Breakfast cereal applications
Advanced technologies
for traditional cereal flakes production
Coperion delivers fully integrated solutions for every stage of traditional flake production. From ingredient handling and cooking to flaking, toasting, and coating, our processing technologies help breakfast cereal manufacturers improve production efficiency, maintain product integrity, and consistently produce high-quality flakes at any scale.
Consistent traditional flake production starts with process control
Producing high-quality traditional cereal flakes requires every stage of the process to work together. Each step influences the final flake thickness, texture, color, flavor, and overall product consistency. Even small changes in moisture or processing conditions can affect product quality and increase breakage, making precise process control essential for reliable production.
As demand grows for multigrain, coated, and other value-added breakfast cereals, manufacturers need production lines that can support new products without compromising quality or efficiency. Flexible processing and reliable product handling help simplify changeovers while maintaining consistent results across different cereal varieties.
This is why an integrated production process is so important. By connecting each stage into one continuous operation, manufacturers can improve process control, reduce product handling, simplify product changeovers, and consistently produce high-quality traditional cereal flakes.
Integrated traditional flake production solutions
Coperion delivers complete processing solutions for traditional flake production, covering every stage from ingredient handling and cooking to tempering, flaking, toasting, and coating. Designed as one continuous production line, the system improves product flow, reduces manual handling, and increases overall production efficiency.
By integrating each stage into a single process, manufacturers gain better control over moisture, flake quality, and product handling, helping ensure consistent production from start to finish. The same platform also allows production to scale, with the ability to increase capacity, introduce new products, or add optional processing stages as requirements change.
The technology brands behind our traditional cereal flakes solutions
Examples of innovative traditional cereal flakes applications
Create a wide range of traditional breakfast cereals, from classic corn, wheat, bran, and oat flakes to multigrain and sugar-coated varieties. Our integrated processing solutions help manufacturers produce consistent, high-quality cereal flakes while providing the flexibility to expand product portfolios and respond to changing consumer preferences.
Bran/wheat flakes
Corn flakes
Multigrain flakes
Oat/rice flakes
Sugar-coated flakes
How traditional cereal flakes production works
Ingredient handling
The Shick Esteve Bag dump stations provide a safe, dust-free way to manually add dry ingredients.
Liquid ingredients, such as glucose, are temporarily stored in our Shick Esteve Tank systems, or Tote systems, and then delivered through pumps.
For automated ingredient handling and recipe preparation, Coperion MIH systems enable precise ingredient dosing, process documentation, and batch traceability to support consistent product quality.
Cooking, drying, and tempering
The traditional flake process starts by cooking whole or milled cereal grains such as wheat, corn, bran, or oats. Using Baker Perkins Cook Master™ rotary cereal cooker, the grains are gently steam cooked with effective mixing to develop the desired texture and flavor while retaining the nutritional benefits of wholegrain ingredients. The cereal is then dried and tempered to achieve the correct moisture level for consistent flaking and reduced breakage.
To support a continuous and hygienic process, Kemutec KEK-lump breaker removes agglomerates to ensure a consistent feed into the cooker. Coperion EDIP conveying systems, together with Coperion E-Finity technology, gently transfer the product between processing stages to minimize product damage. The conditioned cereal is then ready for the flaking and toasting stage.
Flaking & toasting
After conditioning, the cereal moves to the flaking and toasting stage. The cooked grains are passed through Baker Perkins Flake Master™ flaking mills, where precise roll gap control and uniform product feeding produce consistent flake thickness across the full width of the rolls.
The flakes are then gently dried and toasted in the Baker Perkins Thermoglide2™ toaster, where controlled heat removes moisture and develops the desired color, texture, and crispness. Its air-cushion design gently lifts and rotates the product for uniform processing with minimal breakage, while integrated dust extraction helps maintain an efficient and hygienic production process.
Frosting, glazing and coating
At this stage, syrup, frosting, or glazing is applied to enhance flavor, appearance, and product variety. Baker Perkins Syrup coating systems provide fully automated application with precise control for consistent coating of traditional cereals. The system can operate in both sugar and sugar-free modes, allowing manufacturers to produce a wide range of coated cereal products with simple changeovers.
To ensure consistent coating, weighbelts and vibratory feeders accurately control the product feed before the cereal moves to final cooling and packaging.
As part of the Cereal Master™ TX process, the coating system can be added as production requirements evolve. Its modular design allows manufacturers to expand from traditional wheat and bran flakes to multigrain, corn, and coated cereal products without replacing the entire production line.
See traditional cereal flake production in action
Discover how Coperion can enhance your traditional flakes production
Watch the traditional flake production process and discover how Coperion and Baker Perkins solutions help breakfast cereal manufacturers improve efficiency, maintain product quality, and achieve reliable performance at every stage.
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