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Breakfast Cereal Extrusion Equipment

First developed by Will Kellogg in 1894, corn flakes’ popularity grew exponentially. Made from toasting flakes of corn (maize) and served with cold milk, corn flakes have become a favorite breakfast cereal snack for millions around the world. Corn flakes production begins with milling raw corn, creating cornmeal which is then extruded to create corn flakes.

Corn flakes

Children love them, and adults love them too. Extruded cereal is a typical ready-to-eat cereal with different flavors and shapes. You pour cold milk into a bowl of extruded cereal and eat them for breakfast or sometimes as a dessert. These shapes of cereals are refined by thermo-mechanical cereal extruder machines. Typically, extruded cereal can be categorized into three kinds: direct expanded cereal, co-extruded cereal, and extruded flakes. Depending on which kind of extruded cereal you are making among these three kinds, your choice of processing line will differ.

Extruded cereal

Granola is one of the most beloved breakfast menus for its versatility and convenience - you can put it in milk, use it as a topping for yogurt, or even make healthy cookies out of it. Setting up a granola production equipment line is quite similar to muesli. The only difference would be that the sheet of hard grains, nuts, and dried fruits goes through the baking process.

Granola

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.

Muesli

If you like a warm and easy breakfast, oatmeal can be a great option for you. Oatmeal, most commonly known as rolled oats, is prepared oats ready to consume in a form of porridge or cereal. Other than rolled oats, there are other types of oatmeal - such as steel-cut oats, quick oats, and instant oats. You first need to prepare clean oat groats - the hulled kernels of wild oats, and you can decide which oatmeal processing equipment you would like to set up and depending on the oatmeal of your choice.

Oatmeal

From Asia to America, different forms of puffed rice bars - or as known as Rice Krispies - are enjoyed in diverse forms. Puffed rice bars or popped rice bars are made of puffed rice, sugar (or sweetener that works as a binder), additional flavorings such as vanilla or chocolate, and perhaps different sorts of grains and nuts.

Rice Krispies

amandus-kahl-oee-laboratory-extruder-brochure-pdf

Amandus-Kahl-OEE-laboratory-extruder-brochure.pdf

Poultry feed

Extruded aquafeed

In the feed sector, it's common to talk about feed as balanced, compound, or concentrate. Many people use one of these terms to refer to any feed mill product. However, the processing of feed concentrates, only requires grinding and mixing. The further transformation into pellets adds is an added value for the market.

Feed concentrates

Vegan meat alternatives and plant-based foods have rapidly grown in popularity over the last decade. Many people are switching to meat substitute food products. Your body does not discriminate between proteins and calories coming from meats and those coming from plants. From a nutritional point of view, they all have the same value. But chewing on a portion of veggie pumpkin protein does not feel the same as a cut of meat - the texture is completely different.

Textured Vegetable Protein

Stock cubes, also known as bouillon cubes or broth cubes, have been used in cooking for centuries. Think that, the first written version of a stock cube comes from Anne Blencowe’s recipe book from 1694. Made of dehydrated vegetables or meat stock, the bouillon cube production line consists of mixers, homogenizers, cube forming machines and packaging machines.

Stock cubes

What does a $300,000 burger taste like? Meat. The first lab-grown burger took two years and 20,000 strands of muscle tissue to produce. But with rapid advances in cultivated meat processing technology, non-animal meat alternative products can now take a lot shorter to prepare. And cost much less.

Cultivated meat

Pellet snacks, or snack pellets, are intermediate products which you can further process and develop into snack products for consumption. Pellet snacks production involves mixing, extrusion, frying, and packing. Since these are intermediate products, final product customization on the production line will depend on your customer’s desired product and flavor profile.

Pellet snacks

The ubiquitous plastic shopping bag was first designed as a reusable carrier. Its inventor, Sten Gustaf Thulin, will have been appalled to see his creation turn into a single-use object. But this disposable tendency is common to all plastic materials, from screw taps to milk carton lining. With plastic recycling equipment, however, plastic waste can be reprocessed and given a second lease of life.

