Manufacturing process of Breakfast Cereals

Processing of Breakfast Cereals

There are several stages that breakfast cereal goes through before it emerges as a final product. There are
also several types of manufacturing processes, depending on the type of cereal, such as flaked, puffed,
shredded, and more. Regardless of what the type of end product will be, the manufacturing process starts
with preparing the grain. The processing of breakfast cereals involves a harmonious blend of technology,
craftsmanship, and creativity, transforming grains into beloved and nutritious breakfast options enjoyed by
people around the world.

Grain Preparation and Inspection

At the cereal factory, the first step in the processing of breakfast cereals involves receiving the grain, which
undergoes careful inspection and cleaning. Depending on the type of cereal being produced, some cereals
use whole grains, while others process the grain through large metal rollers to remove the outer bran layer
and create fine flour.

Cooking and mixing

The selected grains, whether whole or in flour form, are then mixed with other ingredients in a large rotary
pressure cooker. The cooking process in this stage is tailored to the specific type of grain being used,
considering factors like rotation speed, time, and temperature to achieve the desired consistency and flavor.

Cooking Extrusion

For certain cereal types using flour, the flour is combined with other ingredients and undergoes cooking
extrusion. This process involves a heated housing with a long screw inside, which efficiently mixes the
flour with the other ingredients while transporting the mix through the extruder.

Extrusion and cutting

The cooked dough emerges from the cooking extruder in the form of a continuous, elongated ribbon. This
ribbon is precisely cut into pellets by a rotating knife, resulting in uniform shapes that are later processed
similarly to the cooked grains mentioned earlier.
Final processing

Regardless of the specific manufacturing process, the prepared grains or pellets are subjected to further
steps, which may include flaking, puffing, or shredding, depending on the desired type of breakfast cereal.
These processes add distinctive textures and shapes to the cereal, creating a wide variety of breakfast
delights available to consumers.

Drying and Shaping

After cooking, the grain needs to retain a certain amount of moisture to be shaped effectively. It is
then transferred to a drying oven, where excess moisture is removed while retaining the ideal texture and
form.

Production of Flaked Cereal

Flaked cereals can be produced using either whole grains or extruded pellets. The fundamental process
involves allowing the cooked grains or pellets to rest for several hours, allowing the moisture content to
stabilize. Once this tempering phase is complete, the grains or pellets undergo immense pressure between
two large metal rollers, resulting in their flattening. The obtained flakes are then conveyed to an oven,
where they are exposed to hot air to remove excess moisture and achieve the desired flavor and color
through toasting.

For flaked cereals made from whole grains, maintaining the appropriate grain size is crucial to ensure
overall product quality. To enhance the flakes’ ability to withstand processing, it is common to incorporate
unmodified corn starch into the mixture. The moisture content of flaked cereal after cooking should ideally
be between 28 to 32%. The control of moisture and texture levels for whole-grain flaked cereal primarily
occurs during the initial phases of cooking, drying, and tempering. Conversely, for extruded flakes, this
control is mostly done after the extrusion process. Nevertheless, achieving an optimal moisture level of
between 1 and 3% in the final product is essential to ensure the desired crunchiness and toughness.
Production of Puffed Cereal

Puffed cereal production involves a combination of rice and wheat and requires specialized equipment
known as a “gun.” The process starts with cooking, cooling, and tempering the rice grains. Afterward, the
grains are partially flattened using metal rollers, a technique known as “bumping.” They then undergo
another round of drying before being transferred to a steam oven with high pressure (the one referred to as
the “gun”). The sudden release of pressure causes the grains to puff up rapidly as they release steam.

At this stage, the puffed grains contain around 5 to 7% moisture, which needs to be reduced to a level
between 1 and 3%. It’s important to consider that this type of cereal can easily absorb moisture, so it requires
a protective coating and appropriate packaging materials to maintain its crispiness and prevent spoilage
over time.

Production of Shredded Cereal

Shredded cereal is predominantly made from wheat, which undergoes a specific process to achieve its
shredded form. Initially, the wheat is boiled in water to ensure thorough moisture penetration. Following
this, the wheat is left to temper for a period of up to 24 hours before being passed through two metal rollers.
These rollers are different from those used in flaked cereal production, consisting of one smooth roller and
one grooved roller.

Adjacent to the grooved roller, a metal comb with a tooth inside each groove is placed. When the wheat
passes through, these teeth shred the grains, creating a continuous ribbon-like texture. Subsequently, the
ribbon is cut to the desired size and baked until it reaches the appropriate color and dryness.

