Why is Extruded Snacks Machine Better?

The manufacturing process of extruded snacks involves pushing ingredients through a die under high pressure and temperature, resulting in a variety of snack forms. Advanced equipment from Reading Bakery Systems plays a crucial role in enhancing this process, improving efficiency, product quality, and consistency. Here are just a few of the ways.

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Precision and Control

Advanced extrusion equipment from RBS offers unparalleled precision and control over the manufacturing process. Modern extruders are equipped with sophisticated control systems that allow manufacturers to precisely adjust parameters such as temperature, pressure and screw speed. This level of control ensures consistent product quality and enables the production of a wide range of snack types.

Versatility in Product Design

With advanced equipment, manufacturers can easily switch between different product designs. Multi-functional extruders can handle various dies and cutting systems, allowing for the production of snacks in different shapes and sizes. This versatility is essential for meeting consumer demands and staying competitive in the market.

Enhanced Automation

Automation is a key feature of modern extrusion equipment. Automated systems reduce the need for manual intervention, minimizing human error and increasing production efficiency. Automated feeders, mixers and cutters ensure that ingredients are consistently measured and processed, leading to uniform products. Automation also allows for continuous production, significantly increasing output.

Improved Mixing and Conditioning

RBS advanced extruders are designed to handle complex ingredient mixes, ensuring thorough blending and conditioning. The improved mixing capabilities ensure that all ingredients are evenly distributed, which is crucial for flavor consistency and texture. Conditioning systems pre-treat the ingredients to achieve the desired moisture content and temperature, optimizing the extrusion process.

Consistency in Product Quality

Consistency is a hallmark of successful snack production. Advanced extruders ensure that every batch of snacks meets the same high standards of quality. Precise control over processing parameters means that variations in texture, shape, and flavor are minimized. This consistency builds brand trust and consumer loyalty.

Energy Efficiency

Modern extrusion equipment is designed with energy efficiency in mind. Advanced heating and cooling systems, along with optimized motor designs, reduce energy consumption without compromising performance. Energy-efficient equipment lowers operational costs and aligns with sustainability goals, making the manufacturing process more eco-friendly.

Scalability

As demand for extruded snacks grows, the ability to scale production is critical. Advanced extrusion systems are designed to accommodate increased production volumes. Modular designs allow manufacturers to expand their production lines without significant disruptions. Scalability ensures that manufacturers can meet market demands efficiently.

Hygiene and Safety

Food safety and hygiene are paramount in snack manufacturing. Advanced extruders are constructed with materials that meet stringent hygiene standards. They are designed for easy cleaning and maintenance, reducing the risk of contamination. Automated systems also enhance safety by minimizing the need for manual handling of ingredients and finished products.

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Advanced equipment from RBS revolutionizes the manufacturing process of extruded snacks by enhancing precision, control and efficiency. The benefits of using modern extrusion technology include consistent product quality, energy efficiency, scalability, and improved hygiene and safety. Our innovations continue to push the boundaries of what is possible in snack production.

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Novel ingredients and formulations&#;including some aimed to be &#;better-for-you&#; and others intended to be &#;fun&#;&#;are high on the list of features and benefits snack and bakery companies would like to see in extrusion equipment, along with ease of cleaning and maintenance, efficiency, and (naturally) the ability to produce a high-quality product.

Customers of Clextral USA, Tampa, FL, are asking for innovations to help process and extrude new snack profiles and novel ingredients, says John Barber, sales manager, U.S., and Canada.

&#;Getting the precise amount of expansion and the desired textures can be challenging with some grains and vegetables, depending on their starch, fiber, and oil content,&#; he says. &#;Product shapes, features, and aesthetics can be challenging with these new ingredient blends. When we are processing higher levels of protein, fiber, and/or fat, we have to test and fine-tune the process parameters to get the right snack aspect and texture. We are also being asked to meet specific diet or nutrient claims.&#;

Processors also are looking to keep customers engaged with their brands, Barber notes. &#;This goes far beyond just delivering a quality product,&#; he says. &#;It can be making the snack more fun with a new shape, or more enticing with a new flavor combination. Some companies are asking for customer feedback through their social media channels, and then working to create and design these new snacks. It&#;s important to stand out, both on the shelf and in people&#;s minds.&#;

Nico Roesler, North American pretzel and snack equipment sales manager, Reading Bakery Systems, Robesonia, PA, says customers are focused most on efficiency and &#;bang for the buck, getting the most product out of the machine possible, and making sure that product is consistent and high-quality.&#;

Snack and bakery companies also are increasingly interested in the ability to create gluten-free varieties of traditional snacks like pretzels. These types of doughs require pre-feed rolls to ensure even and accurate distribution of the dough in the extruder because the dough does not have the strength or elasticity that gluten otherwise brings to the process, Roesler says.

&#;A lot of conversations with customers center around better-for-you snacking, adding protein content to traditional snacks, and finding alternate flours to provide better-for-you attributes,&#; he says. &#;We&#;re seeing other types of flavors, like legume flours, incorporated in the pretzel doughs&#;maybe not going fully gluten-free but offering some health benefits.&#;

Product trends like bite-sized snacks and health claims like organic are top-of-mind for customers of Egan Food Technologies, Grand Rapids, MI, says John Micelli, who handles sales and market development. &#;In the granola world, plant-based is big,&#; he says. &#;In the bar world, I am seeing a lot more nut and seed bars coming online.&#;

Sanitation and ease of cleaning are other priorities for customers, Micelli says, adding that Egan&#;s machines are all stainless steel and can be washed down in place. &#;They want it easy to change out one product to the other, with simple maintenance to remove components so they can be cleaned and washed,&#; he says. &#;Sanitation is huge, no matter what piece of equipment. &#; People like tool-less; infrequently as possible do they want [employees] to reach in and get a ratchet or screwdrivers. They want people to do it with their hands.&#;

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