Corn chips production line stuffed with chocolate using an oven system
π«π½ Chocolate Stuffed Corn Sticks Production Line - Oven System This line is used to produce chocolate-stuffed corn chips (corn sticks), a product highly sought after in the market due to its distinctive taste and crunchy texture. β Operation System: Air-cooled oven roasting - without oil β Healthy and light product - suitable for children and health-conscious markets β Continuous production and high quality β Fully automatic design - without manual intervention βοΈ Main Work Stages: 1. Mixing corn flour with water and ingredients 2. Extruding the dough through the extruder to form small tubes 3. Injecting chocolate into the sticks 4. Roasting the product in a hot air oven for perfect crunch π‘οΈ All line parts are made of food-grade 304 stainless steel π¦ Suitable for factories specializing in the production of healthy and stuffed snacks
The line consists of the following parts
1 – Corn Moisturizing Mixer // 400 kg //
2 – Spiral Conveyor
3 – Extruder (Blasting and Shaping Head) with Automatic Feeding Device
4 – Two Chip Finger Cutter
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.
βοΈ Working mechanism:
1οΈβ£ Homogeneous mixing of corn
βοΈ Equipped with a powerful 5-horsepower Turkish-made main motor, ensuring efficient rotation and homogeneous mixing of materials.
2οΈβ£ Corn moisture control
βοΈ Includes a dedicated water tank to control the moisture content, with a water level indicator.
3οΈβ£ Safety and ease of use
βοΈ Equipped with mechanical protection (metal mesh) to prevent operators from entering the mixer.
βοΈ Includes a standard drain hole, as well as a monitoring and cleaning hole.
4οΈβ£ Removing Impurities
βοΈ The blender bowl is equipped with a magnet to remove any metal impurities from the corn.
5οΈβ£ Hygienic Materials
βοΈ The blender is made entirely of 2mm thick, food-grade 304 stainless steel to ensure hygiene and long-lasting durability.
π Technical Specifications:
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Machine Type: Industrial Corn Mixer
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Capacity: 400 kg
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Material Type: Food-grade 304 stainless steel – 2 mm thick
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Motor: 5 HP – Made in Turkey
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Electric Power: 3.75 kW
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Voltage: 380/220 VAC – 50 Hz
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Dimensions:
βοΈ Length: 180 cm
βοΈ Width: 120 cm
βοΈ Height: 230 cm
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Machine Number: 001
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Model: THV-2025PV-Z
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Country of Origin: Turkey
π‘ Why is this mixer an essential component in corn processing?
βοΈ Because it ensures homogeneous mixing and optimal moisture control.
βοΈ Because it is made of hygienic, safe, and easy-to-clean materials.
βοΈ Because it is equipped with safety and operator comfort systems.
βοΈ 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 regularly 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 food-grade 304 stainless steel, with mechanical and magnetic protection to ensure safe operation and product quality.
βοΈ Working mechanism:
1οΈβ£ Automatic extruder feeding
βοΈ Contains a 100 kg capacity tank that automatically and regularly feeds materials into the extruder.
2οΈβ£ Hygienic and safe design
βοΈ The tank and body are made of 2 mm thick food-grade 304 stainless steel.
βοΈ Equipped with a bottom opening for cleaning, allowing for easy maintenance and hygiene.
3οΈβ£ Protects operators and product quality
βοΈ Equipped with mechanical protection (metal mesh) to prevent operators from entering the mixer during operation.
βοΈ It has a special magnetic mechanism to remove metal impurities from the incoming materials.
π Technical Specifications:
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Device Type: Spiral Conveyor for Extruder Feeding
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Capacity: 100 kg
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Material Type: Food-grade 304 stainless steel – 2 mm thick
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Protection System: Mechanical Protection + Magnetic for Metal Impurity Removal
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Voltage: 380/220 VAC – 50 Hz
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Power: 1.25 kW
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Dimensions:
βοΈ Length: 350 cm
βοΈ Width: 100 cm
βοΈ Height: 300 cm
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Machine Number: 002
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Model: THV-2025PV-Z
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Country of Origin: Turkey
π‘ Why is this spiral conveyor an essential part of the production line?
βοΈ Because it ensures consistent automatic feeding of the extruder.
