Co-extrusion technology increases opportunities for snacks and cereals
Date: 20 April 2007
A low cost investment that adds value, variety and consumer appeal
Baker Perkins has developed technology extending the end product capability of the extrusion process in the breakfast cereal, snack and pet food industries. It can be supplied new, or retrofitted to existing single or twin-screw lines supplied by virtually any manufacturer.
This co-extrusion technology is a response to market pressures that requires a steady stream of convenient, tasty and attention-grabbing new products to stimulate interest and satisfy consumer expectations.
Co-extrusion systems provide a capability to make added-value products with out of the ordinary shapes that catch the eye, complemented by exotic flavours and fillings. The fillings can be of virtually any colour or flavour - sweet or savoury creams, fruit pastes or chocolate pralines are typical. Even more appeal can be added with glazings, frostings or coatings such as chocolate.
They also provide the means of incorporating fillings with contrasting textures or colours into a cereal outer. The essential elements are a die, pillow crimper and cream feed system.
The Baker Perkins pillow crimper ends the restriction to conventional squares and rectangles. It provides the opportunity to form a number of attractive and distinctive patterns such as hexagons, 'cats face', chevrons and waves. It is even possible to produce different shapes and flavours simultaneously for variety packs.
A further avenue for investigation is the development of surface textures such as grooves and highlights. Another option makes lighter products by either partially filling or using a special die to inject air.
Investing in a Baker Perkins co-extrusion system is an economical means of expanding marketing opportunities as well as a product range - with minimal investment in R&D. Co-extruded cereal products can be positioned as pet or infant foods as well as mainstream snack or cereal products.
To position cereal products as a more indulgent option, bite-size sweet-filled pieces are already emerging to challenge the chocolate bar. Co-extruded products can be made in virtually any length from 12 to 120mm, so filled bars can be marketed as individually wrapped count lines.
To reach the growing demand for foods with a 'healthy' image, wholegrain products - everything in the grain is in the product - and multigrains with a combination of rice and wheat fulfil all the requirements.
Production with a co-extrusion system is versatile as key parts can be changed over quickly.
The pillow crimper can handle up to eight lanes of product; simultaneous cutting and crimping minimises product handling and transfers that can contribute to surface damage.
The cream feed system provides accurate metering of fillings: modular design allows a range of machine sizes from two to eight pumps to be provided.
Die technology is the key to development of new snacks and breakfast cereals. Retrofitting new dies during the mid-life cycle of an extruder can freshen a product portfolio with new and attractive brands.
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