MANUFACTURING PROCESS FOR RICE FLAKES / MAIZE FLAKES / MILLET FLAKES
Rice Flakes, Maize Flakes and Millet Flakes are generally known as Brewery Adjuncts. These are used by breweries to enhance color, flavor & smoothness of beer.
Manufacturing process of Flakes:
There are six stages in the process of manufacturing of Flakes
- Grain Cleaning
- Dehusking / Degermination
- Grading
- Cooking
- Flaking
- Drying
GRAIN CLEANING
Incoming grains after inspection & testing are subjected to screening & grading through various machines to remove dust, husk, stones & other impurities. The Cleaned grains are stored into bins.
Dehusking / Degermination
As the rice is already polished by rice millers therefore the rice grains (Broken Rice) do not require de-husking / de-germination.
Whereas Maize & Millet grains needs de-germination. During this process the cleaned Maize / Millet grains are applied with water to loosen the skin on the top layer of grains & then the moist grains are passed through de-husking machine to remove husk & germs from the grains & then the whole mass is passed through various machines to separate husk, germs, powder & grains. The cleaned de-husk grains / grits are stored into bins for further process.
COOKING
The cooking process is same for all the grains (i.e. Rice, Maize & Millets).
The grains are filled into SS rotary cooker, the desired quantity of water & other ingredients are added & then steam is injected into the cooker for certain period to cook the grains to desire level. During this process grains are gelatinized. After complete gelatinization the grains are removed from cooker, thereafter subjected to cooling & flaking.
FLAKING
During this process the cooked grains are passed through Flaking Machine to get the flakes of desired thickness. At this stage the moisture level in the flakes is around 22-25%.
DRYING
The moist flakes are collected in the hot air kiln & dried to a moisture level of 8-10%, thereafter the flakes are cooled to room temperature. The dried flakes are stored into the bins.
PACKING & STORE
The dried & cooled flakes are filled into HDPE bags or dispatched as per buyer’s requirements.