Corn chips production line stuffed with chocolate using an oven system

The line consists of the following parts

1 – Corn Moisturizing Mixer, 400 kg Capacity

2 – Spiral Conveyor

3 – Extruder (Blasting and Shaping Head) with Automatic Feeding Device

4 – Two Chip Cutter Machines

5 – Conveyor to the Oven

6 – Hot Air Drying Oven

7 – Chocolate Cooking Tank and Chocolate Fountain

8 – Conveyor for Cooling and Receiving the Product from the Oven

Corn mixer

Homogeneous mixing and precise moisture control – Hygienic design and reliable performance! This mixer is used in the corn preparation stage before shaping or frying. It homogeneously mixes the corn while controlling the desired moisture content, contributing to improved product quality. The mixer features a sturdy body made entirely of food-grade 304 stainless steel, with a design that takes into account safety, ease of operation, and maintenance.

⚙️ Working mechanism:

1️⃣ Homogeneous mixing of corn

✔️ Equipped with a powerful 5-horsepower Turkish-made main motor, ensuring efficient rotation and homogeneous mixing of materials.

2️⃣ Corn moisture control

✔️ Includes a dedicated water tank to control the moisture content, with a water level indicator.

3️⃣ Safety and ease of use

✔️ Equipped with mechanical protection (metal mesh) to prevent operators from entering the mixer.

✔️ Includes a standard drain hole, as well as a monitoring and cleaning hole.

4️⃣ Removing Impurities

✔️ The blender bowl is equipped with a magnet to remove any metal impurities from the corn.

5️⃣ Hygienic Materials

✔️ The blender is made entirely of 2mm thick, food-grade 304 stainless steel to ensure hygiene and long-lasting durability.

📏 Technical Specifications:

✅ Machine Type: Industrial Corn Mixer

✅ Capacity: 400 kg

✅ Material Type: 304 food grade stainless steel – 2 mm thick

✅ Motor: 5 HP – Made in Turkey

✅ Electric Power: 3.75 kW

✅ Voltage: 380/220 VAC – 50 Hz

✅ Dimensions:

✔️ Length: 180 cm

✔️ Width: 120 cm

✔️ Height: 230 cm

✅ Machine Number: 001

✅ Model: THV-2025PV-Z

✅ Country of Origin: Turkey

💡 Why is this mixer an essential component in corn processing?

✔️ Because it ensures homogeneous mixing and optimal moisture control.

✔️ Because it is made of hygienic, safe, and easy-to-clean materials.

✔️ Because it is equipped with safety and operator comfort systems.

✔️ Because it contributes to raising the quality of the final product and improving the performance of the production line.

Screw feeder

Precise automatic feeding with a hygienic and safe design! The screw conveyor is used to automatically and consistently feed materials (such as corn) into the extruder, ensuring continuous operation and consistent production, while adhering to hygiene and food safety standards. It features a robust design made of 304 food-grade stainless steel, with mechanical and magnetic protection to ensure safe operation and product quality.

⚙️ Working Mechanism:

1️⃣ Automatic Extruder Feeding

✔️ It has a 100 kg capacity tank that automatically and evenly feeds materials into the extruder.

2️⃣ Hygienic and Safe Design

✔️ The tank and body are made of 2 mm thick 304 food-grade stainless steel.

✔️ It has a bottom opening for cleaning, allowing for easy maintenance and cleaning.

3️⃣ Operator Protection and Product Quality

✔️ It has a mechanical guard (metal mesh) to prevent the operator's hand from entering the mixer during operation.

✔️ It has a special magnetic mechanism to remove metal impurities from the incoming material.

📏 Technical Specifications:

✅ Device Type: Spiral Conveyor for Extruder Feeding

✅ Capacity: 100 kg

✅ Material Type: Food-grade 304 stainless steel - 2 mm thick

✅ Protection System: Mechanical Protection + Magnetic for Metal Impurity Removal

✅ Voltage: 380/220 VAC - 50 Hz

✅ Power: 1.25 kW

✅ Dimensions:

✔️ Length: 350 cm

✔️ Width: 100 cm

✔️ Height: 300 cm

✅ Machine Number: 002

✅ Model: THV-2025PV-Z

✅ Country of Origin: Turkey

💡 Why is this spiral conveyor an essential part of the production line?

✔️ Because it ensures consistent automatic feeding to the extruder.

✔️ Because it is made of hygienic and easy-to-clean materials.

✔️ Because it is equipped with effective protection systems to ensure worker and product safety.

