Annex I: Example of a Process Flow Diagram (breakfast cereal)

Description of Processing Steps for Breakfast Cereal Products

This is a flow chart that describes the process for producing breakfast cereal. The process is divided into 15 steps.

Step 1

Receiving

This step involves inspecting grain or grits or flour that arrives at the mill.  

Operators should establish purchasing specifications and assess a composite sample of the grain prior to receiving.

Step 2

Other Incoming Material Storage

This step involves storing incoming material other than grain in a designated area upon receipt. Examples include food additives, micronutrient premix, packaging material and non-food chemicals.

Step 3

Flaking Grits or Flour Storage

This step involves loading and storing accepted grain or grits or flour at the mill in large bins, polypropylene bags or silos. 

Step 4

Mixing and Addition of Food Additives

This step involves mixing grain or grits or flour with other incoming ingredients. For example, adding permitted food additives.

Step 5

Cooking

This step involves breaking the softened grain into coarse particles, as an initial step in the milling process. 

Step 6

Drying and Cooling

This step involves removing heat to prevent overcooking and removing moisture to prevent lumping and stickiness.

Step 7

Tempering

This step involves adjusting the moisture content to prevent the product from breaking during flaking. 

Step 8

Flaking

This step involves rolling cooked grits into thin flakes.

Step 9

Toasting

This step involves heating and removing moisture to enhance crispiness, flavour and shelf life.

Step 10

Fortification and

Coating

This step involves spraying and coating the flakes for flavour and fortification.

Step 11

Cooling and Drying

This step involves the final removal of heat and moisture before packaging.

Step 12

Metal Detection

This step involves passing the finished product through a metal detector to detect and eliminate metal in the final product.

Step 13

Weighing, Packaging, Labelling, Coding

This step involves weighing, packaging and labelling, as well as date and lot coding of the finished product. 

Step 14

Final Product Storage

This step involves storing the final product in designated areas before shipping and distributing it.

Step 15

Shipping and  Distribution

This step involves shipping and distribution of the final product to customers using designated carriers.