Recycled plastic

In aquafeed, you can find three types of pellets: floating pellets, sinking pellets, and slow-sinking pellets, because not all aquatic species eat at the same height of the water column. In the case of bottom feeders such as shrimp, river crab, sea bass, and some species of catfish, they eat sinking pellets. Contrary to tilapia and carp that feeds from the surface with floating pellets. Sinking pellets production must control water stability to preserve the quality and form of the pellets, avoiding nutrients' dissolution in the water.

Sinking pellets

Proven design form an industry leader

Up to 200 Kg / h production capacity for OEE 8

Less sensitive process and less wasted product than traditional extruders

Does not require liquid additions at start up

Can be started with an “open die” configuration

Biomass

Feed

Food

Extrusion equipment

The extruder was first developed to make lead pipes in the late 18th century. But the extrusion process technique quickly spread to other manufacturing sectors, including food, feed, and biomass products. An extruder machine presses a fluid or solid material through a die. Depending on your use case, extruders adopt single- or twin-screw systems to push the premixed feed material through a barrel. Thermal pressure applied in this step can chemically modify the mixture, so the screw system must be precisely calibrated to achieve the desired result. Finally, a knife head cuts the extruded material into your designed dimensions. Extrusion machinery produces items of a uniform size, shape, and consistency.

Extrusion

Connect directly with world leading manufacturers of extrusion equipment and find technology to build or improve your production line.

Extrusion - Making.com

Extrusion Equipment and Machines - Making.com

Aquaculture feed is used when rearing marine livestock such as fish, shellfish, and algae. Quality nutrition is needed for healthy growth and reproduction and feed usually consists of fats, carbohydrates, protein, vitamins, and minerals. Extruded aquaculture feed floats on the water surface and pressure-pelleted feed will sink to the bottom.

Aquafeed

Cereals are also defined as breakfast food made from roasted grain and typically eaten with milk or yogurt. Cereal grain is a small, hard, and dry seed, which mainly harvests for human or animal consumption, like wheat, maize, or rye. Processed from the edible components of the grains, breakfast cereals contain rich nutrients and usually serve as the main course during breakfast meals. Different cereal manufacturing equipment allow various options to appear on the market, ranging from cereals, granola, and muesli. Granola and muesli can be converted into cereal bars. The healthy, on-the-go snack bar shows a growing trend due to its nutrient content and convenience.

Breakfast cereal

We continuously talk to suppliers of feed processing technologies that have important know-how on how to create the smarter, better, and greener feed products we need to kickstart a better tomorrow. Are you into making animal feed or pet food and looking for ways to improve your production process? Let’s navigate the world of feed production technologies together!

Our food chain starts in the soil, growing crops and livestock. But between the fields and the stores, there is a line of industrial food processing equipment. Processes may be as minimalistic as cleaning fruit and as complex as homogenizing milk alternatives made from pressed legumes. In each case, processing technology is an important link in the food production chain.

Pet food is a specialty food mostly based on formulated ingredients for various nutritional and dietary requirements. Pet food formulas are becoming more diverse and complex, considering the special health conditions and needs of young and aging pets that live in cities. The production of pet food is similar to processing food in general when it comes to fresh feedstock and flesh products.

Pet food

A snack is a small portion of food ready to eat and simple and fast to prepare. People usually consume snacks during the day between traditional meals such as breakfast, lunch, or dinner. Snack foods include simple products such as nuts, dried fruits, peanuts as well as packaged and processed foods. Puffed corn products made by extrusion or flavored potato chips are examples of processed foods.

Snacks

R&amp;D

Batch

liquid

solid

Amandus Kahl’s Extruder OE 8 is a small batch or laboratory extruder that works on the same principal as the successful Annular gap expander design where a conical stop is used to restrict flow out of a tube as materials are driven through it by a rotating shaft.