✔️ Because it helps improve the continuity and efficiency of the production line.

Chocolate Stuffed Corn Chips Extruder

Continuous production and high-quality filling of stuffed corn kernels – Professional industrial design and unparalleled performance! This extruder is used to form chocolate-filled corn kernels. It features high production capacity, a robust construction, and advanced technology that ensures continuous and precise operation. Designed to meet the highest industrial performance standards, it features fully electronic control of all functions via an intelligent control panel and a frame made of resistant, high-quality materials.

⚙️ Working mechanism:

1️⃣ Precise filling of the kernel

✔️ Operates at a production capacity ranging from 175 to 200 kg/hour, depending on the desired kernel shape.

✔️ The kernel length is controlled by an electronic variable-speed inverter.

2️⃣ Robust mechanical structure

✔️ The main carrier is made of heat-coated steel, with standard steel legs.

✔️ The extruder is insulated with a 304 food-grade stainless steel outer layer for easy cleaning.

✔️ Approximate weight: 1300 kg.

3️⃣ Advanced screw system

✔️ Screws are made of premium metals, treated using vacuum furnace technology.

✔️ Equipped with a main screw to feed the compressor screw, with speed control via an inverter.

✔️ 50 hp / 35 kW compressor screw motor, made in Turkey or Italy, with premium copper windings.

4️⃣ Professional gearbox

✔️ American Extrusion main gearbox, designed to withstand 24-hour continuous operation.

✔️ SKF bearings and bearings – Swedish and Japanese.

5️⃣ Efficient cooling and heating

✔️ Equipped with a start-up heater, electronically controlled via a temperature gauge.

✔️ Dual cooling system: closed-circuit water cooling + air cooling, ensuring stable operating temperatures.

6️⃣ Advanced Control Panel

✔️ Independent control panel made of 304 stainless steel, with a special ventilation system for hot environments.

✔️ Equipped with 3 ventilation filters + 3 cooling fans + dust protection.

✔️ Equipped with a classic control panel for complete control.

✔️ Automatic fault reading system + automatic program storage + detailed electrical diagram.

✔️ Equipped with wheels for easy movement and cleaning.

📏 Technical Specifications:

✅ Machine Type: Chocolate-Filled Corn Chips Extruder

✅ Production Capacity: 175 to 200 kg/hour, depending on the grain shape

✅ Material: 304 food-grade stainless steel outer frame

✅ Cooling System: Closed-Circuit Water Cooling + Air Cooling

✅ Number of Inverters: 3 Speed ​​Controllers

✅ Main Motor: 50 HP (35 kW) - Turkish or Italian Made with Copper Coils

✅ Electrical Voltage: 380/220 VAC - 50 Hz

✅ Electrical Power: 39.75 kW

✅ Dimensions:

✔️ Length: 180 cm

✔️ Width: 120 cm

✔️ Height: 240 cm

✅ Machine Number: 003

✅ Model: THV-2025PV-Z

✅ Country of Origin: Türkiye

💡 Why is this? Is the extruder the ideal choice for producing chocolate-filled corn chips?

✔️ Because it operates at high, continuous production capacity.

✔️ Because it allows precise control over the length and shape of the kernel.

✔️ Because it is designed from durable, easy-to-clean materials.

✔️ Because it provides an efficient cooling and heating system that maintains product stability.

✔️ Because it is equipped with an intelligent control panel and an integrated protection system to ensure optimal industrial performance.

Chocolate cooking tank - Kong

Two integrated solutions for preparing melted chocolate with the highest quality and thermal efficiency! First, the Kong Chocolate Cooker: A professional double-jacket device for melting and grinding chocolate smoothly, equipped with a mixer, internal circulation pump, and metal balls to improve consistency and quality.

⚙️ Technical Specifications – Cooking Unit:

✅ Capacity: 600 kg

✅ Design: Double-walled (Double Jacket) for hot water filling

✅ Heating: Electronically temperature-controlled electric heaters

✅ Chocolate Circulation: Internal pump lifts chocolate from the bottom to the top for better grinding

✅ Grinding: Metal balls inside the tank

✅ Cooling: Double jacket with pump to accelerate water circulation inside the jacket

✅ Walls: Inner wall thickness: 8 mm, Outer wall thickness: 4 mm, Tank floor thickness: 15 mm

✅ Equipped with an electric control panel. Second – Chocolate Comfort Tank (Fanner): A tank designed to maintain the fluidity of chocolate and prevent it from solidifying, thanks to a double-walled heating system and precise electronic control.

