Breakfast Cereals
Cereal Master™ - a comprehensive capability in
breakfast cereal production
Baker Perkins combines a portfolio of modular process lines and unit machines with the process knowledge and
engineering expertise to create systems for virtually every kind of RTE (Ready To Eat) breakfast cereal product.
Our modular approach to process design means that our Cereal Master™ lines can be The product range can then be expanded or output increased by incorporating additional
adapted or extended with additional process units to make the new products required by units into the line. Established businesses work with Baker Perkins to add interest and
this established, yet still developing market. The greater flexibility that this brings to cereal variety to product ranges and install additional capacity by taking advantage of new
production quickly maximises return on equipment investment. We offer steam-cooking, technology and our flexible, modular design philosophy.
extrusion, flaking, shredding, toasting and coating processes for flaked, shredded and
extruded breakfast cereals. Baker Perkins is able to fully support newcomers to the market by helping them to create
a range of high quality products using either a standard extrusion or traditional
steam-cooking line.
Cereal Master™ modular lines provide the ideal
platforms for cereal manufacturers to develop their
businesses or respond to changes in the market.
High Quality
Along with the expert support and advice on offer
Modular & Flexible
from Baker Perkins, plus our promise of Lifetime
Systems
Support, this makes Baker Perkins the supplier of
choice for growing cereal companies worldwide.
Products
Baker Perkins offers complete systems for the production of
high-quality traditional, extruded and co-extruded cereal products.
The modular design philosophy of our Cereal Master™ lines allows
product ranges to be changed or expanded to meet the needs of
growing businesses, or to respond to new market opportunities.
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Traditional corn, wheat, bran or multigrain flakes as Complete granola systems that ensure gentle handling
well as shaped wheat biscuits can be made using and precise baking throughout the process. Baker Perkins’
Baker Perkins’ rotary steam cooking and flaking equipment can be utilised for the production of kibbled cereal
process. clusters or bars with fruit, nuts, seeds or other additions.
A range of shredded cereals, including multi-layer
shredded wheat, bran sticks and layered corn, rice
or wheat shredded squares can be produced with
Baker Perkins’ Shred Master™ systems.
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Baker Perkins’ Cereal Master™ extrusion technology Co-extrusion extends the capability of the extrusion
creates high quality direct expanded cereals and process to make added-value products with a variety
extruded flakes. Typical products include corn flakes, of fillings, such as chocolate, fruit pastes or creams.
multigrain rings, alphabet shapes and cocoa curls. Products may be formed into 2D pillows or 3D shapes.
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Traditional Flakes - Cereal Master™ TX
Dedicated lines that are easily extended to change or diversify the product range.
Gentle steam cooking of cereal grains in the Cook Master™ Rotary Cereal Cooker ensures Cereal Master™ TX is an expandable process. A standard line making traditional wheat and
that the texture, flavour and nutritional benefits of wholegrain ingredients are retained in the bran flakes can be progressively extended to manufacture multigrain products,corn flakes, and
final product. Consistent flake quality is achieved using Baker Perkins’ Flake Master™ flaking coated flakes by incorporating additional units, such as drying and tempering equipment, or
rolls, before controlled toasting and drying of the flakes takes place in the Thermoglide2™ Baker Perkins’ Syrup Coating System.
Toaster.
This modular approach to process design allows the Cereal Master™ TX system to grow as
the customer’s business expands or market demands change.
COOK MASTERTM Bran & Wheat Flakes Multigrain Flakes Traditional Corn Coated Flakes
COOKERS
FLAKE MASTERTM
FLAKING MILL SYRUP SKID
THERMOGLIDE2TM
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Granola Products
The healthy image of oats can be harnessed to make granola cereals or bars with enhanced consumer appeal.
Crunchy granola cereal products are made by blending dry ingredients with oil and sugar to Baker Perkins’ systems ensure gentle handling throughout the process, and accurate baking to
form a mass. Baker Perkins’ systems spread this mass evenly across the width of an oven achieve the ideal balance between product quality and efficient production.
band to provide a metered feed and form a loosely compacted sheet, without damaging any
ingredients.
Fruit Granola Kibbled Granola Crunchy Granola Bars
The product is then gently baked to melt the sugar and remove moisture. Assisted cooling at
the discharge binds the mass together to give the characteristic granola crunch.
After cooling, the sheet is either broken and kibbled into small clusters, or slit and guillotined to
produce granola bars.
