The line at a glance
Grain enters at the intake pit, is cleaned, steam-conditioned and flaked, all on one line laid out on a flat floor.
- Capacity 1.5 t/h; the range covers 0.5, 1 and 2 t/h
- The machine is about 6 m tall and stands on a flat floor; the only civil work is an intake pit
- The 3D shows a project in Brazil; see Layout for the standard arrangement
Grain intake
Grain is tipped into the floor pit, and bucket elevator 1 lifts it to the cleaning platform.
- Intake pit 2500 mm wide and 1800 mm deep (standard layout)
- The pit opening is covered with steel grating
Cleaning
The cleaner-destoner removes impurities and stones, protecting the rolls and giving cleaner, more even flakes.
- Mounted on the steel platform; the cleaned grain drops into bucket elevator 2
- Ladders and guardrails give safe access for checks
Into the steam chest
Bucket elevator 2 lifts the grain to the top of the machine and into the vertical steam chest.
- Automatic feeding: the two elevators and the cleaner start at low level and stop at high level in the chest
- At start-up, filling takes about 35 minutes
Steam conditioning
Steam enters the chest through four nozzles from different sides; the grain cooks for 50–60 minutes and gelatinises evenly.
- Steam at 0.5–0.6 MPa; about 400–500 kg/h of steam
- Steam generator and water treatment are options; this layout uses a 216 kW electric boiler with reverse osmosis
- Chest and nozzles in SS304 stainless steel
Horizontal cooking unit
The cooked grain drops into the horizontal steam cooking unit, which keeps it hot and feeds the flaker evenly.
- Speed set by a frequency inverter: start slowly, then speed up once running steadily
- Gear reducer with a 5-year extended warranty; SKF bearings on the conveyor
Flaking
The cooked grain enters the flaking module, where a pair of rolls presses it into flakes.
- The two motors start one after the other; the hydraulics close the rolls and the pressure is raised step by step to the flake thickness needed
- Flake thickness 1.5–2.5 mm
- Nickel-chromium-molybdenum composite rolls with a 20–25 mm hard layer (1 t/h model, bellaex.com)
Output and daily running
Flakes leave below the flaker and go by conveyor and cooling fan to the TMR mixer. The first flakes come after about 50 minutes of cooking.
- Start-up: automatic filling → boiler on → 45–50 min of cooking → the two flaker motors one after the other → close the rolls → start the conveyor → flakes
- Once running, one part-time operator for checks and refilling
- Installed and producing within 5 days of delivery
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