Products can be extruded with a variety of shapes and characteristics by controlling the nozzle geometry and pressure and temperature characteristics of

Laboratory extruder - Making.com

https://making-tst.imgix.net/2015/01/Kahl-Laboratory-Extruder.png

The marketplace for finding innovative production technology

Making.com

amandus-kahl-extruder-brochure-pdf

Amandus-Kahl-extruder-brochure.pdf

amandus-kahl-extruder-for-petfood-brochure-pdf

Amandus-Kahl-extruder-for-petfood-brochure.pdf

Fodder

When it comes to aquafeed, you can find three types of pellets: floating pellets, sinking pellets, and slow-sinking pellets. Not all aquatic species eat at the same height of the water column. For example, tilapia and carp eat at the surface (floating pellets) while shrimp and sea bass eat at the bottom (sinking pellets). Slow-sinking pellets are ideal for species that eat along the water column such as salmon and cod.  To get the pellets to sink at the right rate, slow sinking pellets production must control water stability in the products.

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Slow sinking pellets

With consumerism comes great responsibility. More and more are switching their diet towards vegan and vegetarian alternatives, varying from dairy to meat. As more plant-based meat technologies are being invented, the production is rising in popularity. Ever wondered which challenges come with that?

Plant-based meat

Production capacity from 200 Kg/h to 8 Ton/h

Does not require liquid additions at start up and can be started with an “open die” configuration

Protein

Process

Continuous

Products can be extruded with various shapes and characteristics by controlling the nozzle geometry and pressure and temperature characteristics of

Extruder with annular gap expander - Making.com

https://making-tst.imgix.net/2015/01/Kahl-Expander1.png

bakerperkins_twin_screw_extruder-pdf

BakerPerkins_Twin_screw_extruder.pdf

bakerperkins_breakfast_cereals-pdf

BakerPerkins_breakfast_cereals.pdf

High quality extruder for lines up to 2300kg per hour

Capable of basic extrusions as well as premium multi-ingredient products

Lower costs due to high efficiency motors, minimal waste, and reduced changeover time

  Modular design allows for perfect setup for each product type, enhancing quality

High-torque gearbox with splined shafts provide extended service life

Shaped and filled extruded breakfast and snack products are extremely popular with consumers, but can be complex and inefficient to manufacture on a large

Extruder for large-scale production of breakfast cereals - Making.com

https://making-tst.imgix.net/2018/02/extruder.jpg

brochure_dsc_entry-level-cereal-bar-making-machine-pdf

Brochure_DSC_Entry-level-cereal-bar-making-machine.pdf

The cereal bar production line consists of mixing, cutting and cooling a dough of chosen ingredients. These can be seeds, nuts, chocolate chips, dried fruits - and many more options. It may seem simple, but it needs attention to provide an appetizing look and taste.

Cereal bars

You make granola bars from caramelized nuts, grains, and cereals, baking and shaping them into crunchy snacks. Granola bar production involves mixing, forming, baking, and cutting into bars. The quality of granola bars is affected by baking. How the sugar caramelizes and blends with the other ingredients determines the final taste and texture of your granola bar.

Granola bars

In NASA's early years, a research program was established on how to provide food for astronauts while in space. In fact, in the 1960s, nutrition bars were launched with a label called "Space Food Sticks" because they were designed to allow astronauts to eat them easily while wearing their helmets. Protein bar manufacturing equipment is used to mix ingredients, extrude the mixture at a set temperature, cool the product before cutting it to size, coating it, and allowing it to cool to prepare it for packaging.

Protein bars

Nougat is a delicious confection that contains lots of nuts and dried fruits. The word “nougat” itself derives from an old Latin word for nuts. In addition to nuts, the white variety of nougat contains egg whites, honey, and sugar. Similar ingredients make brown nougat variations, except caramelized sugar replaces egg whites as the base ingredient. Depending on your intended scale of production, there are quite a few nougat making equipment you should consider getting.

