The Future of Breakfast: High-Protein Cereals

Protein is associated with longer-lasting satiety and has become a preferred choice for those who want to reduce their calorie intake while maintaining muscle mass.

Cutting-Edge Equipment and Expertise

The production of extruded breakfast cereals involves several vital processes, each essential for a high-quality and consistent final product.

Dry ingredients are weighed and blended in the normal way and transferred to a gravimetric feeder which precisely meters them into the extruder. The highly accurate gravimetric feeders from Coperion K-Tron are particularly suitable for this task. Liquid ingredients are injected directly into the barrel. In some instances, a preconditioner mixes, hydrates and heats the ingredients prior to the extruder to optimise quality and output. A preconditioner also widens the range of products that can be made on the extruder.

The extruder uses a combination of temperature, pressure and mechanical shear to cook the mass in a matter of minutes. The cooked mass is extruded through multiple die orifices where it expands to achieve the desired texture and shape - whether it's puffs, rings, or flakes, and rotating cutter blades form the individual pieces. 

The cereal is then dried or toasted to reduce moisture content, ensuring crunch, bowl-life and shelf stability. Critical for achieving the signature crisp texture that consumers expect. A coating process is applied to cereals requiring additional flavours or nutrients, followed by final drying to set the coating.

A Complete Solution

Coperion’s collaboration with Baker Perkins ensures a complete solution for high-protein cereal production. Our complete solution includes:

• Shick Esteve components and systems for ingredient handling
• Coperion K-Tron high accuracy feeders and
• Baker Perkins technology for preconditioning, twin-screw extrusion, pellet forming, flaking, coating, and drying

With the Baker Perkins SBX Master™ Twin-Screw Extruder, manufacturers can produce a wide range of cereals, from direct-expanded shapes like balls, rings and curls to traditional flakes. Adjusting the extruder to handle protein-based formulations is simple, and manufacturers can effortlessly switch back to conventional cereal production.

This versatile extruder can output from 500 to 2,300 kg/hr. It features a modular design, allowing for easy reconfiguration, splined shafts for added torque, and a high-torque gearbox that ensures robust performance. Additionally, its hygienic open-frame design makes it easy to clean and maintain.

For established producers, we can advise on the necessary process adjustments and provide any equipment or modifications needed for a seamless transition.

Test and Refine Your Recipe

Although high-protein varieties are well within the scope of the SBX Master extruder, they require different extruder configurations and process settings to standard cereals. Unfortunately, it isn’t as simple as swapping ingredients, as the proteins used offer different properties that can impact texture, flavour, and nutritional profile. At Baker Perkins Innovation Centre, businesses can take advantage of a full-scale pilot line to test and refine their cereal. This hands-on development allows you to optimise your recipe, ensuring that the final product meets customer expectations and production efficiency.

Staying Competitive In a Growing Market

With consumer demand for healthy, protein-rich breakfast cereals rising, now is the perfect time to innovate and stay ahead of the trend. We are able to partner with manufacturers, giving them ongoing support, from development and testing to full-scale production, ensuring that their products meet market demand both now and in the future. Contact our team to bring your high-protein cereal to life and stay ahead of market trends.