⚙️ Technical Specifications – Comfort Tank:

✅ Capacity: 600 kg

✅ Design: Double Jacket for Hot Water Heating

✅ Heating: Electric Heaters with Electronic Control

✅ Hot Water Circulation: Built-in Pump

✅ Walls: Inner Wall Thickness: 4 mm, Outer Wall Thickness: 4 mm, Floor Thickness: 6 mm

✅ Material: Food-grade 304 stainless steel

✅ Equipped with an electric control panel

✅ Voltage: 380/220 VAC – 50 Hz

✅ Power: 10.5 kW

✅ Dimensions:

✔️ Length: 180 cm

✔️ Width: 120 cm

✔️ Height: 170 cm

✅ Machine Number: 004

✅ Model: THV-2025PV-Z

✅ Country of Origin: Turkey

💡 Why is this system ideal?

✔️ Maintains the quality and smoothness of the chocolate throughout the process.

✔️ Easy to clean and maintain thanks to its hygienic design.

✔️ Precise temperature control to prevent clumping or burning.

✔️ Integrated cooking and ergonomic units provide smoothness and stability in the production line.

Chips Finger Cutter

Perfect control of chip length – precise cutting and quality design! This cutter is used in the post-forming stage, cutting corn chips (puffs) to the desired length with precision and smoothness. It features electronic kernel length adjustment via an inverter, making it ideal for meeting various production requirements.

⚙️ Working mechanism:

1️⃣ Adjustable precision slicing

✔️ The cutter speed is electronically controlled via an inverter.

✔️ The kernel length can be set from 2 cm to 15 cm with high precision.

2️⃣ Hygienic and durable design

✔️ The outer body is made entirely of food-grade 304 stainless steel, ensuring product safety and easy cleaning.

📏 Technical Specifications:

✅ Device Type: Corn Chips Slicer

✅ Cutting Mechanism: Motorized with Inverter for Length Adjustment

✅ Adjustable Length: From 2 cm to 15 cm

✅ Material: Food-grade 304 stainless steel

✅ Voltage: 380/220 VAC – 50 Hz

✅ Power: 1.25 kW

✅ Dimensions:

✔️ Length: 120 cm

✔️ Width: 90 cm

✔️ Height: 150 cm

✅ Machine Number: 005

✅ Model: THV-2025PV-Z

✅ Country of Origin: Turkey

💡 Why choose this slicer for your production line?

✔️ Because it offers flexible control of grain length as required.

✔️ Because it is made of hygienic materials suitable for the food industry.

✔️ Because it is easy to operate and clean and suitable for continuous work in production lines

Chip conveyor line

Professional Product Transfer Between Manufacturing Stages. Product conveyor belts are essential equipment in production lines, ensuring smooth and safe transfer of materials from the extruder to the oven. Their robust design and advanced features ensure the highest standards of hygiene and efficiency. Advanced Operation Mechanism

1️⃣ Sturdy structure to ensure durability and longevity. Made entirely of 304 food-grade stainless steel, they are highly resistant to rust and easy to clean. They are equipped with sturdy wheels for easy movement and periodic cleaning within the production line.

2️⃣ High-quality food-grade conveyor belt. The conveyor belt is made of PVC or food-grade plastic to ensure hygienic and safe product transfer. The surface has a non-stick texture to prevent material from sticking during transfer, thus preserving product quality.

3️⃣ Integrated cleaning system with dedicated cleaning holes for easy maintenance and preventing residue buildup. They include automatic cleaning brushes that operate continuously to remove any impurities or residual materials during operation.

4️⃣ Highly efficient and economical operation. They consume low energy (1.25 kW), ensuring economical operation without energy waste. Technical Specifications

✅ Material: Made entirely of 304 food-grade stainless steel to ensure hygiene and durability.

✅ Electrical Power: 1.25 kW | 380/220 V | 50 Hz.

✅ Dimensions:

Length: 300 cm

Width: 80 cm

Height: 200 cm

✅ Machine Number: 006

✅ Model: THV-2025PV-Z

✅ Country of Manufacture: Turkey - High industrial quality according to European standards. Product Conveyor Features

✔️ Durable design entirely made of 304 food-grade stainless steel to ensure the highest hygiene standards.

✔️ Smooth and safe transfer of materials from the extruder to the oven without any damage to the product.

✔️ Conveyor belt made of PVC or food-grade plastic to ensure hygienic transportation.

