Co-Extrusion

As the cereal industry develops, manufacturers have to generate a steady stream of attention grabbing new products to stimulate interest and satisfy consumer expectations.

Taste, convenience, health, indulgence and variety are all issues affecting a purchase decision.

 There is a clear trend towards more complex products, with improved shape and colour definition to provide differentiation in a crowded market.

Companies competing in the cereal sector also need equipment with the flexibility to produce a range of products that match the latest trends in consumer preference; an inbuilt ability to bring new products to market quickly; and move easily into adjacent market niches.

Twin-screw extrusion is a process that connects all these requirements, and a new co-extrusion system from Baker Perkins can be added to an existing single or twin-screw extrusion line supplied by virtually any manufacturer.

The Baker Perkins co-extrusion system provides the means of incorporating fillings with contrasting textures and colours into a cereal outer.

It provides a capacity for making added-value products with out of the ordinary shapes that catch the eye, complemented by exotic flavours and fillings.

Fillings can be of virtually any colour or flavour – creams, fruit pastes, and chocolate praline are typical.

Exotic flavours, plus glazings, frostings or chocolate coating, add even more appeal.

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 and snacks as well as cereals.

In addition, to position co-extruded 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.

Production with a co-extrusion system is versatile as key parts can be changed over quickly.

The essential elements of a Baker Perkins system are a cutter crimper, cream feed system and die.

 

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