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Muesli, known as the adults’ cereal, is a loose mixture of rolled oats, whole grains, seeds, nuts, and dried fruits. Unlike granola, the muesli manufacturing process goes through rather simple steps. All of the ingredients are combined in the mixer without any specific cooking or baking process. This loose mixture is then packed individually, either in stand-up pouches, paper bags, paper tube and so on.

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The muesli manufacturing process - it’s all about choosing and mixing!

First, you need to find ingredients you would like to add to the combination of the loose mix; most often they are whole grain, oats, seeds, nuts, and dried fruits. Before mixing, ingredients such as oats and barley have to go through hulling process to separate the wheat from the chaff. The cereal also has to be cleaned based on weight – straw and chaff are lighter than cereal. A day before flattening, this cleaned cereal is soaked in water. Then, this soaked cereal goes into a bed with infrared burners – as known as a micronizer system – for 600 to 900°C for 10-15 seconds, so the cereal becomes softer for the flattening process. Then, you flatten the cereal with a strong roller and cooled it down to dry the extra moisture.

Then, combine all of these ingredients in the mixer. Without adding any oil or sweetener such as sugar and syrup, the batch goes through the mixing process. Usually, you need gentle mixing equipment for muesli that can preserve the shape and texture of the ingredients, and you have to mix them for a short period of time – from 10 to 30 seconds.

After the mixing, the loosely combined ingredients are transferred to a packaging machine, which packs the muesli in either paper bags or stand-up pouches. This process pertains to making plain muesli. However, muesli is often also combined with dried fruits such as apricots and coconut flakes. And, with nuts such as almonds and walnuts to give extra flavor. Muesli is a snack enjoyed on its own or mixed with yoghurt and fresh fruits.

Muesli vs. granola - baking or no baking?

To bake or not to bake, that is the question! The difference between muesli and granola lies in the production process of these two products. Simply put, muesli is a mix of rolled oats, whole grains, nuts, seeds, and dried fruits that is not cooked or baked, but in a natural form. On the other hand, granola is a mix of the similar ingredients as muesli, but oil and sugar are added to the baking process as these two additional ingredients allow the mixed batch to stick together better.

What is the best packaging for muesli?

Among three common packaging options of muesli – paper bag, paper tube, or Doypack (stand-up pouches) – it is proven that the Doypack is the best choice. According to a research, the moisture content and water activity of muesli in these three containers were varied after 9 months, showing Doypack with the highest percentage for both criteria. This demonstrates that the muesli packed in Doypack was dried out the least after a certain period. Also, evaluation of other criteria such as sensory evaluation microbiological parameters showed that Doypack was the best packaging solution for muesli.

Processing steps involved in muesli making

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