✔️ Built-in automatic cleaning system with cleaning brushes and maintenance holes.

✔️ Wheels for easy movement and cleaning, providing operational flexibility.

✔️ Low energy consumption with high operating efficiency.

💡 The ideal solution for safely and efficiently transporting product within food production lines!

Hot air-drying oven

Professional Roasting and Drying Using Hot Air Technology. The hot air roasting oven is one of the latest technologies used in roasting and drying chips. It relies on homogeneous heat distribution, ensuring the production of a final product of optimal quality, with precise humidity and temperature control to adjust the desired texture and taste. Advanced Operation Mechanism

1️⃣ High productivity with precise temperature control. Production capacity reaches 300 kg per hour, making it ideal for large production lines. Temperature can be adjusted up to 300°C depending on the product type and manufacturing requirements. The humidity of the final product can be controlled from 0% to 5% upon request to ensure the ideal texture.

2️⃣ An efficient and energy-saving heating system that runs on diesel or natural gas (LPG) as desired by the customer, ensuring economical and efficient operation. It is equipped with a detachable and integrated heating chamber for easy maintenance, made of 304 chrome and stainless steel to withstand temperatures up to 800°C. The primary burner, Baltur or Riello (Italian - Model 2025), ensures high operating efficiency.

3️⃣ A sturdy structure with optimal thermal insulation, made entirely of 304 food-grade stainless steel to ensure high rust resistance and easy cleaning. The oven is fully insulated with a 15 cm thick layer of fiberglass on all sides to maintain internal heat and reduce energy consumption.

4️⃣ Advanced product conveyor system with automatic cleaning. The conveyor grate is made of 100 cm wide 304 food-grade stainless steel, ensuring even roasting. It is equipped with an automatic conveyor grate cleaning mechanism, maintaining product cleanliness and operating efficiency. The oven is equipped with an LS inverter for precise control of grate speed.

5️⃣ Professional air distribution for even roasting. It is equipped with powerful hot air pumping and circulating fans to ensure optimal heat distribution from the top and bottom with side recirculation. 3 HP hot air pumping fan motor (Italian or Turkish - excellent quality). 3 HP air extraction and circulating fan motor (Italian or Turkish - excellent quality).

6️⃣ Advanced operating and control system. A separate control panel made of 304 food-grade stainless steel, removable and reusable for easy maintenance and transportation. A modern touch screen with a smart fault reading system via text messages to quickly identify and resolve problems. All electrical parts are Schneider (France) and LS (Korea) to ensure high operational reliability. The main gearbox is Italian, and the motors are Italian or Turkish of excellent quality. The rotation of the hot air pumping and circulation fans is electronically controlled via inverters. Technical Specifications

✅ Material: Made entirely of 304 food-grade stainless steel to ensure the highest standards of hygiene and quality.

✅ Electrical Power: 10.5 kW | 380/220 V | 50 Hz

✅ Dimensions:

Length: 650 cm

Width: 140 cm

Height: 200 cm

✅ Machine Number: 007

✅ Model: THV-2025PV-Z

✅ Country of Manufacture: Turkey - High industrial quality according to European standards. Features of the Hot Air Roasting Oven

✔️ High production capacity of up to 300 kg/hour with precise humidity and temperature control.

✔️ Durable design and optimal thermal insulation to maintain internal temperature and reduce energy consumption.

✔️ Integrated heating chamber that can be detached and installed for easy maintenance.

✔️ Advanced air distribution system to ensure even roasting on all sides.

✔️ Conveyor grill made of 304 food-grade stainless steel with an automatic cleaning system.

✔️ Smart touch screen control panel with automatic fault reading system.

✔️ Powerful European-quality motors and fans to ensure continuous production.

💡 The perfect solution for high-quality roasted chips, delicious taste, and perfect texture!

Conveyor belt for cooling and receiving the product from the oven

Convenient Receiving and Effective Cooling of Chip Sticks – Stability and Quality After Roasting! This conveyor belt is used in the post-oven stage to receive chocolate-filled corn chips after roasting, helping to cool and distribute them comfortably and evenly throughout the production line. This ensures smooth flow and optimal thermal stability of the product before packaging or tasting.

⚙️ How it works:

1️⃣ Post-oven product reception

✔️ Receives chips directly after they come out of the oven, helping to reduce their heat and distribute them evenly.

2️⃣ Hygienic and efficient conveyor belt

✔️ The belt is made of food-grade PVC or food-grade plastic, ensuring hygienic and safe transportation of hot chips without harmful thermal interaction.

