1. The selection of raw materials is crucial for quality. The corn used should be mildew-free, free from insect damage, fully matured, and have a bright, clean appearance. Corn with a golden yellow color is preferred to ensure the best flavor and texture.
2. After peeling and removing the germ, the corn is carefully screened to eliminate any impurities. It is then briefly soaked in hot water at around 90°C for 3 to 5 minutes to make peeling easier. The corn is milled using a rice mill, a vibrating screen, and a pulverizer. Through crushing and sieving, the corn bran, germ, and endosperm are separated, resulting in pure corn residue. This residue has a fat content of less than 10% and an ash content of under 0.6%, ensuring a high-quality base for the final product.
3. Next, 10 kg of the prepared corn residue is placed into a boiling water pot. Alongside it, 500 grams of salt, 30 grams of pepper, and 25 grams of aniseed are wrapped in gauze and added to the pot. The mixture is kept at a constant temperature of 100°C for 50 minutes. Afterward, it is transferred to a steaming container and cooked for 90 minutes to fully gelatinize the corn residue. Once done, the material is crushed into granules for the next step.
4. A horizontal two-roller tablet machine or a simple household press is used to shape the steamed corn residue into thin, flat flakes. The thickness of the flakes is maintained between 0.2 to 0.4 mm to ensure a crisp texture when fried later.
5. The corn flakes are then dried in an oven. The drying process starts at an inlet temperature of 120°C, gradually increases to 160°C in the middle, and reaches 200°C at the outlet. The total baking time is about 8 minutes, during which the moisture content is reduced to below 10%. After baking, the flakes are quickly cooled to room temperature to preserve their texture and prevent clumping.
6. In the final step, a suitable amount of peanut oil or soybean oil is heated to 200°C and maintained at that temperature. The dried corn flakes are then fried until they puff up and turn a light golden-brown color. Once ready, they are removed, cooled, packaged, sealed, and prepared for sale. This process ensures a delicious, crispy, and shelf-stable snack that retains the natural flavor of corn.
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