Nougat

Flexible production of dry or paste-based soft bars

  Extrusion kit is simple to put in place

Quick and easy cleaning

Touchscreen HMI with recipe storage

Ideal for small-scale production

Do you have a sweet tooth, or are you more into a warm loaf of bread for a savory lunch? The bakery shop window displays something for everyone, from baguettes over croissants to muffins. Bakery products are a wide range of baked goods prepared from flour or meal derived from grains. These undergo mixing, fermentation, and baking processes with the help of bakery processing equipment such as a series of low- and high-speed mixers, fermentation tanks, and baking chambers.

Bakery

Fruit pulp is a mass of pressed fresh fruit not meant for immediate consumption. Production of fruit pulp avoids wasting food and preserves the flavors and nutrient value of the fruit product. Processed fruit pulp is an ingredient in beverages, sauces, baby foods, jellies, smoothies, and bakery products.

Tradition and manufacturing procedures dictate the distinction between fruit juice, puree, and pulp. Still, naming and labeling are complex and depend on regulations, type of fruit, texture, consistency, preservation methods, and sugar or solid content (measured in Degrees Brix). Depending on your desired output, there are various fruit pulper machines for different stages of production that make the process quicker and more efficient.

Fruit pulp

If Popeye needed spinach for his power, you need healthy snacks to boost your energy! From dried fruit chips to nuts and protein bars, healthy snacks have become more popular since the 2000s, and the global healthy snack market will reach USD 98 billion by 2025. In the wide range of healthy snacks, raw fruits and vegetables appear as the main ingredient, and these snacks focus on the high protein content and reduced fat or carbohydrate percentages. Also, “less processed” and “less amount of added chemicals” are the primary trend in making healthy snacks as the clean eating movement began after the 2000s.

Healthy snacks

Whether it is marmalade or pizza, sauce or hummus, chocolate or fruit puree, most food products undergo a cooking step during their production process. Cooking is nothing more than applying heat to food, but there are different methods to do it. For instance, baking, frying, and roasting involve cooking food without using water, unlike boiling or steaming. Industrial cookers such as vacuum and pressure cookers, industrial fryers, industrial ovens, and industrial roasters focus on specialized applications that meet the different needs of the food industry by helping producers achieve a homogeneous cooking process.

Cooking

Dosing systems are a line of hoppers, feeders, filling machines, and checkweighers that operate in sync to dispense materials accurately. Dosing is an essential feature of the packaging process, whether you’re filling shampoo bottles or tea bags. But dosing equipment is critical for formulations, too, particularly in the pharmaceutical and chemical industries. Imprecise dosing may cause quality degradation in the best-case scenario. In the worst scenario, it creates serious health risks.

Dosing

The process of forming allows you to shape your products homogeneously. Forming machines are fed the manufactured material in bulk and cut it down to specification, so the process takes place between formulation of the mass and the packaging of the final item.

A special class of this equipment – Form, Fill, and Seal Machines (FFS) – creates bags and pouches from flat material such as plastic sheets, fills them with your designated product, and seals them.

Forming

The heating process is a step of raising the temperature of food, pharma, cosmetics, and many other types of products. You may employ different heating solutions for this process, depending on the type of product you intend to manufacture. Selecting the appropriate heater machine for your product is quite important since various products require different ranges of temperatures and different ways of heat transfer using exchangers. Industrial heating equipment varies in two ways - the type of material it can process and the reaction you want to achieve.

Heating

Are you interested in flexible bar machine for grain, cereal or fruit paste-based bars? Visit oour web -site to learn more.

Cereal and grain bars are increasingly popular, both as snack foods and as functional foods using natural ingredients. Traditionally, a higher-quality

Entry-level cereal bar making machine - Making.com

https://making-tst.imgix.net/2019/02/DSC_entry-level-cereal-bar-making-machine.jpg

coperion_3141_brochure-pdf

Coperion_3141_brochure.pdf

Hygienic design with easy cleaning minimizes downtime

High operational reliability and durability

Low thermal stress on raw materials for quality retention

Scalable from lab to production scale

Flexible configurations for various applications

Industrial

Industrial mixing equipment is used to combine two or more solid, liquid or gaseous segregated ingredients into a homogenous single product. The choice of mixing technology depends largely on the physical state of the ingredients and the desired final product. But the sensitivity of the ingredients, the process temperature, and pressure requirements are also critical factors. All these parameters result in a wide range of industrial mixers.

