With the development of feed technologies, flake feeds are one of the feed types of which use and production have become widespread throughout the world. It is preferred for its digestibility, easy consumption and nutritional content.

Yusuf Elman
General Manager / Genel Müdür
Yemsa Makina

Flake feed is obtained by steam-softening grains such as corn, barley, wheat, oats and soybeans and crushing them by pressing them between rolls. The most preferred products in Turkey are corn and barley flakes.

This process increases the surface area of the grain and increases the digestibility by gelatinizing the starch in the grain. As the surface area increases, bacteria spread over the surface and the grain is utilized more effectively.

Consequently, there is no change in the starch content of the grain, yet the conversion rate of the grain is increased. For example, if a corn kernel contains 8% protein on average, flaked corn contains 8.5% protein. If the caloric value is 3000kcal, it is 3200kcal in flaked corn. If corn kernel is considered 88% dry, it consists of 70% starch, 8% protein and 10% oil.

Increased digestibility also increases the amount of energy taken from feed, thus increasing the efficiency of dairy cows.

PRODUCTION STEPS

•  Raw material selection,
•  Steam cooking (tempering),
•  Flaking (crushing),
•  Drying and cooling,
•  Resting and packaging
  
  
• 1. After the feed raw materials are firstly removed from the husk and foreign materials by screening method, they are transferred to the steam cheast with a vertical conveyor.

2. After being cooked with steam at the appropriate temperature (130-150 C°) for 45-60 minutes, it is crushed at the appropriate rate by passing through the crushing rollers (flaker) through the feeder and transferred to the drying unit by conveyor belt to prevent damage to the product.

3. In the dryer cooler unit, it is passed through hot and cold air chambers to be rested and reduced to ambient temperature and transferred to the finished product warehouse with conveyor systems.

4. The grain between two rotating rollers is compressed and the starch matrix (cell wall) is cracked and causes gelatinization.

5. Structural expansion and 100% crushing is achieved with a thickness below 0.8-1.5 mm.

6. After dryer cooler, it is taken to resting silos. The products are kept until shipment in silos that automatically establish moisture and heat balance.

MACHINERY USED IN THE PROCESS

As Yemsa Makine, all production processes of our machines are produced in accordance with international technical standards.

Steam Chamber, ensures that the raw material to be made into flakes is cooked with hot steam.

•  The cooking process takes place when the specially designed steam distributor system sprays the saturated steam evenly over the product from several points. The amount of steam can be adjusted according to the level in the steam chamber.
•  With the level and temperature sensors on the chamber, the temperature can be monitored and the maximum and minimum product quantity can be controlled.
•  There is a safety valve in the system that prevents pressure increase that may occur in excessive steam loads.
•  Chamber volumes vary according to the capacity of the flake unit. The cooking process takes place when the specially designed steam distributor system sprays the saturated steam evenly over the product from several points. The amount of steam can be adjusted according to the level in the steam chamber.
  
  With the level and temperature sensors on the chamber, the temperature can be monitored and the maximum and minimum product quantity can be controlled.
•  There is a safety valve in the system that prevents pressure increase that may occur in excessive steam loads.
•  Chamber volumes vary according to the capacity of the flake unit.
• Flaking mill ensures that grain products such as corn, barley, wheat and soybean, which are cooked with steam from the steam chamber, turn into flakes.
•  The flake rolls are independently driven by two separate motors.
•  All parts exposed to steam are made of stainless steel,
•  Product thickness can be adjusted manually or electronically via hydraulic system,
•  There is a feeder system on the machine where the flow amount can be adjusted and distributes the product evenly to the flake rolls,
•  Mass and vibration are absorbed thanks to the spring chock kit on the underside,
•  Cleaning mechanism for flake rolls is available.
• Horizantal Dryer Cooler; dehumidifies the products coming out of the flake press by heating them with hot dry air provided by steam radiators, then reduces the temperature with cold dry air and makes them ready for packaging,
•  Product drying and cooling is carried out in layers in perforated pans connected to a staggered aligned palletized chain system,
•  The small materials passing through the perforated pans are sieved and separated by bottom scraping at the bottom floor and added to the system,
•  The product particles mixed in the air drawn through the machine are brought back into the system with the cyclone placed in the aspiration system,
•  Pan cleaning is realized with jet pulse system,
•  Speed control is provided with speed regulated motors,
•  Product flow is controlled and homogeneous product distribution is ensured with the valve systems located at the product inlet,
•  The body can be optionally manufactured from galvanized, AISI 304 stainless steel or S235JR sheet.
  
  
  

ADVANTAGES

1. High energy content: Barley and maize are cereals known for their high energy value. Barley and maize flake feed provides a high-calorie food source for cattle. This helps animals meet their energy needs and help them grow.

2. Digestibility: Barley and corn flake feed comes in thin pieces that are easy to digest. This can easily pass through the digestive tract of cattle and improves the digestive process. It can be more effectively fermented by rumen bacteria.

3. Consumption becomes easier: Barley and maize flake feed has a structure that quickly disperses under water and can be easily consumed by cattle. The flaked structure allows animals to use less effort to chew or break up the feed.

4. Nutritional value: Barley and maize offer a significant nutritional content. Barley and maize flake feed contains important nutrients such as protein, carbohydrates, fiber and some vitamins and minerals. This helps cattle to meet their nutritional needs and grow healthy.

5. Shelf life: Barley and maize flake feed usually has a long shelf life once it has been dried and properly packaged. This ensures that you can store and use the feed for longer.

6. Cost effective: Barley and maize is often a more economical option compared to other feed sources. Barley and maize flake feed can be more cost-effective because it is produced by processing maize.

Yemsa Makina has been manufacturing and marketing in the feed machinery sector since 1999.

Our company, which produces in an area of 34.000 m² today, was established in order to provide the best service to meet the expectations of its customers operating in the feed sector, to respond to the need for the products it manufactures with the developing machinery and equipment technology in the sector in the fastest, highest quality and most economical way with the YEMSA MAKİNA brand.

We are exhibiting at VIV Turkey 10th International Trade Fair for Poultry and Technologies

We, as Yemsa Makine, are proud to be the leading organization of the industry with our machinery and equipment that have proven themselves with numerous facilities in Turkey and abroad. For your opinions, requests and suggestions, we would be happy to welcome you with many of our machines at our booth in Hall 3/Hall B22 at the VIV Turkey 10th International Trade Fair for Poultry and Technologies, which will be held in Istanbul on July 6-8.