1. Working Principle

1. Raw Material Mixing: High-quality raw materials (such as wheat flour, corn powder, rice powder, or their mixture) are put into the mixer, mixed evenly with an appropriate amount of water and auxiliary materials (such as oil, salt, seasoning) to form a uniform dough, laying a solid foundation for subsequent extrusion molding.
2. Twin-Screw Extrusion & Shaping: The mixed dough is conveyed to the twin-screw extruder through a screw conveyor. Under the combined action of high temperature, high pressure and shear force inside the extruder, the dough is fully gelatinized, puffed and plasticized, and then extruded through a special bugle-shaped mold to form the iconic curved shape of bugles. The extruder uses precise pressure control and mold design to ensure that each bugle has a uniform size and shape.
3. Frying & Deoiling: The extruded bugle blanks are conveyed to the continuous fryer, where they are fried at a constant temperature (controllable between 160℃-180℃) to achieve a crispy texture and golden color. After frying, the bugles are sent to the deoiling machine to remove excess surface oil, making the finished product non-greasy and healthier.
4. Seasoning & Cooling: The deoiled bugles are evenly coated with various seasonings (such as cheese, barbecue, spicy, original flavor) by the seasoning machine while they are still hot, ensuring uniform flavor distribution. Then they are sent to the cooling conveyor to cool down to room temperature, which helps to maintain the crispness of the bugles and prevent moisture regain.
5. Packaging: The cooled and seasoned bugles are conveyed to the automatic packaging machine, which completes weighing, bagging, sealing and coding in one go, ensuring the freshness of the finished product and extending its shelf life.

2. Application

• Snack Food Factories: Specialized in producing fried bugles of various flavors (original, cheese, barbecue, spicy, etc.) for wholesale and retail in supermarkets, convenience stores, and online e-commerce platforms.
• Food Processing Enterprises: Used to expand the product line, add fried bugles and other fried snack products, enrich the product portfolio, and meet the diverse needs of consumers.
• Customized Production: By replacing the mold, shaping or cutting machine, the production line can also produce other 2D and 3D fried snacks, such as salad chips, rice crust, pillow-shaped snacks, goldfish-shaped snacks, sticks, square sheet rib chips, diamond chips, wavy chips, etc., realizing multi-purpose production and improving equipment utilization rate.
• Global Market Supply: The finished bugles produced by the production line are crispy, non-greasy, rich in nutrition and easy to digest, which are popular among consumers all over the world. They are suitable for export to Europe, America, Southeast Asia, Africa and other regions, meeting the food safety standards of various countries.

3. Product Advantages

• High Automation & Efficiency: The entire production line adopts PLC automatic control, from raw material mixing to finished product packaging, realizing fully automatic operation, reducing manual labor intensity, saving labor costs (only 2-3 operators are needed for the whole line), and the production efficiency is 5-8 times that of manual production. The production capacity can be customized according to your needs, ranging from 100kg/h to 400kg/h.
• Stable Product Quality: The twin-screw extruder adopts precise temperature and pressure control, and the special mold ensures that each bugle has a uniform shape, consistent size and crispy taste. The continuous fryer maintains a constant temperature, avoiding uneven frying caused by manual operation, and the deoiling machine effectively removes excess oil, making the product non-greasy and meeting food safety standards. All equipment is made of food-grade 304 stainless steel, which is corrosion-resistant, easy to clean, and complies with international food hygiene standards (CE, ISO 9001 certified).
• Multi-Purpose & Flexible: By replacing different molds and adjusting production parameters, the production line can produce bugles of different sizes, shapes and flavors, as well as other types of fried snacks. It can meet the personalized production needs of different enterprises and adapt to the changing market demand. The raw materials can be single or mixed, such as wheat flour, corn powder, rice powder, starch, etc., with wide adaptability to raw materials.
• Energy Saving & Environmental Protection: The production line adopts advanced energy-saving technology, the extruder uses efficient heating elements, the fryer adopts energy-saving insulation design, which reduces energy consumption by 20% compared with ordinary production lines. It does not need a boiler, the production process is simple, with little pollution and low carbon emissions. The waste material can be reused, reducing material waste and production cost.
• Durable & Easy to Maintain: The screw is made of 38CrMoAl alloy, processed by nitriding technology, with high strength, wear resistance and self-cleaning ability. There is no need to discharge or clean the barrel and screw when changing materials. The gearbox has an automatic lubrication function, extending the service life of the gear. The overall structure of the equipment is reasonable, easy to disassemble, assemble and maintain, reducing the maintenance cost and downtime.
• Customizable & Turnkey Service: We provide customized solutions according to your production scale, workshop size, product requirements and budget. The production line can be customized in terms of production capacity, equipment configuration, voltage (380V/50Hz, 220V/50Hz, or customized according to local voltage of different countries) and other aspects. We also provide turnkey service, including installation, commissioning, training and after-sales support, helping you put the production line into use quickly.

