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Magazine
Healthy, crispy food
How exactly does this process work? Can you give a concrete example from practice?
Carol Krech: The Bühler Cerex Puffing process (Figure 2) is based on a hydrothermal process for processing food and animal feed. Raw materials such as rice, maize or quinoa are puffed for ready-to-eat breakfast cereals or as ingredients for bars, chocolate or toppings. The starting products are preheated to up to 120 °C and then exposed to steam and pressure. As a result, the pressure is suddenly reduced and the moisture contained vaporises, causing the product to expand explosively and increase its volume by up to 12 times.
A practical example: Puffed amaranth is often used as a crunchy component in muesli bars or as a visually and sensorily appealing topping in chocolates (see Figure 3).
Bühler Cerex technology combines preheating, puffing and expansion in a single system and can be flexibly expanded with upstream and downstream processes. This makes it ideal for ready-to-eat cereals and their further processing along the value chain. Copyright: ©Bühler Group
Which raw materials are particularly suitable for the process?
Carol Krech: Various cereals and pseudo-cereals such as wheat, kamut, oats, rice, maize, spelt, barley, rye, millet, quinoa, amaranth and extruded pellets are suitable. The process requires raw materials with a moisture content of 10 to 14 percent and a starch content of 65 to 75 percent, as this promotes expansion.
What distinguishes the new puffing process from existing methods and what technological innovations is it based on?
Carol Krech: Compared to other processes, the industrial Bühler Cerex Puffing technology is a closed, hydrothermal process that can be operated semi-continuously. It enables optimum hygienic safety, maximum energy efficiency and a low proportion of unpuffed products.
To what extent does the puffing process affect the texture, flavour and nutritional stability of the final products?
Carol Krech: The puffing process increases the porosity of the product, making it lighter and crispier. At the same time, digestibility is improved due to the breakdown of starch, and the shelf life is extended as a result of the reduced moisture content. The integration of puffed ingredients such as rice or quinoa into various foods offers numerous benefits and additional nutritional potential. Examples include protein and chocolate bars, bread rolls and other baked goods in which puffed components can increase the volume, increase the fibre and protein content and positively influence the texture.
How does the new process contribute to greater sustainability - whether through energy savings or better utilisation of raw materials?
Carol Krech: The Bühler Cerex Puffing process enables production yields of up to 95 percent, supports uniform expansion and reduces waste. It also consumes up to 50 percent less energy than comparable solutions and allows the processing of locally available raw materials, significantly reducing CO₂ emissions through shorter transport distances.
A broad range of applications - from snacks (with amaranth, top right), confectionery (chocolate bar, bottom left) and breakfast cereals (top left) to dairy products (bottom right) and plant-based alternatives. Copyright: ©Bühler Group
How might the puffing process develop over the next few years? Is there potential for innovation?
Carol Krech: Advanced technologies could further reduce energy consumption. Health and well-being trends are leading to innovative flavour combinations and new recipes. Regions with limited food supplies and specific nutritional requirements could benefit from enrichment with vitamins, minerals or proteins.
We are observing that all trends from the food industry are also reflected in pet food - and we are prepared for this. At our Application Centers, we work with our customers to develop innovation potential in a wide range of applications - from snacks and chocolate to innovative product solutions.
Finally, what should companies know about Bühler Cerex technology? What are your three key recommendations?
Carol Krech: In summary, the Bühler Cerex Puffing process provides companies with a sustainable technology that can be used flexibly and efficiently. The three most important reasons for using it are:
- Simple operation and high production yield
Energy efficiency
Ensuring quality and consistency
For additional information:
Carol Krech
Head of Market Segment Cereals & Snacks
Bühler AG, Uzwil, Switzerland
www.buhlergroup.com
