Breakfast Cereal Processing Technology

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Breakfast Cereal Processing Technology
An Academic presentation by Dr. Nancy Agnes,
Head, Technical Operations, FoodResearchLab
Group www.foodresearchlab.com Email
info_at_foodresearchlab.com
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TODAY'S DISCUSSION
Breakfast Cereal Processing Technology Production
Of Flaked Cereal Production of Puffed Cereal
Production of Granola Coatings Are A Type Of
Finish. Food Research Lab's Healthy Granola
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INTRODUCTION
Before it becomes a finished product, breakfast
cereal goes through various steps. Depending on
the kind of cereal, several production
procedures are used, such as flaked, puffed,
shredded, and so on. Contd...
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The preparation of the grain is the first step,
regardless of the type of finished product.
Most functional foods and ready to eat food
products utilize similar technologies for
production. Contd...
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The grain will be examined and cleaned once it
arrives at the cereal facility.
Some cereals use entire grains, while others
grind the grain into fine flour by crushing it
between massive metal rollers to remove the
outer layer of bran. Contd...
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In a huge rotational pressure cooker, whole and
partial grains will be combined with other
ingredients.
The type of grain used will all influence the
rotational speed, duration, and temperature
employed during this operation. Contd...
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Instead of whole grains, flour is used in other
varieties of cereal.
This flour is combined with other ingredients in
a culinary extruder and cooked. In essence,
this is a piece of machinery that consists of a
long screw contained in a heated
enclosure. Contd...
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The screw moves the mixture through the extruder
while mixing the flour with the other components.
The baked dough is ejected at the opposite end
in the shape of a long, continuous ribbon, which
is then chopped into pellets by a revolving
knife. Contd...
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These pellets will next be processed the same
way as the cooked grains were.
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Production Of Flaked Cereal
Whole grains or extruded pellets can be used to
make flaked cereals. The cooked grains or pellets
are left to temper for several hours to allow
the moisture content to stabilise. Contd...
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After this tempering, two enormous metal rollers
will flatten the grains or pellets under many
tonnes of pressure.
The resultant flakes will be placed in an oven
and exposed to hot air, eliminating excess
moisture and toasting them until they attain the
appropriate colour and flavour. Contd...
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Ready to eat breakfast cereals product
developments are helping food
industries to produce flaked cereal products
from a variety of ingredients. Contd...
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Grain size is vital for flaked cereals derived
from whole grains to ensure overall product
quality.
Most of the time, unmodified corn starch will be
added to the mix to ensure that the flakes can
endure processing Contd...
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Flaked cereal should have a 28 to 32 per cent
moisture level after heating. The early heating,
drying, and tempering steps.
Are crucial for controlling the moisture and
texture levels of whole-grain flakes
cereal. Contd...
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This occurs mostly after extrusion in the case
of extruded chips. However, the end product's
moisture content should be between 1 and 3 per
cent to get the desired crunchiness and
toughness.
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Production of Puffed Cereal
Cereals and pulses formulation companies use
puffed products for easy digestion and
taste. Contd...
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Puffed cereal is often rice and wheat and is
produced using a gun.
Bumping is a procedure that involves slightly
flattening rice grains between metal rollers
after they have been cooked, cooled, and
tempered. Contd...
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The rice grains will be bumped again before
being dried and put in a
high-pressure steam oven (gun) to grow in size.
The temperature should be between 400o and
500oF, and the pressure should be around 200
lbs. Contd...
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psi for the procedure to be effective. The
pressure in the oven will abruptly be released,
forcing the grains to release steam and puff up
in size immediately.
The moisture level of the puffed grains will be
approximately 5 to 7 per cent at this
point. Contd...
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And it will need to be reduced to between 1 and
3 per cent.
It's also worth noting that because these
cereals absorb moisture rapidly, they'll need a
layer of coating and the right kind of packaging
to protect them from deteriorating and
maintaining their crispiness over time.
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Production of Granola
In the cereals processing sector, Granola is
created by combining grains with additional
ingredients . Such as nuts, dried fruits, seeds,
honey, malt extract, various flavours, and so
on, and then baking the mixture. Contd...
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Granola, unlike other cereals, requires oil in
the mix to keep the other components from
sticking together.

• Agglomeration is the term for this process. To
  obtain a mild browning and a moisture content of
  roughly 3, the combination will be cooked at
  temperatures ranging from 300o to 425oF.
• Contd...

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5 inulin (a prebiotic fibre) and other carbs
may be added to aid with the binding
process. The granola will be broken up into
bits when the heating and drying operations are
completed.
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Coatings Are A Type Of Finish
After the initial manufacturing phase, some
cereals may be sprayed with a coating containing
sweeteners, tastes, food colouring,
preservatives, vitamins, and minerals. Contd...
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Most grains include a sugar coating that
combines a sugar formula and application process
to guarantee.
that the sugar crystals dry with the proper
colour, flavour, size, and structure.
Contd...
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Traditionally, beet or cane sugar is used as a
coating, and however, brown sugar or honey can
also be used in white sugar.

• Using oil to avoid clumping is also a good idea.

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Food Research Lab's Healthy Granola
Food Research Lab is a global contract RD firm
developing new food, beverage and nutraceutical
products for food companies.
Contd...
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We have assisted several companies in launching
their convenience food products, especially
breakfast cereals.
Our functional granola mix that helps athletes
and sportspeople was a huge success for our
client in the market. Contd...
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We have various such products ready-to-eat food
products in our portfolio.
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UNITED KINGDOM 44- 161 818 4656 INDIA 91
9566299022 EMAIL info_at_foodresearchlab.com