Extruded snacks processing machines
Jas enterprise bring forth an impeccable range of Extruded Snacks that are highly demanded by our clients for their taste and crispness. Apart from this, we also offer baked and fried type extruded snacks processing lines.
Kurkure Processing line includes following equipments
- Grit mixer and feeder
- kurkure extruder
- Feeding elevator
- Rotary sieve machine
- Continuous frying system with heat exchanger
- De-oiling belt
- Linear feeder
- Flavour applicator and drum
- Slurry system
- Control panel
fully automatic kurkure making machines
Introduction of Fully Automatic kurkure type snacks food production Lines
Kurkure are extruded snacks, very crunchy and great in taste. Kurkure are made by extrusion process. The kurkure corn meal is moisturized in the flour mixer with water and fed to the rotary die extruder. In the extruder, due to excess heat and pressure from the screws the meal gets heated and the moisture content gets reduced. The meal passes through the die and gets cut by the cutting knifes into required lengths. The kurkure are fried in cooking oil and then cooled before flavoring. Seasoning is sprayed on the kurkure to improve their taste.Machines involved in making kurkure:
1. Flour mixer with feeder - to mix corn meal with water to prepare the flour for kurkure and more mixture from mixer machine to rotary head extruder for kurkure type snacks.
2. Rotary head extruder for kurkure type snacks - to cook the corn meal and extrude the kurkure from the die. The rotary die twists and curls the meal before extruding giving a uniform texture.
3. Feeding elevator - this equipment is proved for transfer the corn curls from extruder to rotary sieve.
4. Rotary sieve - the fines or small particles that are produced as the collets are removed by this rotary sieve.
5. Continuous frying system with heat exchanger - to fry the kurkure in hot cooking oil. The uniform frying introduces the crunchy taste to the kurkure.
6. De-oiling belt – to remove exceed oil from corn curls.
7. Linear feeder - this devices used to feed corn curls for flavouring on seasoning system.
8. Automatic seasoning system with Slurry System - to add required seasoning to the fried and cooled kurkure to give the different flavours to them
Grit mixer feeder
Description of Grit mixer feeder
To mix corn meal with water to prepare the flour for Kurkure from corn meal, rice meal, corn grits, millet, etc as raw materials for production of puffed corn curls, Jas enterprise manufacturer of continuous proportioning in-line mixers. In-line mixers are made from polished stainless steel 304. Discharged material convey to the rotary head single screw extruder by screw feeder. Cornmeal is carefully chosen for use in puffed corn curls. The cornmeal must be of fine texture so that it produces a pleasant feel as it is eaten. Also, cornmeal with a low moisture content is used in this process. Too much moisture in the meal will render the product soggy. Cornmeal inspected for moisture content is placed into a mixing bin and sprayed with a fine mist of water as it is stirred. Water poured directly into the meal will result in gluten formation, uneven distribution of moisture, and clumping of wet grain. When the desired consistency is achieved, the mixture is immediately extruded.
Description of Kurkure extruder
We manufactuer kurkure extruder where in we carry the process of gelatinization in a concentric cavity between two dye, one rotary with 3 blades (fingers) plus grooves, and the other one with grooves only.
The action of these blades on the rotating head creates the necessary condition of pressure and heat to achieve gelatinization of the raw material. Product is expanded and formed in a narrow gap between the two plates.
Blades affixed to a circular knife support ring mounted on the outer edge of the rotor cuts to the desired size. Constructed with painted mild steel, 2" tubular frame, mild steel painted belt guard, stainless steel hopper, stainless steel guard at product discharge and painted castings.
Our kurkure extruder inclueds following features and applications:
- Easy metered flow of raw material enabled because of gravity food hopper
- Speed control of feed screw via variable-frequency drive
- Manual head gap controlled by mechanical ratchet
- Table slides back via hand crank for easy access to extruder component
- Production capacity 70 kg/hr
- Motor feed screw 5 hp with variable-frequency drive
- Main drive motor 15 HP
- Dimensions 84 inch length X 24 Inch Width X84 Inch height
Description of Feeding elevator
After extruding of corn curls from kurkure exruder the kurkures are convey for separating the fines or small particles. This incline feeding elevators all cotacting parts are food grade.
