This line is the combination production line, which can be used to make snacks pellet, and also can be used to make salad sheet and salad sticks. The extruder, flour mixing machine, water tower is the same. But when make salad sheet and salad sticks, it need to add the cutting machine.
3D Snack Production Line
The 3D pellet snacks processing Line is used to produce double-layer composite puffed food by a Double & Single-extrusion process. The main raw materials are potato starch, potato whole powder, corn starch, wheat flour, corn flour and cassava starch and RO water.
Through the extrusion of the press system , the raw material is squeezed into two layers, and the product is reconstructed and molded into the desired shape through the Kp molding machine. By replacing the roller on the type machine, it can also be used to produce many different and unique shapes, such as triangles , rackets, hexagons, rectangles, Christmas trees, animals, bends, and heart shapes. After drying and frying, the size of the product expands several times in a uniform manner .
How does a snack pellet production line work ?
Starches, fibers and liquids are introduced into a batch mixer according to the recipe for the end product and the dough is then conveyed continuously and uniformly to the heart of the twin-screw system where it is cooked, formed and cut to extrude a homogeneous and controlled product under pressure. This combined cooking, forming and cutting process in a single integrated unit is the critical advantage of Clextral system over traditional pellet making machine. Multiple shapes are produced by the die inserts at this point, including stars, wheels, cones, animals and other 2D and 3D variations. Wet pellets are then sent to a drying line where the product is smoothly dried.
STAGE 1 - TWIN-SCREW EXTRUSION SYSTEM (FIRST IN INDIA)
KP Automations offer a wide range of twin-screw extruders with different characteristics depending on the industrial food application and the degree of smoothness required. These machines are the centre of our continuous production lines for snaks foods
The extruder is a building block structure of SS 304 , and the material adopts a special alloy with high strength and high wear resistance. The extruder cavity adopts multiple blocks. Each cavity can independently control the temperature , and there are heating and cooling belt channels.
The main motor, feeder, cutter, and liquid feed system of the extruder are all used for variable frequency speed adjustment. The extruder system adopts PLC control, and the touch screen controls the man-machine operation terminals.
STAGE 2 - SHAPING UNIT
The compound snack shaper is mainly used to shape the 3D pellet food like bugles, triangle, fish, racket & Many more.
By changing the roller mould and dies syetem, the product shape is different. The roller speed and product thickness can be adjusted as per the customer requirement.
Starches, fibers and liquids are introduced into a batch mixer according to the recipe for the end product and the dough is then conveyed continuously and uniformly to the heart of the twin-screw system where it is cooked.
STAGE 3 - FLAVORING SYSTEM
The KP flavoring line is composed of elevator, rotary drum, powder sprayer and oil sprayer control Through PLC system
The elevator transmits the dried extrusion snack to the rotary drum, and at the same time, powder seasoning and edible oil are sprayed into it separately by the Four spraying system. In the rotary drum the snacks are flavored equally and Correct manner .
The flavoring machine uses hoists to feed materials automatically and hoists use food-grade raw materials to ensure food safety standard.
The cooked, cooled and oil free product is discharged directly into the rotating drum. A series of longitudinal flights catch the cooked product and gently tumble them within the drums interior.. The dry flavoring is applied to the product as it passes through the drum. An extended auger tube transfers the flavoring from the flavoring hopper into the center of the drum. As the flavoring exist the apertures of the auger tube, it is distributed equally over the product.
STAGE 4 - FRYER
This Process is use for Purpose of cooking the product with hot oil as per desired temperature depending on the product properties. Fryer system has temperature controllers for easy of operations as per the product requirements. Fryer has contain steam, hot air and cooking fumes and to direct these into a 3d stack for removal from the factory with the aid of an extraction fan. The fryer Infeed flume and fryer inlet header each have an inlet jet, Which gives maximum control to the oil flow rate along the pan system.
Fryer has temperature controllers for easy of operations as per the product. Fryer has a hood over its cooking area to contain steam, hot air and cooking fumes and to direct these into a stack for removal from the factory with the aid of an extraction fan ( a mechanically powered hoist system to provide access to the pan of cleaning). The fryer Infeed flume and fryer inlet header each have an inlet jet at the Infeed end with a flow adjusting valve, Which gives maximum control to the oil flow rate along the pan.
STAGE 5 - ELEVATOR SYSTEM
De-oiling conveyor helps in draining the excess oil from the cooked product & carries the product up to the vibratory feeder for further flavouring process. Purpose is to provide continuous feed of the cooked product to the flavoring drum for seasoning process with help of electromagnetic vibratory feeder.