Puffed and extruded snacks are a fun category to follow. As reported in our recent coverage of the category, Snack Food & Wholesale Bakery reported that sales have been mixed in recent months. However, the field is still rife with opportunities, especially for producers who stay in tune with what consumers want while successfully wrangling with the associated challenges.

For a broader perspective on puffed/extruded trends, challenges, and chances of success in the category, SF&WB connected with Sylvain Courbon, regional account and sales manager with extrusion technology supplier Clextral.

Jenni Spinner: Could you please talk about some of the key trends around puffed and extruded snacks? What bases, flavors, shapes, and other attributes are consumers hungry for?

Sylvain Courbon: Today’s consumers expect more from their puffed and extruded snacks, seeking a balance of health, sustainability, indulgence, and bold sensory experiences. 

Health and wellness trends are driving demand for nutrient-dense bases like chickpeas, lentils, and whole grains (e.g., sorghum, quinoa), with clean-label and plant-based options gaining traction. 

At the same time, sustainability is influencing ingredient sourcing and production, with an increasing focus on upcycling ingredients such as brewing byproducts and juicing byproducts.

Global flavors are captivating adventurous eaters, with spicy, smoky, and tangy profiles—like pickle, lime, sweet potato, spicy taco, and honey BBQ—bringing excitement to snacking.

While better-for-you options are key, indulgence remains essential, with rich seasonings, creamy fillings, and sweet-savory combinations enhancing the sensory appeal. 

Finally, innovative textures (ranging from crispy and airy to layered and crunchy) are redefining the eating experience, ensuring every bite is as satisfying as it is exciting. Meanwhile, creative shapes (e.g., peapod, twisted pillow, croissant) elevate the snack's appeal, offering consumers a visually engaging and shareable snack that aligns with both health-conscious trends and a fun, memorable eating experience.

JS: Could you please talk about some of the challenges snack producers can face when considering adding such products to their portfolio?

SC: Adding innovative products like extruded legume snacks to a portfolio presents several challenges for snack manufacturers. While twin-screw extrusion offers versatility, the production process for a legume-based snack differs significantly from that of traditional corn snacks. Each ingredient—whether it's legumes, grains, or other plant-based sources—requires careful recipe development, testing, and adjustments to achieve the desired flavor, shape, and texture.

R&D capabilities are crucial in perfecting these recipes and achieving consistent product quality. This process demands a deep understanding of food science, as well as expertise in industrial machinery and extrusion processes. Manufacturers must navigate the complexities of ingredient behavior, extrusion parameters, and optimal textures.

To help overcome these challenges, we support our customers by upgrading both their equipment and human resources. Through our Pilot Plants, we offer hands-on testing and experimentation, allowing manufacturers to refine their products before scaling up. Our process engineers, with their diverse and rich backgrounds in food science and extrusion technology, provide invaluable guidance throughout the development process, ensuring that new products meet the desired specifications. Additionally, through our network of contract manufacturers, we help businesses scale production, offering the flexibility to launch and test new products in the market before making substantial investments in their own facilities. This approach enables manufacturers to minimize risk, refine their products, and explore new opportunities with confidence.

JS: Specifically, what types of equipment might they have to choose from when looking to produce puffed and extruded items?

SC: When looking to produce puffed and extruded snacks, manufacturers must choose the right equipment to ensure efficiency, flexibility, and product quality. A typical direct-expanded snack extrusion line consists of three main components: a twin-screw extruder, a dryer, and a savory coating unit. At Clextral, we go beyond the basics by providing turnkey and flexible solutions, covering everything from raw material handling and preparation to the final seasoning process—all tailored to each customer’s specific needs.

Unlike single-screw extruders, twin-screw extrusion technology is very versatile and offers highly controlled processing parameters, a higher production rate, and greater ingredient flexibility, making it ideal for today’s evolving snack formulations. Depending on the specific extruded snacks the manufacturers are aiming at, we can customize their setup by adjusting key factors such as the extruder’s length-to-diameter (L/D) ratio, screw profile, and die design to achieve the desired shape, and the desired texture and structure.

To further expand extruded snacks possibilities, manufacturers working with Clextral can integrate clip-on ancillary equipment, such as a co-extrusion kit (for filled snacks), or specific shaping equipment such as a chipstick cutter, a Pinching Former (aka Crimper), or the crouton cutter. Additionally, a wide variety of dies enables the creation of unique shapes, allowing brands to differentiate their products and enhance consumer appeal.

At Clextral, we don’t just respond to market trends—we anticipate them. Each year, our teams proactively develop a new puffed and extruded snack shape, expanding our already extensive catalog and providing our customers with fresh opportunities to stand out in a competitive market.

By leveraging our expertise, advanced extrusion technology, and commitment to innovation, we help manufacturers optimize their production lines and develop innovative, high-quality snacks that meet consumer demand.

