Extruded Bran, Wheat & Corn Flakes

Extruded Bran, Wheat & Corn Flakes schematic

1. Pellet Forming 

Ingredients are texturized and cooked in Baker Perkins' SBX Master™ Extruder, through a combination of heat, mechanical shear and moisture addition; a second extruder then forms the pellet.

2. Pellet Flaking & Toasting

The pellet is conditioned for handling before passing into the FlakeMaster™ Flaking Roll. Controlled toasting and drying of the flakes takes place in Baker Perkins' Thermoglide2™ Toaster, where the fluidized bed process minimizes product damage.

3. Syrup Coating and Drying

Cereals are glazed or coated by atomized spraying systems and rotating drum before the product is dried.

  • Extruded Flakes

    Extruded flakes are made from flours and other powdered ingredients that require no preparation or pre-conditioning on site. Instead, they are fed directly to a twin-screw extruder with a barrel extension for cooking.

    Ingredients are fed into one end of the enclosed extruder barrel. At the same time, the liquid feed system meters process liquids into the barrel. These ingredients are conveyed along the extruder barrel by the forwarding action of the screw elements: during this process they are subjected to a combination of heating, cooling, mixing and shearing.

    There are then two process options. A new technique involving an extended extruder barrel with a super-cooled final section enables pellets to be formed using a single extruder. This provides a compact system suitable for the majority of extruded flakes.

    For high output and some multigrain products, two separate cooking and forming extruders will continue to be the preferred option. The cooked mass is discharged through a pipe die to a second extruder for forming and discharged through a plate die where it is cut into pellets.

    In both processes, each pellet will eventually become an individual flake.

    The pellets are conveyed to a conditioner, where they are held for a short time to allow their moisture content to equalize. The pellets are fed into Baker Perkins' Flake Master™ Flaking Roll Unit at a controlled rate, via a vibratory feeder. The flakes are then toasted and dried in a Thermoglide2™ Toaster, which removes excess moisture and toasts the surface to enhance the flavour and colour. 

    If flakes are to be frosted or glazed they are conveyed to a revolving coating drum that keeps them gently turning in a sugar syrup spray. The final process is drying and cooling.

  • Required Equipment
    Extrusion & Co-Extrusion  








    SBX Master™ Extruder



    Cereal Forming  





    FlakeMaster™ Flaking Roll


    Cereal Toasting  







    Thermoglide2™ Toaster

    Syrup Coating  







    Preparation & Coating Systems


Brochure: Breakfast Cereals

Brochure: Breakfast Cereals

Extruded Flake Products

Extruded Flake Products

View some of the extruded flake products that can be made on Baker Perkins' cereal process lines.

Cereal Master EX™

Cereal Master EX™

Expandable modular process lines for a wide variety of extruded and co-extruded breakfast cereals.

Cereal Innovation Centres

Cereal Innovation Centres

Baker Perkins offers all its customers facilities to develop new products and processes, produce samples for test marketing, and conduct feasibility trials.