How can extrusion technology create innovative snack products?

2 Types of extrusion

There are two main types of extrusion technology used in the food industry: cold extrusion and hot extrusion. Cold extrusion operates at low or ambient temperature and pressure, and is mainly used to produce snack products that have a soft or chewy texture, such as bars, nougats, and marshmallows. Hot extrusion operates at high temperature and pressure, and is mainly used to produce snack products that have a crispy or crunchy texture, such as cereals, chips, crackers, and puffs.

3 Extruder components

An extruder is a complex machine with several components that impact the quality and characteristics of the final product. The feeder delivers the raw materials into the extruder at a controlled rate and moisture content. The barrel encloses the screw that transports and mixes the raw materials along the extruder, while the die shapes the product by forcing it through a narrow opening at the end of the barrel. After exiting the die, a cutter cuts the product into desired lengths or pieces. Lastly, a dryer or cooler removes excess moisture or heat from the product to improve its stability and texture.

4 Extruder parameters

The extruder parameters are the variables that can be adjusted to modify the properties and performance of the extruder and the product. The main parameters include screw speed, which determines the rate of material flow and shear stress applied; barrel temperature, which affects cooking, gelatinization, expansion, and browning; die pressure, which influences expansion ratio, density, and porosity; die geometry, which determines shape, size, and surface appearance; and feed composition, which includes type, amount, and quality of ingredients, additives, and fillers. All of these parameters are essential to achieving desired results.

5 Extrusion challenges

Extrusion technology poses some challenges for the food industry and consumers, such as requiring a high level of technical expertise and equipment maintenance to ensure product consistency and safety. Additionally, the high temperature and pressure involved can cause undesirable changes in the nutritional, sensory, and functional properties of the products. Furthermore, the process may generate environmental and health issues due to its emission of volatile organic compounds, acrylamide, and other potentially harmful substances. Lastly, there may be regulatory and ethical barriers due to the use of novel or genetically modified ingredients, additives, and fillers in the products.

6 Extrusion opportunities

Extrusion technology offers many opportunities for the food industry and consumers to create innovative snack products that can address current and future market trends and challenges. For example, it can develop customized products that cater to different consumer segments, incorporate alternative and sustainable sources of protein, fiber, and antioxidants into the products, explore new flavors, textures, and formats, and integrate smart and interactive features into the products. These features can provide information, feedback, and convenience to the consumers.

7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?