3️⃣ Indirect cooling and optimal distribution system

✔️ The product is passed along the conveyor with natural airflow, allowing it to gradually cool before entering the packaging or wrapping stages.

✔️ It can be equipped with an air-cooled system (optional) if faster temperature reduction is needed.

4️⃣ Ease of movement and cleaning

✔️ Equipped with wheels for easy movement during cleaning or organizing inside the lab.

✔️ It includes automatic cleaning brushes that keep the conveyor clean during operation and prevent residue buildup.

5️⃣ Completely hygienic design

✔️ The overall structure is made of food-grade 304 stainless steel, providing high rust resistance and ease of washing and sterilization.

📏 Technical Specifications:

✅ Device Type: Conveyor Belt for Cooling and Receiving the Product from the Oven

✅ Belt: PVC or Food-Grade Plastic

✅ Cleaning System: Automatic Cleaning Brushes

✅ Equipped with Wheels: for Smooth Movement

✅ Material: Food-Grade 304 Stainless Steel

✅ Voltage: 380/220VAC – 50Hz

✅ Power: 1.25 kW Dimensions:

✔️ Length: 400 cm

✔️ Width: 80 cm

✔️ Height: 200 cm

✅ Machine Number: 008

✅ Model: THV-2025PV-Z

✅ Country of Origin: Turkey

💡 Why is this conveyor necessary in a stuffed chips production line?

✔️ Because it receives the product directly after the oven and gradually reduces its temperature.

✔️ Because it provides a clean and safe conveying surface thanks to the automatic cleaning brushes.

✔️ Because it prevents product cracking caused by sudden temperature changes.

✔️ Because it's easy to move and wash thanks to its smart design and practical wheels.

Electrical parts and control panels

Schneider breakers

Schneider contactors

Delta control panel

Delta inverters

Gamak motors

Yilmaz gearboxes

Or as per customer request

Basic information

✨ Chocolate-Filled Corn Stick Production Line

📌 Introduction:

The chocolate-filled corn stick production line is one of the latest innovations in the food industry, combining the crispiness of golden corn with the rich taste of melted chocolate filling. This line utilizes modern European technology and is considered one of the most profitable and popular projects in the global snacks sector.

⚙️ Product Concept:

The product consists of hollow, crispy corn sticks filled with creamy chocolate.

It features a unique combination of a crispy exterior and a smooth, creamy filling.

Available fillings: Milk chocolate – Hazelnut chocolate – White chocolate – Caramel – Vanilla cream.

🔄 Production Process:

1. Raw Material Preparation

Mixing corn flour with other ingredients in an industrial mixer.

2. Extruder

Cooking the ingredients under high heat and pressure, and shaping them into hollow sticks or tubes.

3. Filling Injection

Injecting the chocolate or other filling into the sticks as they exit the extruder.

4. Roasting & Drying Oven

The filled corn sticks pass through a modern, hot-air industrial oven.

This oven performs three essential functions:

🔥 Roasting: Giving the sticks a golden color and a distinctive crispy texture.

💨 Drying: Reducing moisture content to maintain quality and extend shelf life.

⚖️ Temperature Control: Stabilizes the internal filling (chocolate) and prevents it from melting or leaking during storage and transportation. Made of food-grade stainless steel and equipped with automatic control systems for temperature and conveyor speed.

5. Cooling

The product is cooled gradually to maintain the texture of the chocolate and the consistency of the filling.

6. Packaging

Automatic packaging machines are used to package the product in various sizes and weights.

📊 Features of Chocolate-Filled Corn Sticks:

🥇 Perfect combination of crispness and smooth filling.

🔥 Baking in the oven gives a rich flavor and an attractive color.

💯 An innovative and globally sought-after product.

🌍 Possibility to diversify fillings according to market demand.

⏱️ High productivity and excellent profit margin.

🏭 Importance of the oven in the production line:

It enhances the quality of the final product and gives it the desired taste.

It maintains crispness and texture for a longer period.

It reduces moisture content, thus extending shelf life.

It helps stabilize the filling and prevents any issues during storage or transportation.

⚙️ Technical Specifications of the Line:

📏 Line Dimensions:

Length: 17 meters

Width: 300 cm

Height: 280 cm

⚡ Power Consumption: 80 kW

⛽ Gas or Diesel Consumption: 5 liters per hour

📈 Production Capacity: 175 to 200 kg per hour

🏢 Required Operating Area: 300 square meters