βοΈ Because it is made of hygienic and easy-to-clean materials.
βοΈ Because it is equipped with effective protection systems to ensure worker and product safety.
βοΈ 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 chips. It features high production capacity, a robust construction, and advanced technology that ensures continuous and precise operation.
It is designed to meet the highest industrial performance standards, with full electronic control of all functions via an intelligent control panel and a frame made of resistant, high-quality materials.
βοΈ Working mechanism:
1οΈβ£ Precise filling of the kernel
βοΈ Operates at a production capacity ranging from 175 to 200 kg/hour, depending on the desired kernel shape.
βοΈ The kernel length is controlled by an electronic variable-speed inverter.
2οΈβ£ Robust mechanical structure
βοΈ The main carrier is made of heat-coated steel, with standard steel legs.
βοΈ The extruder is insulated with a 304 food-grade stainless steel outer layer for easy cleaning.
βοΈ Approximate weight: 1300 kg.
3οΈβ£ Advanced screw system
βοΈ Screws are made of premium metals, treated using vacuum furnace technology.
βοΈ Equipped with a main screw to feed the compressor screw, with speed control via an inverter.
βοΈ 50 hp / 35 kW compressor screw motor, made in Turkey or Italy, with premium copper windings.
4οΈβ£ Professional gearbox
βοΈ American Extrusion main gearbox, manufactured for 24-hour continuous operation.
βοΈ SKF bearings and bearings – Swedish and Japanese.
5οΈβ£ Efficient cooling and heating
βοΈ Equipped with a start-up heater, electronically controlled via a thermometer.
βοΈ Dual cooling system: closed-circuit water cooling + air cooling, to ensure temperature stability during operation.
6οΈβ£ Advanced Control Panel
βοΈ Independent control panel made of 304 stainless steel, with a special ventilation system for hot environments.
βοΈ Equipped with 3 ventilation filters + 3 cooling fans + dust protection.
βοΈ Equipped with a classic panel for complete control.
βοΈ Automatic fault reading system + automatic storage program + detailed electrical diagram.
βοΈ Equipped with wheels for easy movement and cleaning.
π Technical Specifications:
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Machine Type: Chocolate-Filled Corn Chips Extruder
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Production Capacity: 175 to 200 kg/hour, depending on the grain shape
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Material: 304 food-grade stainless steel outer body
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Cooling System: Closed-circuit water-cooled + air-cooled
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Number of Inverters: 3 speed controllers
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Main Motor: 50 HP (35 kW) – Turkish or Italian made with copper coils
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Electrical Voltage: 380/220 VAC – 50 Hz
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Electrical Power: 39.75 kW
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Dimensions:
βοΈ Length: 180 cm
βοΈ Width: 120 cm
βοΈ Height: 240 cm
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Machine Number: 003
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Model: THV-2025PV-Z
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Country of Origin: Turkey
π‘ Why is this extruder the ideal choice for producing chocolate-filled corn chips?
βοΈ Because it operates at high, continuous production capacity.
βοΈ Because it allows precise control of grain length and shape.
βοΈ Because it is designed from durable, easy-to-clean materials.
βοΈ Because it provides an efficient cooling and heating system that maintains product stability.
βοΈ 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 – Kong Chocolate Cooking:
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.
βοΈ Technical Specifications – Cooking Unit:
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Capacity: 600 kg
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Design: Double-walled (Double Jacket) for hot water filling
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Heating: Electric heaters with electronic temperature control
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Chocolate Circulation: Internal pump lifts chocolate from the bottom to the top to ensure better grinding
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Grinding: Metal balls inside the tank
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Cooling: Double jacket equipped with a pump to accelerate water circulation inside the jacket
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Walls:
Inner wall thickness: 8 mm
Outer wall thickness: 4 mm
Tank floor thickness: 15 mm
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Equipped with an electric control panel
Second – Chocolate Comfort Tank (Fanner):
A tank designed to maintain the chocolate's fluidity and prevent it from solidifying, thanks to a double-walled heating system and precise electronic control. βοΈ Technical Specifications – Comfort Tank:
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Capacity: 600 kg
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Design: Double Jacket for hot water heating
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Heating: Electric heaters with electronic control
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Hot water circulation: Built-in pump
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Walls:
Inner wall thickness: 4 mm
Outer wall thickness: 4 mm
Floor thickness: 6 mm
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Material: Food-grade 304 stainless steel
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Equipped with an electric control panel
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Voltage: 380/220 VAC – 50 Hz
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Power: 10.5 kW
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Dimensions:
βοΈ Length: 180 cm
βοΈ Width: 120 cm
βοΈ Height: 170 cm
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Machine number: 004
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Model: THV-2025PV-Z
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Country of origin: Turkey
π‘ Why is this system ideal?