The crucial step of tempering the cooked wheat for the specified duration ensures even moisture distribution
and enables starch retrogradation, which plays a significant role in achieving the right texture for the cereal.
Failing to temper the wheat adequately could result in shredded wheat that is excessively gummy and sticky,
making it unsuitable for further processing.

Production of Granola

Granola is made by mixing and cooking grain with other ingredients, such as nuts, seeds, dried fruits, honey,
malt extract, different flavors, and the alike. Unlike other types of cereal, granola also needs oil in the mix
to allow the other ingredients to stick together. This process is known as agglomeration. The mixture will
be cooked at temperatures between 300º to 425ºF to achieve a light browning and a moisture content of
around 3%. Around 5% of inulin (a prebiotic fiber) and other carbohydrates may also be added to help with
the binding. Once the cooking and drying processes are complete, the granola will be broken up into chunks.

Adding Coatings

After the initial processing phase, some cereals may be sprayed with a layer of coating with sweeteners,
food coloring, flavors, vitamins, preservatives, and/or minerals. The commonly-used sugar coating in most
cereals combines a sugar formula with an application method that regulates the right color, flavor, size, and
structure of the sugar crystals when dry. Beet or cane sugar is typically used as a coating, but brown sugar
or honey can also partially replace white sugar. Adding oil can also help prevent clumping.

Aside from making the cereal sweet, sugar coatings also provide an additional layer between the milk and
cereal, thus prolonging their crispiness. Adding different starches, such as dextrin or maltodextrin, to the
cereal’s surface will help improve the storage stability and not add any sweetness to the overall taste during
the process. High-fructose corn syrup and crystalline fructose, on the other hand, can be used to provide
sweetness and adhering properties for dry flavor-bit applications. In sweetened cereals, the coating’s
visibility will also add some level of appeal to the consumer. As such, the coating can account for up to
50% of the cereal’s weight.

Packaging and Quality Control

While certain cereals, like shredded wheat, demonstrate resistance to moisture spoilage and can be directly
placed in cardboard boxes, the majority of other cereals require airtight and waterproof plastic bags for
packaging. These bags are then inserted into cardboard boxes to safeguard the cereals from spoilage. Present
trends indicate that modern customers prioritize flexible packaging and sustainable materials.

In the packaging of breakfast cereals, traditional choices have involved rigid plastics. Traditional packaging
materials include:

 Polyethylene,
 Polypropylene,
 Polyamide,
 Polyethylene terephthalate,
 Ethylene-vinyl alcohol.
However, a growing number of cereal manufacturing businesses are shifting their attention towards more
sustainable alternatives, embracing plant-based packaging materials. This change reflects the industry’s
commitment to eco-friendly practices and reducing its environmental impact. Options that have convenient
packaging are also being considered, such as resealable, flexible, and stand-up bags. These options tend to
remove the need for the traditional cardboard box and reduce the volume of packaging as a whole. Single-
serve pouches are also a trend that’s worth keeping an eye on.

Quality Control in Breakfast Cereal Production

Like with all other food production industries, the breakfast cereal production process needs to be carefully
monitored for quality and sanitation. This means that the equipment used should be cleaned and sterilized
regularly, while the grain should be inspected for any foreign matter as soon as it arrives in the factory.

Monitoring Temperature and Moisture and Microbial Growth Surveillance

The temperature and moisture content should also be monitored constantly during the manufacturing
process, as well as the quality of the stored cereal. On top of that, the processing of cereal needs to be
constantly inspected for any signs of microbial growth. The most common microorganisms to watch out
for include Salmonella, fungi, Aspergillus, Penicillium, spore-forming bacteria, and Fusarium. Some of
these molds will produce mycotoxins, which can cause severe illness or even death.

While mold contamination in raw cereal grains cannot be prevented entirely, microbial growth can be
controlled if sanitary manufacturing practices and equipment are used.

Challenges with Additional Ingredients and Contamination During Production

It’s important to keep in mind that, while microbial growth can be halted when heat is applied, there is the
possibility of later contamination when other ingredients are added. These ingredients include:

 Sweeteners,
 Coloring,
 Flavorings,
 Preservatives,
 Vitamins,
 Minerals,
  Other additives.

Transferring the product between different areas of production on bulk material handling equipment can
also pose a high risk of contamination (from heating to drying, to coating, and to packaging).