JS: Can you talk about some of the key questions they should ask when selecting equipment?

SC: Selecting the right equipment for puffed and extruded snacks requires careful consideration of several key factors to ensure optimal performance, efficiency, and long-term adaptability. Manufacturers should ask themselves the following critical questions:

• What production rate range do we need? Understanding both current and future capacity requirements helps determine the right extruder size and configuration to support business growth while maintaining cost efficiency.
• How does the equipment impact utility consumption? Energy and water efficiency are essential for controlling operational costs and aligning with sustainability goals. Clextral’s extrusion solutions are designed for optimized energy efficiency, reducing waste while maintaining high performance.
• How flexible is the system in terms of capacity, shapes, and recipe changes? Consumer preferences evolve rapidly, making it essential to have equipment that can easily adapt to new formulations, ingredient variations, and product innovations. With Clextral’s twin-screw technology, manufacturers benefit from unmatched flexibility, allowing for quick adjustments in texture, density, shape, and ingredient composition without extensive downtime. Additionally, Clextral’s patented barrel opening system enables fast access to the screws in just a few minutes, making it easier than ever to change screw profiles for new recipes, perform maintenance, and clean the equipment efficiently maximizing uptime and production versatility.
• What level of process control and automation is available? Advanced control systems enhance efficiency and consistency while minimizing manual intervention. Clextral’s smart automation solutions offer real-time monitoring and precision control over key extrusion parameters, ensuring high-quality, repeatable results.
• Does the supplier offer technical support, training, and R&D resources? Beyond equipment, manufacturers need a reliable, responsive partner who can support their production goals with expertise and innovation. At Clextral, our human-scale organization allows us to build close, personalized relationships with our customers, ensuring that every solution is tailored to their exact needs. In addition, our dense network of contract manufacturers worldwide helps businesses ramp up production, test new products in the market, and scale efficiently before committing to full in-house investment.

By considering these key factors, snack manufacturers can invest in the right extrusion solutions—ones that not only meet immediate production needs but also provide the flexibility, efficiency, and expert support required for future market success.

JS: Then, please talk about some of the solutions Clextral offers such producers, and the advantages these offer to folks considering a leap into puffed/extruded.

SC: For manufacturers looking to enter or expand in the puffed and extruded snacks market, Clextral offers a range of tailored solutions that combine technological expertise, production flexibility, and dedicated support to ensure success at every stage of the process.

• Complete Line Solutions: Clextral provides turnkey extrusion lines covering the entire production process, from raw material handling to drying and seasoning. These solutions are designed for efficiency, reliability, and high-quality output, allowing manufacturers to streamline operations while maintaining consistency.
• Flex Line Solutions: Clextral’s Flex Line solutions offer unmatched versatility, enabling manufacturers to produce a variety of extruded products—including snacks, breakfast cereals, and TVP (Texturized Vegetable Proteins)—on the same extrusion line. These lines are designed to evolve with customer needs, allowing for easy adaptation to new recipes, shapes, and textures. Additionally, clip-on equipment such as co-extrusion devices, shaping tools, and crimpers can be integrated seamlessly, offering manufacturers the flexibility to expand their product portfolio without the need for a complete system overhaul.
• Aftermarket Support: More than just supplying equipment, Clextral’s Aftermarket services ensure that customers receive comprehensive long-term support to maximize their production efficiency and equipment lifespan. This includes technical assistance, preventive maintenance programs, spare parts availability, process optimization, and training programs, helping manufacturers keep their lines running smoothly and efficiently.
• R&D Platforms and Partner Network: Innovation is central to Clextral’s approach. Through its Pilot Plants and global network of R&D platforms, manufacturers can test new formulations, refine extrusion parameters, and validate products before scaling up. This extensive network increases geographical accessibility, allowing customers to collaborate with Clextral’s expert Process Engineers and partner facilities worldwide, reducing development time and minimizing risk before market launch.

By offering complete, adaptable, and innovation-driven solutions, Clextral empowers snack producers to confidently enter or expand in the extruded snack market, ensuring they have the right technology, expertise, and support to stay competitive and agile in a rapidly evolving industry.

JS: Do you have any final thoughts or words of advice?

SC: Let’s turn ideas into reality.

At Clextral, we don’t just provide equipment—we partner with you to develop, optimize, and scale your snack innovations. We invite you to test your formulations in our Pilot Plants, working alongside our expert Process Engineers to fine-tune recipes, textures, and processes before full-scale production.

With our flexible solutions, hands-on support, and global network of contract manufacturers, we help you reduce risk, accelerate market entry, and stay ahead of trends.

Let’s shape the future of snacks together: come explore the possibilities with us!

Related: Consumers search for better-for-you puffed and extruded snacks