Description of Rotary sieve
The fines or small particles tend to absorb oil and flavorings and are undesirable to include in a package of cheese curls. The fines or small particles that are produced as the collets are removed by this rotary sieve. Adapted for a variety of products and can simultaneously sort into several different grading classifications.
Pellet kurkure nicknack continuous fryer
Description of Pellet kurkure nicknack continuous fryer
State-of-the-art Pellet frying line for uniform frying of various pellet snacks like curls, balls, rings, wheels, tubes, chips, sticks, kurkure, Nik Naks, chataka pataka, Twisties, Bingo! Tedhe Medhe etc. The product quality is excellent and system is simple and easy to operate.
This phase represents the heart of the whole process as the immersion of pellet into the oil bath causes its expansion: the final step is the edible snack.
The key principle is that the quick heating of the pellet (frying temperature ranges between 185-200°C) causes the softening of the matrix and the very quick transformation of its residual water in vapour, so that the consequent pressure produces the expansion of the pellet.
Complete system consists of frying section and peddles, sub merger belt, top hood, takeout belt, oil filter, heat Exchanger.
The flow of oil ensures a linear flow of oil, which is necessary in order to have a uniform frying time for the entire product.The equipment is designed to have a low oil holding capacity (150 Liter) in order to achieve low oil turnover ratio.
It is Coil type- Seamless Stainless, Steel tubes fitted in mild steel shell, the oil is heated by hot air not direct flame in coils which has an inlet system from one end and heated oil will be coming out from other end and will go to the fryer. Whole burnt fuel used in this system that gives you more than 55% saving in Fuel.
Oil Tank with Cooling System
A double jacketed stainless steel oil Tank with 250 Liter capacity will be supplied with the fryer for storing fresh and used oil. The Tank is designed in such a Way so that the flow of water is there in the outer shell for cooling the oil.
Technical spacification of Pellet Frying Line
- Belt Width: 500 mm
- Oil Holding Capacity: 150 Liter
- Fuel: Deisel/Kerosene or Gas
- Heat Energy: 100,000 kcal
- Power Energy: 3.5 KW
Pellet De-Oiling conveyor
Description of Pellet De-Oiling conveyor
We are expert in providing a broad range of de oiling conveyors, which is used to de-oil the material after frying and transfer to next process of flavour application. This is broadly used in snacks and potato chips lines for separating extra oil are separated from fried material. This is fabricated from better quality raw materials which are sourced from trustworthy and reliable vendors in compliance with international standards. Offered conveyor is highly appreciated for smooth operation, easy mechanism, heavy load carriage capability and longer functional life.
Description of Linear Feeder
The feeder receives fried pellets from takeout belt and feed to the flavoring drum the feeding speed can be controlled by a VFD. A tray is also fitted on the top of the feeder where dry flavor falls from the applicator.
flavour applicator and tumbler
Description of flavour applicator and tumbler
Fried snacks are flavoured according to consumer tastes and the type of pellet to be used. From the technical point of view, it is necessary that flavouring be made immediately after the frying process, so that the absorption of the oil in the surface is completed.
flavouring system should grant:
- A uniform distribution of snack seasoning, avoiding the forming of lumps;
- Reduced quantity of flavour wasted;
- gentle handling of snacks.
Jas enterprise's flavouring drum, where pellets are put into and are continuously overturned due the rotation of the drum. The flavour is sprayed on the pellet in order to avoid the forming of lumps.
In the case of hot-air expansion or �Puffing press� technology, it is necessary to spray first the oil and then the flavour on the pellets; as a consequence, the total oil content is normally kept under 10%.
We manufacture Continuous Flavouring Applicator, which is a rotary horizontal drum blending the fried products and flavor together so that the flavor is evenly coated as for as practically possible. Degree of inclination of the drum is adjustable according to product. Constructed with stainless steel 304, the drum is provided with inwardly projecting product lifters.
Slurry mixing and application systems
Description of Slurry mixing and application systems
Many things are born out of necessity, and Jas Slurry mixing and application systems is no exception. Jas Slurry mixing and application systems is a slurry mixing and application system which has been developed for the requirements of today's modern snack food processing lines. The unit is designed to mix seasoning and oil at a required ratio and deliver resultant slurry, at a predetermined rate, to products passing through a flavour drum.
Due to continuous improvements, we reserve the rights to alter and/or amend dimensions/design without prior notice.
The figure for capacities given are for guideline only may very force case to case and depending many factors.