrating screen → magnetic separator) to remove impurities, gravel, and metal debris.
- Optional Layouts:
- External Deep Cleaning: Pre-treatment at the silo entrance before raw materials enter the workshop, reducing dust pollution.
- Internal Graded Cleaning: Multi-stage screening within the workshop (recommended).
Soaking
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
Cooking
1. Key Process Points:
- Water-Material Separation: Soaked corn is transported to a conditioning tower for steam cooking.
- 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)
Roller Flaking
1. Flaking Process
- Continuous Online Flaking: Cooked corn is directly fed into the flaking machine, with roller surface temperature maintained at 80–90°C.
- 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
- Key Operations:
- Horizontal Dryer:
- Hot air temperature: 80–100°C
- Drying duration: 25–28 minutes (reducing moisture from 18–19% to below 14%)
Finished Product Handling
- Packaging Strategy:
- Bulk Storage & Transport: Conveyed to vertical silos (humidity monitoring ≤12%), compatible with large-scale feeding systems.
- Custom Packaging: 15–25 kg woven bags or vacuum-packed ton bags.
Material Cleaning System
| ITEM | DESCRIPTION | MODEL | Q’ty | POWER (kW) UNIT | POWER (kW) TOTAL |
|---|---|---|---|---|---|
| C01 | 1#Elevator | TDDM40/23 | 1 | 4 | 4 |
| C02 | Vibration cleaning machine | TQLZ100X200 | 1 | 0.74 | 0.74 |
| C03 | Cycle winnowing | TFXH100 | 1 | 2.95 | 2.95 |
| C04 | Gravity graded stone removal machine | TQSFB150 | 1 | 0.5 | 0.5 |
| C05 | Cyclone | Ø1400 | 1 | 0 | 0 |
| C06 | Air closer | TGFZ8 | 1 | 1.1 | 1.1 |
| C07 | Pulse dust collector | MCY104-2000 | 1 | 0 | 0 |
| C08 | Dust fan | 4-72-5.5A | 1 | 15 | 15 |
| C09 | Silencer | G550X1000 | 1 | 0 | 0 |
| C10 | Cache Warehouse | / | 1 | 0 | 0 |
| C11 | Moisture Detector | MYFE-30 | 1 | 0 | 0 |
| C12 | Magnet | CX330 | 1 | 0 | 0 |
Material Soaking System
| ITEM | DESCRIPTION | MODEL | Q'ty | POWER(kW) UNIT | POWER(kW) TOTAL |
|---|---|---|---|---|---|
| W01 | 2#Elevator | TDDM40/23 | 1 | 2.2 | 2.2 |
| W02 | Automatic Watering Machine | MOZL-30/150 | 1 | 5.5 | 5.5 |
| W02-1 | water-add screw conveyer | LSS25 | 1 | 2.2 | 2.2 |
| W03 | Moisture Controller | MOZH-315 | 1 | 0 | 0 |
| W04 | Hot water tank | 1.7m³ | 1 | 0 | 0 |
| W05 | Distributor | BL4-200 | 1 | 0.55 | 0.55 |
| W06 | Soaking tank | 50m³ | 4 | 0 | 0 |
| W07 | Material level device | / | 8 | 0 | 0 |
| W08 | Manual elctric water retaining plate | 30x40 | 4 | 0.55 | 2.2 |
| W09 | Buffer Bin | 800x800 | 1 | 0 | 0 |
Steam--Flaking--Drying and Cooling System
| ITEM | DESCRIPTION | MODEL | Q'ty | POWER(kW) UNIT | POWER(kW) TOTAL |
|---|---|---|---|---|---|
| F01 | 3#Elevator | TDDM40/23 | 1 | 3 | 3 |
| F02 | 2#water-add screw conveyer | LSS25 | 1 | 1.5 | 1.5 |
| F03 | Air closer | GFWZB-80 | 1 | 2.2 | 2.2 |
| F04 | Steam chest | 45m³ | 1 | 0 | 0 |
| F05 | High temperature resistant material level device | / | 4 | 0 | 0 |
| F06 | Temperature sensor | / | 2 | 0 | 0 |
| F07 | Corn flaking mill | FC7175SF | 1 | 135.3 | 135.3 |
| F08 | Dehumidification fan | 4-72-3.2A | 1 | 2.2 | 2.2 |
| F09 | Off-wind feeder | GFWZB-300 | 1 | 4 | 4 |
| F10 | Horizontal dryer and cooling box | WGL-3.2 | 1 | 2.25 | 2.25 |
| F11 | Material level device | / | 2 | 0 | 0 |
| F12 | Temperature sensor | / | 2 | 0 | 0 |
| F13 | Hot air fan | 4-73-10.8C | 1 | 55 | 55 |
| F14 | Cold Air fan | 4-72-9.5A | 1 | 15 | 15 |
| F15 | Heat exchanger | SZL1100 | 1 | 0 | 0 |
| F16 | Scraper conveyor | TGSS25 | 1 | 2.2 | 2.2 |
Finished Product-Packing System
| ITEM | DESCRIPTION | MODEL | Q'ty | POWER(kW) UNIT | POWER(kW) TOTAL |
|---|---|---|---|---|---|
| P01 | 4#Elevator | TDDM40/28 | 1 | 3 | 3 |
| P02 | Single cylinder cleaning screen | TSCY85x200 | 1 | 1.5 | 1.5 |
| P03 | Temporary storage and plantform | / | 1 | 0 | 0 |
| P04 | Packing scale | JDB-2 | 1 | 2.2 | 2.2 |
| P04-1 | Automatic traction bag sewing system | 1 | 3.3 | 3.3 |
Materials consumed for installation