βοΈ Maintains the quality and smoothness of the chocolate throughout the process. βοΈ Easy to clean and maintain thanks to its hygienic design.
βοΈ Precise temperature control to prevent clumping or burning.
βοΈ Integrated cooking and comfort 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.
βοΈ Working mechanism:
1οΈβ£ Adjustable precision slicing
βοΈ The cutter speed is electronically controlled via an inverter.
βοΈ The kernel length can be set from 2 cm to 15 cm with high precision.
2οΈβ£ Hygienic and durable design
βοΈ The outer body is made entirely of food-grade 304 stainless steel, ensuring product safety and easy cleaning.
π Technical Specifications:
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Device Type: Corn Chips Cutter
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Cutting Mechanism: Motorized with Inverter for Length Adjustment
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Adjustable Length: From 2 cm to 15 cm
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Material: Food-grade 304 stainless steel
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Voltage: 380/220 VAC – 50 Hz
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Power: 1.25 kW
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Dimensions:
βοΈ Length: 120 cm
βοΈ Width: 90 cm
βοΈ Height: 150 cm
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Machine Number: 005
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Model: THV-2025PV-Z
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Country of Origin: Turkey
π‘ Why choose this cutter for your production line?
βοΈ Because it offers flexible control of grain length upon request.
βοΈ Because it is made of hygienic materials suitable for the food industry.
βοΈ Because it is easy to operate and clean and suitable for continuous operation in production lines
Chip conveyor line
Professional Product Transfer Between Manufacturing Stages
Conveyor belts are essential equipment in production lines. They ensure smooth and safe transfer of materials from the extruder to the oven, thanks to their robust design and advanced features that guarantee the highest standards of hygiene and efficiency. Advanced Operation Mechanism
1οΈβ£ Sturdy structure to ensure durability and sustainability
Made entirely of 304 food-grade stainless steel, ensuring high rust resistance and easy cleaning.
Equipped with sturdy wheels to facilitate movement and periodic cleaning within the production line.
2οΈβ£ 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 transport, thus preserving product quality.
3οΈβ£ Integrated Cleaning System
Equipped with dedicated cleaning slots to facilitate periodic maintenance and prevent residue buildup.
It includes automated cleaning brushes that operate continuously to remove any impurities or residual materials during operation.
4οΈβ£ Economical Operation with High Efficiency
Low power consumption (1.25 kW), ensuring economical operation without energy waste.
Technical Specifications
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Material: Made entirely of food-grade 304 stainless steel to ensure hygiene and durability.
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Electrical Power: 1.25 kW | 380/220 V | 50 Hz.
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Dimensions:
Length: 300 cm
Width: 80 cm
Height: 200 cm
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Machine Number: 006
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Model: THV-2025PV-Z
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Country of Origin: Turkey – High-quality manufacturing according to European standards.
Product Conveyor Features
βοΈ Durable design entirely made of food-grade 304 stainless steel to ensure the highest hygiene standards.
βοΈ Smooth and safe transfer of materials from the extruder to the oven without any damage to the product.
βοΈ Conveyor belt made of PVC or food-grade plastic to ensure hygienic transportation.
βοΈ Integrated automated cleaning system with cleaning brushes and maintenance ports.
βοΈ Wheels for easy movement and cleaning, providing operational flexibility.
βοΈ Low energy consumption with high operating efficiency.
π‘ 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 to ensure the production of a final product of optimal quality, with precise humidity and temperature control to adjust the texture and taste as desired. Advanced Operation Mechanism
1οΈβ£ High productivity with precise temperature control
Production capacity up to 300 kg per hour, making it ideal for large production lines.