4. Technical Parameters

• Extruder Type: Twin-screw extruder (co-rotating)
• Fryer Type: Continuous fryer (electric, oil-fired or gas-fired optional)
• Screw Material: 38CrMoAl alloy (nitriding treatment)
• Motor Type: 3-phase asynchronous motor (Siemens optional)
• Control System: PLC automatic control, touch screen operation
• Weight: Customized according to model (about 3000-8000 kg)
• Workshop Requirement: About 50-100 square meters (depending on model)

5. FAQ (Frequently Asked Questions)

1. Q: What raw materials can be used in this production line? A: The production line can use a variety of raw materials, including wheat flour, corn powder, rice powder, starch, and their mixtures. You can also add appropriate auxiliary materials (such as oil, salt, sugar, seasoning, etc.) according to the taste of the finished product. The raw material adaptability is wide, which can meet different formula requirements.
2. Q: How long does it take to install and commission the production line? A: The installation and commissioning time depends on the model and configuration of the production line. Generally, it takes 7-15 days for standard models. Our professional technical team will send engineers to your site to complete installation, commissioning and staff training, ensuring that the production line can operate normally and stably.
3. Q: Can the production line produce bugles of different sizes and shapes? A: Yes. By replacing different bugle-shaped molds and adjusting the cutting machine, the production line can produce bugles of different diameters, lengths and curved shapes. At the same time, it can also produce other types of fried snacks by changing molds, realizing multi-purpose production.
4. Q: What is the warranty period of the production line? A: We provide a 1-year warranty period for the entire production line. During the warranty period, if there is any quality problem with the equipment (excluding man-made damage and wearing parts), we will provide free replacement of parts and on-site maintenance services. After the warranty period, we will provide lifelong maintenance services and supply original parts at preferential prices.
5. Q: Do you provide technical training and after-sales support? A: Yes. We provide free technical training for your staff, including equipment operation, daily maintenance, parameter adjustment, fault handling, etc., until your staff can operate the equipment independently. We also have a professional after-sales team, providing 24-hour online consultation and on-site maintenance services (supporting on-site service and long-distance service) to solve your problems in a timely manner.
6. Q: Is the production line compliant with international food safety standards? A: Yes. All equipment of the production line is made of food-grade 304 stainless steel, which is non-toxic, tasteless, corrosion-resistant and easy to clean. The production line has passed CE, ISO 9001 and other international certifications, complying with the food safety standards of Europe, America, Southeast Asia and other regions, and can be used for export-oriented production.
7. Q: How to reduce the production cost when using this production line? A: The production line adopts energy-saving design, which can reduce energy consumption by 20% compared with ordinary production lines. At the same time, the waste punching chips can be reused after grinding into powder, reducing material waste. In addition, the fully automatic operation reduces labor costs, and the durable equipment reduces maintenance costs, comprehensively reducing your production cost.

6. Packaging

• Packaging Material: High-quality wooden cases (fumigation-free, in line with international export standards) to prevent moisture, collision and corrosion during transportation. The inside of the wooden case is lined with shockproof foam and plastic film to further protect the equipment from damage.
• Packaging Method: The equipment is disassembled into appropriate parts according to the structure, and each part is wrapped with plastic film and shockproof foam, then placed in a wooden case. The key parts (such as extruder, mold, control system) are specially fixed and protected to avoid shaking and collision during transportation.
• Labeling: Each wooden case is labeled with detailed information, including product name, model, quantity, weight, dimensions, destination, and warning signs (such as “Handle with Care”, “Keep Dry”, “No Collision”), to facilitate transportation and receiving.
• Customized Packaging: If you have special packaging requirements (such as customized wooden case size, additional waterproof treatment, etc.), we can provide customized packaging services according to your needs.

7. After-Sales Service

• Warranty Service: 1-year free warranty for the entire production line. During the warranty period, if there is any quality problem with the equipment (excluding man-made damage and wearing parts), we will provide free replacement of parts and on-site maintenance services. We will send engineers to your site within 3-7 working days (depending on your region) to solve the problem.
• Lifelong Maintenance: After the warranty period, we provide lifelong maintenance services. We will charge a reasonable fee for maintenance and parts replacement, and provide original parts at preferential prices to ensure the long-term stable operation of your equipment.
• Technical Support: 24-hour online technical consultation service. You can contact our after-sales team by phone, email, WhatsApp, etc., and we will reply to your questions and provide solutions in a timely manner. We also provide regular technical return visits to understand the operation status of the equipment and provide professional suggestions for maintenance and optimization.
• Spare Parts Supply: We have a large number of original spare parts in stock, including screws, molds, heating elements, sensors, etc., which can be delivered to you quickly to avoid long downtime caused by lack of spare parts.
• Training Service: Free on-site training for your staff, including equipment operation, parameter adjustment, daily maintenance, fault diagnosis and handling, etc., until your staff can operate the equipment independently. We also provide follow-up training services if you have new staff or need to upgrade your skills.
• Customized After-Sales Plan: According to your production scale and usage needs, we can provide a customized after-sales service plan, including regular maintenance, spare parts reserve, technical upgrade, etc., to meet your personalized after-sales needs.

Why Choose Us?