Mixing

In the production of diverse food and pet food items, ensuring a consistent texture and quality throughout the process can be a challenge. Precise control

Food extruders for pet food production - Making.com

https://making-tst.imgix.net/2024/09/Coperion_3141_image.png

bakerperkins_small_batch_extruder-pdf

BakerPerkins_small_batch_extruder.pdf

High-quality, scalable results for product design and recipe or process testing

Full process controls including comprehensive data recording allows easy analysis

  Portable - can be moved into production areas as a small batch production unit

Dry powder and liquid feed systems for maximum flexibility

Small batches of product using high value ingredients are not economical or practical to run on full scale production extruders. Similarly, research and

Pilot extruder for cereals and snacks - Making.com

https://making-tst.imgix.net/2018/02/snack-equipment-extrusion-co-extrusion-mpf24-small-batch-twin-screw-extruder-1.jpg

bakerperkins_benchtop_extruder-pdf

BakerPerkins_Benchtop_extruder.pdf

Rice cakes are a versatile, low-calorie, fiber-rich food consumed in many cultures either as a dish, like in Asian countries or as a healthy snack. Rice cake production and properties come in a wide range of varieties, and it’s important to have rice cake making equipment that can accommodate the manufacturing of all of them.

Rice cakes

Shrimp or prawn crackers are savory snacks common in Asian countries. Believed to have its origins in West Malaysia, this snack is part of daily common cuisines or as a midday snack. Prawn cracker manufacturing has a strong demand, with Indonesia exporting 1.648 million kg as of May 2019.

Shrimp crackers

Allows for the rapid testing of new product ideas for evaluation

Perfectly scaled with full size production extruders means it can be used for process troubleshooting

Effects of new ingredients or formulations can be tested without impacting main production

  Small form factor allows batch size as low as 5kg per hour, up to 25kg per hour

Onboard touchscreen HMI for full recipe control and operational data

Extruded products are very popular in the breakfast cereal and snack sectors. It is extremely inefficient to design, test and perfect new product ideas

Benchtop extruder for cereals and snacks - Making.com

https://making-tst.imgix.net/2018/02/snack-equipment-extrusion-mpf19-benchtop-development-extruder-2.jpg

buhler_2399_brochure-pdf

Buhler_2399_brochure.pdf

Extended operating lifetime due to wear-resistant barrel interiors

Customizable for different processing requirements

Consistent product quality with intelligent recipe memory

Time efficiency via robust screw ejection unit

High-quality end product with two-stage preconditioner

Processing

In the production of breakfast cereals, achieving consistent quality while minimizing downtime is crucial. Challenges such as ingredient mixing

Twin-screw extruder for breakfast cereal - Making.com

https://making-tst.imgix.net/2024/09/Buhler_2399_image.png

buhler_2469_brochure-pdf

Buhler_2469_brochure.pdf

Reduced downtime with fully automatic screw ejection

Consistent end-product quality with flexible cutter and preconditioner

Minimal operator error with intelligent recipe memory

Extended equipment lifespan with wear-resistant barrel interior

Customizable processing with high torque and variable speeds

Cutting

Optimizing the production of breakfast cereals requires consistent quality and precise control over processing parameters. Challenges include wear and

Breakfast Cereal Extrusion Equipment

Which breakfast cereal extrusion technology do you need?

Laboratory extruder

Extruder with annular gap expander

Extruder for large-scale production of breakfast cereals

Entry-level cereal bar making machine

Food extruders for pet food production

Pilot extruder for cereals and snacks

Benchtop extruder for cereals and snacks

Twin-screw extruder for breakfast cereal

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