Potato chips, tortilla chips, popcorn, nuts and crackers are all popular snacks that have withstood the test of time are technically termed first-generation snacks. Corn puffs, balls and rings are second-generation of snacks and made using extrusion technology.
I have found that extrusion technology offers an efficient, innovative way to mix, cook and form snacks with a specified texture and design that appeals to consumers. In short, a bin holding the ingredient blend feeds into an extruder barrel containing a screw that turns and pushes material toward a die end. A 15-20% dough moisture and mechanical energy provided by the kneading screw elements and steam locks build barrel pressure to cook starch. Thoroughly cooking starch permits structural modification necessary for good expansion and thin product cell walls that help provide the characteristics of a light texture.