Bellaex is showcasing its steam‑flaked corn (SFC) production line solution, delivering uniform flakes, higher starch availability, and reliable 24/7 uptime for ruminant nutrition. Designed for capacities from 1 to 30 TPH, the line is suitable for corn, oats and barley, and is already field‑proven in multiple countries with over 150 large deployments each year.

Built around the principle that “75% of corn energy comes from starch”, the Bellaex SFC line focuses on maximizing starch gelatinization and digestibility. Steam flaking typically increases the net energy of corn by around 18%, with starch digestibility reaching up to 99% compared with 90% for dry‑rolled corn, while non‑starch organic matter digestibility also improves by about 10%.

From Raw Corn to Finished Flakes: A Fully Integrated Process

Bellaex’s steam‑flaked corn production line is engineered as a complete process from raw material intake to finished product storage and quality control. The standard flow chart is:

Cleaning → Moisture Addition / Soaking → Steam Conditioning → Metered Feeding → Flaking → Drying → Cooling → Screening → Storage / Packaging → Data & QA

Step 1 – Raw Material Selection and Cleaning

The line is designed for semi‑gelatinous corn (half vitreous, half floury), using either new crop or old grain, with a bulk density above 680–700 and aflatoxin within safe limits.

After intake, corn passes through a three‑stage cleaning system:

• Stone remover – removes stones and heavy impurities

• Vibrating screen – eliminates dust and larger foreign materials

• Magnetic separator – captures metal debris

The system supports both external deep cleaning at the silo entrance to reduce dust in the plant, and internal graded cleaning inside the workshop for multi‑stage impurity removal.

Step 2 – Moisture Addition and Soaking

To achieve optimal steam flaking performance, moisture is carefully adjusted before cooking:

1. Standard soaking process

   1. After cleaning, corn is lifted by bucket elevator and passes through a screw conveyor where it is evenly sprayed with 40–50°C warm water.

   2. The moistened corn then enters a soaking bin for 8–18 hours, allowing surface moisture to penetrate the kernel. Soaking time is adjusted based on the original moisture content of the corn.

2. High‑efficiency soaking (optional)

   1. A German ultrasonic moistening machine can be integrated to accelerate water penetration through micro‑cracks in the endosperm.

   2. This reduces soaking time to 4–12 hours and helps control the internal‑external moisture gradient to ≤ 2%, improving process consistency.

For new grain with very high initial moisture (>20%), the system can process directly into flakes, but Bellaex recommends pre‑drying to 17–19% in a drying tower to improve appearance, reduce energy consumption and maintain stable capacity.

Step 3 – Steam Conditioning and Cooking

Conditioned corn is then transferred to a conditioning tower for controlled steam cooking. The system focuses on water–material maturation and precise parameter control to ensure proper gelatinization:

• Cooking time: 45–65 minutes, adjustable according to starch type

• Temperature: 100–108°C, with steam pressure at 0.15–0.25 MPa

• Gelatinization degree: typically 65–85% (verified by DSC testing)

• Moisture change: from about 14% up to 18 ± 0.5%, which is a critical range for effective starch gelatinization

By balancing moisture, heat and time, the line prepares each kernel for efficient flaking and high digestibility in the final feed.

Step 4 – Roller Flaking

Immediately after cooking, corn is continuously fed into the flaking mill:

• Continuous online flaking keeps the process stable and ensures consistent product quality.

• The roller surface temperature is controlled at 80–90°C to maintain flake structure and prevent condensation issues.

• Flake thickness is precisely adjustable:

  • Standard cattle feed: 1.2–1.8 mm with a tolerance of ±0.05 mm

  • Ultra‑thin flakes (≤ 1.0 mm) for high‑digestibility rations

  • Thicker flakes (≥ 2.0 mm) for controlled rumen degradation rates

This level of control allows nutritionists and feed mills to fine‑tune rumen starch availability depending on production goals and health requirements.

Step 5 – Drying and Cooling

Fresh steam‑flaked corn leaves the flaker with elevated moisture and temperature. Bellaex’s line integrates horizontal drying and counterflow cooling to stabilize the product:

• Drying

  • Hot air temperature: 80–100°C

  • Drying duration: approximately 25–28 minutes

  • Moisture reduction: from 18–19% down to <14%, suitable for storage and transport

• Cooling

  • Counterflow cooling protects flake structure, prevents caking and reduces the risk of mold.

  • Controlled cooling helps maintain the aromatic smell, golden color and low fines that characterize high‑quality steam‑flaked corn.

Step 6 – Screening, Storage and Packaging

After drying and cooling, flakes are passed through a screening section to remove fines and ensure particle size consistency. Qualified product is then transferred to storage bins or packaging stations depending on the customer’s operation mode:

• Bulk storage for direct delivery to TMR mixing lines or feed mills

• Bagging systems (manual or semi‑automatic) for flexible logistics

• Optional palletizing and forklift handling to improve labor efficiency

The line also supports data collection and quality assurance, tracking key indicators such as bulk density, flake thickness and gelatinization degree for process optimization and full traceability.

Energy, Utilities and Operational Efficiency

Bellaex provides clear baseline data for capacity and energy planning. For a 10 TPH steam‑flaked corn line, typical utility demands include:

• Electricity: Installed power around 260 kW, with actual average energy consumption at roughly 65% of rated power

• Steam: 4–5 tons/hour at 0.8 MPa, with a 6‑ton boiler recommended

• Water: about 2 tons/hour, with recycling for kernel soaking

On this basis, producing 1 ton of steam‑flaked corn typically requires:

• 0.08 tons of water per hour

• 0.4–0.5 tons of steam per hour

• 16.9 kW of effective electrical power

These figures help operators plan infrastructure while keeping operating costs under control.

Delivering High‑Value Steam‑Flaked Corn for Modern Ruminant Nutrition

From cleaning and soaking to cooking, flaking, drying and storage, Bellaex’s steam‑flaked corn production line is designed as a tightly integrated system that enhances starch utilization, improves feed efficiency and supports higher performance in cattle feed programs.

With capacities from 1 to 30 TPH and flexible options such as ultrasonic moistening, advanced drying and cooling, and automated bagging, Bellaex offers a scalable solution for farms and feed mills seeking stable, high‑quality steam‑flaked corn as a core energy source in ruminant rations.