The 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% as required to ensure the ideal texture.
2οΈβ£ Efficient and Energy-Saving Heating System
Operates on diesel or natural gas (LPG) as desired by the customer, ensuring economical and efficient operation.
Equipped with a built-in heating chamber that can be detached and installed for easy maintenance. Made of 304 chrome and stainless steel, it can withstand temperatures up to 800°C.
The primary burner is Baltur or Riello (Italian - Model 2025), ensuring high operating efficiency.
3οΈβ£ Robust construction and perfect thermal insulation
Made entirely of 304 food-grade stainless steel to ensure high rust resistance and ease of cleaning.
The oven is fully insulated with a 15 cm thick fiberglass layer on all sides to maintain internal heat and reduce energy consumption.
4οΈβ£ Advanced product conveyor system with automatic cleaning
The conveyor belt is made of 100 cm wide 304 food-grade stainless steel, ensuring even roasting.
It is equipped with an automatic conveyor belt cleaning mechanism, maintaining product cleanliness and operating efficiency.
The oven is equipped with an LS inverter for precise control of the conveyor belt speed.
5οΈβ£ Professional air distribution for homogeneous roasting
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 circulation fan motor (Italian or Turkish - excellent quality).
6οΈβ£ Advanced operating and control system
A separate control panel made of food-grade 304 stainless steel, removable and retractable for easy maintenance and transportation.
A modern touch screen control panel equipped 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 extraction and circulation fans is electronically controlled via inverters.
Technical Specifications
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Material: Made entirely of food-grade 304 stainless steel to ensure the highest standards of hygiene and quality.
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Electrical Power: 10.5 kW | 380/220 V | 50 Hz.
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Dimensions:
Length: 650 cm
Width: 140 cm
Height: 200 cm
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Machine Number: 007
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Model: THV-2025PV-Z
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Country of Manufacture: Turkey - High industrial quality according to European standards.
Features of the Hot Air Roasting Oven
βοΈ High production capacity of up to 300 kg/hour with precise humidity and temperature control.
βοΈ Durable design and optimal thermal insulation to maintain internal temperature and reduce energy consumption.
βοΈ Integrated heating chamber that can be disassembled and installed for easy maintenance.
βοΈ Advanced air distribution system to ensure even roasting on all sides.
βοΈ Conveyor grill made of 304 food-grade stainless steel with an automatic cleaning system.
βοΈ Smart touch screen control panel with automatic fault reading system.
βοΈ Powerful European-quality motors and fans to ensure continuous production.
π‘ 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.
βοΈ How it works:
1οΈβ£ Post-oven Product Receiving
βοΈ Receives the chips directly after they come out of the oven, helping to reduce their temperature and distribute them evenly.
2οΈβ£ Hygienic and Efficient Conveyor Belt
βοΈ The belt is made of food-grade PVC or food-grade plastic, ensuring hygienic and safe transportation of hot chips without harmful thermal interaction.
3οΈβ£ Indirect Cooling and Optimal Distribution System
βοΈ The product is passed along the conveyor with natural airflow, allowing it to cool gradually before entering the packaging or wrapping stages.
βοΈ It can be equipped with an air-cooled system (optional) if faster temperature reduction is needed.
4οΈβ£ Ease of movement and cleaning
βοΈ Equipped with wheels for easy movement during cleaning or organizing inside the laboratory.
βοΈ It includes automatic cleaning brushes that keep the belt clean during operation and prevent residue buildup.
5οΈβ£ Completely hygienic design
βοΈ The overall structure is made of food-grade 304 stainless steel, providing high rust resistance and ease of washing and sterilization.
π Technical Specifications:
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Device Type: Conveyor Belt for Cooling and Receiving the Product from the Oven
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Belt: PVC or Food-Grade Plastic
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Cleaning System: Automatic Cleaning Brushes
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Equipped with Wheels: for smooth movement and handling
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Material: Food-Grade 304 Stainless Steel
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Voltage: 380/220VAC – 50Hz
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Power: 1.25 kW
Dimensions:
βοΈ Length: 400 cm
βοΈ Width: 80 cm
βοΈ Height: 200 cm
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Machine Number: 008
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Model: THV-2025PV-Z
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Country of Origin: Turkey
π‘ Why is this conveyor necessary in a stuffed chips production line?
