Better-for-you (BFY) products become better than ever with the use of extrusion.

That’s what bakers and snack producers are discovering with new products that pack a punch not only with protein, but with other nutrition, flavors, textures and handheld snacks that provide meals to go. 

It’s easy to see why. A consumer study by Glanbia indicates protein snacks are most often eaten at a computer in the home (43%) followed by before or after sports activities.

For companies, it means hopping on the bandwagon or missing the ride, especially when it comes to this super-popular ingredient.

“It’s about any way you can get protein into a product,” observed Mike Shaw, sales manager, snacks and cereals, North America, Bühler. “We’re seeing different forms of products that are trying to get as much protein in them as possible.”

Specifically, companies are incorporating a variety of plant- and animal-based proteins into the doughs of pretzels and baked extruded snacks, noted Nico Roesler, North American snack equipment sales manager, Reading Bakery Systems (RBS).

“Pretzels not only make a good on-the-go snack, but they also serve as a good carrier for dips,” he explained. “So, consumers can add protein not just to snack occasions but also add protein pretzels to meal occasions to get even more.”

Rafael Alvarenga, area sales manager, Wenger Manufacturing, pointed out that snack makers are searching for new ways to accommodate the next generation of BFY ingredients and flavors.

 “Direct-expanded snacks made via extrusion cooking can deliver unique textures and snacking experiences for consumers at an efficient scale, using sets of complex or simple ingredients,” he said. “Extrusion is often the process of choice because it offers consistent and continuous production, but also because it provides the flexibility to meet changing customer preferences.”

Co-extrusion also provides a distinctive eating experience with expanded snacks as well as new twists on already established products.

“One can have a crunchy, savory outside texture with a smooth, soft contrasting texture and flavor of the inside filling,” said John Barber, regional sales manager, Clextral USA. “Another way extrusion has impacted the snack market is by providing high-protein, alternative meat-like snacks, such as plant-based jerky, which are produced via a high-moisture extrusion technology system.”

Andres Lopez, business development director, Handtmann Inc., suggested extrusion is all about convenience and creativity. More recent technology such as triple extrusion, where a cookie dough may be filled with jelly and topped with a layer of peanut butter, allows bakers to develop a full portfolio of products with less labor and often on just one machine. 

“With triple extrusion, the natural question we get is, ‘What can you do?’ Whatever sets customers’ products apart is going to help them win in the market,” he explained. “Visual appearance is also critical when you’re talking about snacks.”

For hot appetizers and handheld items, co-extruders can produce value-added, filled foods of almost any size, ranging from 0.5 oz to 10 oz, said John Giacoio, Rheon USA.

“Rheon has the capability of extruding up to five different materials into one final product,” he said. “This is particularly handy if you’re making a specially designed, wirecut logo cookie that requires different color doughs to make the design. Although the Rheon machines are called co-extruders, a company can easily increase the number of materials being extruded into a single product.” 

Once food producers decide what type of dough they would like to use, they just then need to figure out what filling goes well within it.

“If you’re using a rye bread dough, your filling could be corned beef, pastrami or even ham and Swiss cheese,” Giacoio said. “The options are limitless.”

For bakers and snack makers, extrusion enables them to knock out innovative products that wallop the competition when it comes to health, wellness, convenience and flavor.

This article is an excerpt from the March 2025 issue of Baking & Snack. To read the entire feature on Extrusion, click here.