Global Solutions for the Food Industry

Doritos Production Process with Jinan Twin Screw Extruder

Making Doritos (tortilla chips) with a Jinan twin-screw extruder follows a continuous, high-efficiency process: mixing → extrusion → shaping → drying/frying → seasoning → packing. Below is a step-by-step guide with formula, parameters, and line configuration.
 
  1. Raw Material & Formula (Standard Cheese Flavor)
     
    Use 80–100 mesh corn flour (main), corn starch, and minor additives.
 
Ingredient Percentage Notes
 
Corn flour 70–75% Base material
 
Corn starch 10–15% Improves crispness
 
Wheat flour 5–8% Enhances ductility
 
Vegetable oil 2–3% Lubrication
 
Salt 1–1.5% Basic seasoning
 
Cheese powder 2–4% Flavor core
 
Water 18–22% Adjust to 20–22% moisture
 
  1. Production Flow & Key Operations
     
    Step 1: Raw Material Mixing
     
    Use a double-shaft mixer (Jinan standard) for 5–10 min.
     
    Target: uniform mixture with 20±1% moisture, “clumps when squeezed, breaks when touched.”
 
Step 2: Twin-Screw Extrusion (Core)
 
Use Jinan SLG65/SLG70 twin-screw extruder (L/D=24–32, 100–300 kg/h).
 
Barrel temperature (3 zones):
 
Zone 1 (feed): 60–80°C
 
Zone 2 (kneading): 120–140°C
 
Zone 3 (die): 140–160°C
 
Screw speed: 300–400 rpm (high shear for starch gelatinization).
 
Die: thin sheet die (0.8–1.2 mm gap) for flat tortilla base.
 
Extrusion effect: starch gelatinization ≥90%, forms microporous structure for crispness.
 
Step 3: Shaping (Triangular Doritos)
 
Extruded sheet → roller compactor (adjust thickness to 0.6–0.8 mm).
 
Triangular cutter (custom mold) cuts into classic Doritos triangles.
 
Conveyor speed synchronized with extruder to avoid stretching.
 
Step 4: Drying or Frying (Choose One)
 
Option A: Baked (Low-Fat, Healthier)
 
Multi-layer hot air dryer: 120–140°C, 15–20 min.
 
Final moisture: ≤3.5% (crisp, no sogginess).
 
Option B: Fried (Authentic Crispy)
 
Continuous fryer: 170–180°C, 8–12 sec.
 
Oil: palm oil (high smoke point).
 
De-oiling: vibration de-oiler (remove excess oil, oil content ≤20%).
 
Step 5: Seasoning
 
Drum seasoning machine: spray cheese/barbecue/salsa flavor evenly.
 
Seasoning formula: cheese powder, maltodextrin, salt, sugar, paprika, etc.
 
Step 6: Cooling & Packaging
 
Cool to room temperature (prevent flavor loss).
 
Automatic packaging: nitrogen-flushed bags (extend shelf life to 6–9 months).
 
  1. Jinan Extruder Line Configuration (150 kg/h)
     
    Mixer → Twin-screw extruder (SLG65) → Roller & cutter → Dryer/fryer → De-oiler (if fried) → Seasoner → Cooler → Packer.
     
  2. Critical Parameters for Quality
     
    Moisture control: feed 20–22%, final ≤3.5%.
     
    Temperature gradient: avoid overheating (burning) or undercooking (soft texture).
     
    Cutting precision: triangle size 3–5 cm, thickness uniformity ±0.05 mm.
     
  3. Advantages of Jinan Twin-Screw Extruder for Doritos
     
    High efficiency: 100–800 kg/h, continuous production.
     
    Flexibility: switch shapes (triangle, round, 3D) and flavors quickly.
     
    Consistency: uniform texture, color, and flavor batch-to-batch.
     
    Cost-effective: lower energy/labor vs. traditional stone-mill process.
     
  4. Troubleshooting Common Issues
     
    Soft, not crisp: dry longer or increase dryer temperature; check feed moisture (too high).
     
    Burnt edges: reduce die temperature or screw speed; check for local overheating.
     
    Uneven seasoning: adjust seasoning drum speed and spray nozzle position.
     
 
With a Jinan twin-screw extruder, you can produce high-quality, consistent Doritos-style tortilla chips efficiently, with flexible options for baked or fried, and various flavors.
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