Medium to large-scale biscuit manufacturers are increasingly seeking higher production speeds and greater flexibility as consumer preferences shift towards varied textures, fillings, and product formats. This trend has prompted equipment suppliers to develop systems capable of handling multiple production styles within single installations.

GEA's latest response to these market pressures is the Bake Extruder, unveiled at IBA 2025 in Düsseldorf. The system addresses production requirements for wirecut, co-extruded, filled, continuous extruded, and deposited products—formats commonly used for cookies, bars, and textured biscuits.

Market Requirements Drive Design

Industry surveys indicate manufacturers prioritise performance improvements, operational flexibility, simplified cleaning procedures, and expanded product variety capabilities. These requirements reflect broader challenges in industrial baking, where production lines must accommodate shorter runs of diverse products whilst maintaining efficiency.

The modular extruder design responds to these constraints through interchangeable dies and cutting mechanisms. Operating speeds reach 350 strokes per minute across 1,700-millimetre working widths, with performance varying by product complexity—from 130 cuts per minute for encapsulated products to 250 cuts per minute for continuous extrusion.

Technical Capabilities

The system incorporates brushless motors and servo-driven axes for consistent product dimensions, addressing quality control requirements in high-throughput environments. Optional lobe pumps handle aerated doughs and inclusion-containing formulations, such as those with chocolate chips or dried fruits.

Hygiene considerations influence the design significantly. Servo motors, shafts, and supports are positioned for maintenance access, whilst removable hoppers and open-head configurations enable cleaning cycles. Photoelectric safety barriers facilitate safe sanitation procedures.

Industry Context

The equipment launch reflects broader automation trends in industrial baking, where manufacturers seek to reduce labour costs whilst increasing production flexibility. Integration capabilities with existing oven systems and ERP platforms indicate the industry's move towards connected production environments.

Predictive maintenance features through performance analysis tools address operational efficiency concerns, particularly relevant as manufacturers operate under tighter margins and extended production schedules.

The development suggests continued investment in modular equipment design, allowing manufacturers to adapt production capabilities without complete line replacements—a consideration particularly relevant for mid-sized operations expanding their product portfolios.