KIBBLING UNIT/
TRUBAKETM SLITTER GUILLOTINE
CONVECTION OVEN
MIXER
COMPRESSION TRUBAKETM
ROLL CONVECTION OVEN
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Extruded & Co-Extruded Cereals - Cereal Master™ EX
Expandable lines with the capability to make an extensive range of breakfast cereals.
Based on Baker Perkins’ SBX Master™ twin-screw cooker extruder, a standard Cereal Additional units can be easily incorporated to build capability: co-extrusion equipment, flaking
Master™ EX line can produce a variety of high-quality direct expanded and extruded cereal rolls, cereal cookers and dryers can be added to form versatile plants suitable for volume
products, such as multigrain rings, cocoa balls, bran sticks and crisped rice. production of high-specification co-extruded cereals and extruded flakes.
The SBX Master™ Extruder and preconditioner have been designed to bring additional A co-extrusion system extends the capability of the process to make high-value co-extruded
flexibility and throughput to the production of breakfast cereals. Mixing, pre-heating and products, such as chocolate, fruit or cream-filled pillows, in a range of eye-catching 2D or 3D
hydrating the dry ingredients in the preconditioner rather than the extruder enables it to be shapes.
smaller and optimised to allow more time for cooking, texture development and cooling.
Direct Expanded
Cereals Filled Pillows Extruded Flakes Multigrain Flakes
PILLOW CRIMPER
SBX MASTERTM
PRECONDITIONER
SBX MASTERTM SYRUP SKID
EXTRUDER
THERMOGLIDE2TM
COOK MASTERTM
CREAM FEED TOASTER
COOKER
SYSTEM FLAKE MASTERTM
FLAKING MILL
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Shredded Cereals
Distinctive, multi-layered shredded or stranded cereals can be produced with Baker Perkins’
Shred Master™ system. Shredding is an excellent alternative to flaking that can widen the
appeal, interest and variety of a cereal range.
Multi-layer shredded wheat or shredded squares can be created with a range of crunchy The cooked grains are formed into very thin sheets by passing them between pairs
textures, using both single and multigrain recipes. Many shredded cereal products contain of contra-rotating shredding rolls. Several pairs of rolls are used in series to lay webs
just a single ingredient, making them attractive to both traditional and health-conscious cereal on top of one another to form a multi-layered sheet. Up to 20 layers can be combined; fillings,
consumers. such as chocolate or fruit, can also be incorporated between layers for additional variety.
Corn, bran, wheat, oat or rice grains can be processed without the need for additional
ingredients, giving the cereals impeccable health credentials. Natural flavours can be
enhanced by glazing or frosting to create innovative products with unique texture and taste
variations.
Malted Shredded Filled Shredded Sugar Coated Shredded
Cereals Cereals Cereals Shredded Wheat
COOK MASTERTM SHRED MASTERTM THERMOGLIDE2TM
COOKER SHREDDING LINE TOASTER
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Equipment Shredding
Shred Master Shredding Rolls
TM
Baker Perkins’ shredding rolls form cooked
cereal grains into distinctive, multi-layered
shredded or stranded products. Cooked grains
Cooking are formed into very thin sheets between pairs
of contra-rotating shredding rolls: sheets are
Cook Master Rotary Cereal Cooker
TM
then layered on top of each other to build the
shredded product. Fillings may be incorporated
Baker Perkins’ Cook Master™ Rotary Cereal
to enhance consumer appeal and add value.
Cookers have fully automatic batch operation
and a highly effective mixing action. The
rotating steam cooker handles milled or whole
grain cereal products including
wheat, corn, bran and oats.
Toasting
Thermoglide2 TM
The Thermoglide2™ is designed for drying and
toasting breakfast cereals uniformly and consist-
ently. The product is gently lifted and
rotated in a cushion of air to ensure it is
processed with minimum damage.
Flaking
The Thermoglide2™ combines excellent
Flake Master Flaking Rolls
TM
processing with efficient dust extraction in a
State-of-the-art control technology enhances the compact and energy-efficient unit.
performance of the latest generation of flaking
rolls for high-output, high-quality cereal
production. These units provide consistent
processing of a wide range of corn and Extrusion
multigrain flakes, from both traditional
rotary cookers and cooker-extruders. SBX Master Twin-Screw
TM
Cooker-Extruder
The SBX Master™ is a multi-purpose
extruder that handles a wide variety of cereal
products. Ingredients are texturised and
cooked through a combination of heat,
mechanical shear and moisture addition;
flavours and colours can be added easily.
