How to Produce kurkure: A Complete Manufacturing Guide

Corn sticks,Kurkure also known as Kurkure or Cheetos-style snacks, are a popular extruded puffed snack made primarily from corn grits or cornmeal. They are crispy, flavorful, and widely enjoyed as a ready-to-eat snack. This article provides a step-by-step guide on how corn sticks are produced, covering raw materials, processing methods, and key equipment.

1. Selezione della materia prima

The main ingredient for corn sticks is corn grits o cornmeal . Additional ingredients may include:

• Starches (potato, tapioca) for texture improvement
• Condimenti (salt, cheese powder, spices)
• Olio (for frying or coating)
• Fortification agents (vitamins, minerals for nutritional enhancement) .

2. Production Process Overview

There are two main methods for producing corn sticks: frying e baking.

A. Fried Corn Sticks Production Line

Flusso del processo:

1. Miscelazione – Corn grits are blended with water and minor ingredients in a mixer.
2. Estrusione – The mixture is fed into a rotary-head extruder, where it is cooked under high pressure and temperature (120-180°C), forming irregularly shaped sticks .
3. Debris Removal – A vibrating screen o roller sieve removes broken pieces.
4. Frying – The extruded sticks are deep-fried in a continuous fryer (170-190°C) for crispiness.
5. Condimento – A rotary drum coater evenly applies oil and flavor powders.
6. Cooling & Packaging – The sticks are cooled and packed in moisture-resistant bags .

Equipment Used:

• Mixer → Screw feeder → Rotary extruder → Elevator → Vibrating sieve → Continuous fryer → Seasoning drum → Packaging machine.

B. Baked Corn Sticks Production Line

Flusso del processo:

1. Mixing & Extrusion – Similar to the fried process, but with adjusted moisture content.
2. Drying/Baking – Instead of frying, the sticks pass through a multi-zone belt oven (120-160°C) to reduce moisture to 3-5%.
3. Seasoning & Packaging – Same as the fried version but with less oil .

Equipment Used:

• Mixer → Extruder → Conveyor dryer → Seasoning system → Packaging machine.

3. Key Equipment in Corn Stick Production

• Rotary Extruder: Uses a copper alloy die for wear resistance and produces twisted shapes .
• Continuous Fryer/Oven: Ensures uniform cooking (frying at 170°C or baking at 150°C).
• Seasoning Drum: Applies flavors evenly (cheese, chili, barbecue, etc.).
• Packaging Machine: Uses nitrogen flushing to extend shelf life .

4. Quality Control & Shelf Life

• Controllo dell'umidità: Final product moisture should be <5% to prevent sogginess.
• Texture Testing: Crispiness is measured using a texture analyzer.
• Durata di conservazione: Properly packed corn sticks can last 6-12 months if stored in dry conditions .

5. Variations & Market Trends

• Flavors: Cheese, spicy, sour cream, and seafood are popular.
• Healthier Versions: Baked, low-fat, or fortified with protein/fiber.
• Automation: Modern lines allow one operator to manage multiple extruders .

Conclusione

Producing corn sticks involves extrusion, frying/baking, seasoning, and packaging. Manufacturers can choose between fried (crispier) or baked (healthier) versions based on market demand. With advancements in extrusion technology, corn sticks remain a profitable and scalable snack food product.

Would you like additional details on seasoning formulations or packaging innovations?