βοΈ Because it receives the product directly after the oven and gradually reduces its temperature.
βοΈ Because it provides a clean and safe conveying surface thanks to the automatic cleaning brushes.
βοΈ Because it prevents product cracking resulting from sudden temperature changes.
βοΈ Because it is easy to move and wash thanks to its smart design and practical wheels.
Electrical parts and control panels
Schneider brand cutters
Schneider brand contactors
delta control screen
delta inverters
Engines company GAMAK
YILMAZ gearboxes
Or according to the customer's request
Basic information
Chocolate-Filled Corn Chips Production Line – With a Smart Convection Oven System: Crispy, Consistent, and High-Quality Product – The Ideal Solution for High Humidity Environments
Overview: This integrated line is specially designed to produce a high-quality final product of chocolate-filled corn chips, with perfect crunch and excellent stability even in high-humidity environments. It is an ideal choice for factories seeking an innovative product that combines an attractive appearance, delicious taste, and the required hardness during storage and shipping.
The convection oven system is a valuable addition to this line, intelligently roasting and drying the product to achieve the best possible final product texture.
Processing Steps in the Line:
1οΈβ£ Corn Mixer – Machine No. 001: Mixes the corn, water, and sometimes a little oil until homogeneous in a professional mixer with a capacity of 400 kg. Made entirely of food-grade 304 stainless steel, equipped with an internal water tank and magnets to remove metal impurities.
2οΈβ£ Spiral Conveyor – Machine No. 002: Automatically transfers materials from the mixer to the extruder. Tank capacity: 100 kg. Equipped with a safety net and permanent magnets to ensure a smooth and safe flow.
3οΈβ£ Stuffed Extruder – Machine No. 003: Forms hollow corn fingers ready for stuffing and baking. Production capacity: 175-200 kg/hour. Built-in cooling systems, controlled by three inverters, powerful motors, and a precise screw compressor. Adjustable grain length and knife speed.
4οΈβ£ Finger Cutter – Machine No. 004: Cuts fingers to the desired length (from 2 to 15 cm). Equipped with an inverter for precise control.
5οΈβ£ Product Conveyor – Machine No. 005: Transports the cut fingers to the oven. Food-grade PVC belt with automatic cleaning brushes. Wheels for easy movement. And cleaning
6οΈβ£ Smart convection oven – (Golden addition) The major turning point in product quality! It roasts and dries corn fingers after shaping. It is equipped with a precise temperature control system and internal fans for even heat distribution. It is fully enclosed in a design with thermally insulated doors. It is suitable for diesel or gas operations, as per customer request.
– Ideal for humid areas to absorb internal moisture, maintain crunch, and extend product shelf life.
7οΈβ£ Chocolate Cooking and Relaxer - Machine No. 006 - Prepares and injects chocolate into the fingers. It has a 600 kg double-jacket tank equipped with grinding balls, heaters, and circulation pumps. It maintains the chocolate's temperature, making it ready for injection.
8οΈβ£ Product Receiving and Relaxing Line After the Oven - Machine No. 007 - Receives the chips directly from the oven and allows them to cool and settle before filling or stuffing. A hygienic design made of 304 stainless steel helps ventilate the product and prevent steam condensation.
Technical Line Specifications:
βοΈLine Length: 19 meters
βοΈWidth: 300 cm
βοΈHeight: 280 cm
βοΈElectrical Capacity: 85 Kilowatts
βοΈOven fuel type: Gas or diesel upon request
βοΈWorking space required: 300 square meters
Ease of operation: The line is designed with intelligent control systems for easy operation and maintenance, with visual and operator-friendly control panels.
Special features of this line:
βοΈ Full control of baking temperature – suitable for humid climates
βοΈ Consistent final crispness in every production batch
βοΈ Extended shelf life during storage
βοΈ Adjustable roasting degree to suit taste
βοΈ Hygienic and food-safe design
βοΈ Easy operation and cleaning
Final product:
Chocolate-filled corn chips – oven system
Excellently crispy outer layer with a delicious chocolate center, ideal for export, supermarkets, and markets seeking lasting quality and distinctive taste.
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