Equipment Colour Change
Spectrum Colour Change System
An innovative, cost-cutting colour-change
system for extruded cereals that extends
Extrusion Baker Perkins’ cereal extrusion capability.
The skid-based Spectrum system enables
SBX Master Preconditioner
TM changeover between colour variations of an
extruded cereal to be made ‘on the run’,
The preconditioner mixes, heats and hydrates with minimal waste. A typical application
ingredients for processsing in Baker Perkins’ is mixed fruit colours in a single pack.
SBX Master™ extruders. Cooking times and
mechanical shear energy in the extruder are
reduced, which widens the range of products that
can be made on the extruder and maximises both
output and quality. Frosting & Glazing
Syrup Coating Systems
Fully automated systems apply frosting and
glazing to enhance the flavour and appearance
of both traditional and extruded cereals.
They enable a product range to be expanded
Co-Extrusion efficiently and cost-effectively. Syrup skids,
coating drums and driers can operate in both
CoEx Master Co-Extrusion System
TM sugar and sugar-free modes, with simple
interchange between the two.
Filled pillows comprise a crispy outer shell with
a fruit, cream or chocolate filling. These can be
made on any new or existing Baker Perkins
extrusion line simply by adding a co-extrusion
die, cream feed and pillow crimper to create Laboratory Equipment
diverse, high value co-extruded products with
unique shapes and fillings. MPF19 /MPF24 Research &
Development Extruders
Benchtop and low-output twin-screw extruders
for research, development and laboratory work;
used to try out new ideas, assess ingredients,
provide test marketing samples, and even
make small production batches
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Baker Perkins’ Innovation Centres in the UK and USA are staffed by expert process technologists who help
customers turn concepts into commercially viable products.
Both centres contain a full range of extrusion development and test facilities for conducting The range of equipment is permanently available, and specialised units can be brought in from
equipment trials, developing products and producing evaluation samples, with the assurance other suppliers to complete a process if necessary.
of complete confidentiality. The UK facility also has the capability for traditional flakes and
shredded products. Alternatively, customers are welcome to bring along their own technologies to integrate with
our existing equipment and cross conventional process boundaries.
Development work can comprise a number of small runs to test a range of different
ideas, or longer runs to produce samples for test marketing or other types of assessment. Companies from every part of the world find that thorough trials, often using their own raw
All the equipment faithfully reproduces the processes used in full size plants, so process materials or ingredients, provide a reliable basis for trouble-free commissioning of a new plant
settings and product characteristics achieved in the lab are easily transferred to a production or launch of a new line.
environment.
Whether supplying a complete line or a single unit machine, we offer the same comprehensive service from start to finish.
Our commitment to Lifetime Support includes full process and engineering assistance for the life of the equipment.
For base fondant, fully automatic ingredient weighing and mixing is followed by cooking and Use of the fondant preparation system alongside Baker Perkins’ ServoForm™ depositor
drum cooling. Agitation in a fondant beater then crystallises the sugar to produce a fine provides great flexibility and process control. Product quality is improved through a more
fondant. consistent shape, and depositing brings the flexibility of making a variety of shapes, colours
and flavours simultaneously.
To produce a fondant crème, the fondant is passed to a crème mixer where it is combined with
hot ‘bob’ syrup. This has been cooked with the fondant syrup but bypasses the cooling and Compared with traditional forming processes, space, labour and cost are reduced, while
beating stages. Adding ‘bob’ syrup to the beaten fondant produces a fine-crystal confectionery hygiene and safety are improved. Production cycles are cut considerably.
crème, ideal for depositing.
Individual fondants can be produced in a range of colours, flavours and shapes, and can
incorporate centre fillings such as nuts, jelly, fruit pieces and liquids. The regimented
discharge from the depositor enables a direct link to the enrober for
output that is chocolate coated.
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Baker Perkins Ltd Baker Perkins Inc
Manor Drive 3223 Kraft Ave SE
Paston Parkway Grand Rapids
Peterborough MI 49512-2027
PE4 7AP USA
United Kingdom
T: +44 1733 283000 T: +1 616 784 3111
F: +44 1733 283004 F: +1 616 784 0973
E: bpltd@[Link] E: bpinc@[Link]
I: [Link]
© Baker Perkins 04/24