Bühler acquires puffing technology for cereal and snack applications

Swiss technology group Bühler has acquired puffing technology from CEREX for food, petfood and feed applications.

The acquisition of the puffing technology is designed to broaden Bühler’s product offerings, providing enhanced solutions to address the growing demand for healthier and more diverse food options.  The technology is suitable for a broad range of products — from snacks, ready-to-eat breakfast cereals and confectionery to bakery items and dairy products.

“The puffing process is a game changer in how we approach cereal and snack production, offering a broad range of recipe possibilities, including coatings and fillers across many product categories,” said Christoph Vogel, Head of Business Unit Human Nutrition at Bühler.

The demand for snacks like bars, extruded snacks, nuts, seeds, popcorn and plant-based alternatives such as puffed oats has increased in recent years. The global ready-to-eat snack market size is expected to expand at a compound annual growth rate (CAGR) of 9.7% from 2024 to 2031. Puffing technology can help companies quickly adapt to these emerging consumer trends.

At a time when cocoa prices are high, the puffing technology also enhances production efficiency by increasing volume and weight, reducing sugar content and cutting production costs.

Puffing is a hydrothermal process that uses heat and pressure to expand the volume of raw materials. The process requires the material to contain 10–14% water and 65–75% starch, with protein and fat levels also affecting the outcome. Puffed products offer several advantages. Their increased volume and porosity make them lighter and crispier — a desirable quality for snacks and cereals. The puffing process also enhances digestibility by breaking down starches, and improves shelf life by reducing moisture content and preventing spoilage. It also helps to boost nutritional potential as the product can easily be enriched with vitamins, minerals or proteins.

Puffed products are said to be healthy as they contain no added ingredients — just a single, natural component — and are available as white-label options. The technology can be used in a variety of products. In breakfast cereals, grains like rice, corn, wheat or quinoa are puffed to create expanded, crunchy textures that are suitable for morning meals. In cereal bars, puffed grains add texture, visual appeal and a distinctive crunch. The grains are either mixed with melted chocolate or layered on top, depending on the desired structure of the final product, providing a balance of crunch and lightness. Puffing technology is also used in dairy products, such as yoghurt and ice cream, where puffed grains like quinoa, rice or buckwheat serve as crunchy toppings or mix-ins to enhance the eating experience and nutritional value.

Bühler’s Cerex puffing technology is designed to enhance grain processing by achieving maximum yields of over 95%, reducing waste while ensuring uniform puffing across all grains. The system operates with energy efficiency; it uses 60 kilowatt hours (kWh) per 100 kg. Additionally, it is designed to ensure a stable and industrial-grade puffing process compliant with food safety regulations.

In April 2025, Bühler will open an Application & Training Center at its headquarters in Uzwil, Switzerland, focused on the puffing technology. At the Center, visitors will be able to test new product recipes with ingredients such as pulses and develop new processes applying this technology.

“By incorporating advanced puffing technology, we are confirming our commitment to innovation, addressing both current market demands and anticipating future consumer trends,” Vogel said.

Top image credit: iStock.com/Marina Shvedak