Food Extrusion Market Size, Disruptive Innovations and Market Projections 2024-2032

Food Extrusion Valuation – 2024-2031

The rise in veganism and the increasing demand for plant-based protein alternatives are significantly influencing the food extrusion market. Extrusion technology is widely used to produce plant-based protein products and meat substitutes, catering to a growth of health-conscious and environmentally aware consumers. This trend towards plant-based diets is a major driver of market growth, as it aligns with the broader shift towards sustainable and ethical food choices. Thus, the growing demand for veganism and plant-based proteins surged the growth of market size surpassing USD 67.96 Billion in 2023 to reach a valuation of USD 91 Billion by 2031.

The food extrusion market is also being driven by the continuous expansion of snack product portfolios. Manufacturers are leveraging extrusion technology to develop new and innovative snack options that appeal to changing consumer preferences. The ability to produce a wide variety of snack products through extrusion supports market growth by meeting the demand for diverse and appealing snack choices. Thus, the expansion of snack portfolios enable the market to grow at a CAGR of 4.10% from 2024 to 2031.

Food Extrusion Market: Definition/ Overview

Extrusion is a pivotal food processing technique that involves pushing a blend of soft, mixed ingredients through a perforated plate or die to shape the food into the desired form. The process begins with the extruder, a specialized machine that forces the mixture, known as the extrudate, through the die. The die, typically located at the end of a large extruder, is positioned within a stationary barrel and operated by a revolving screw. Once the extrudate exits the die, it is cut to the required size by blades, ensuring uniformity in the final product.

This technique allows for the efficient, continuous production of food items, which is crucial for mass manufacturing. Extrusion provides consistency and homogeneity in the products, which often have high starch content. Common examples of extruded food products include various types of pasta, bread (such as croutons, breadsticks, and flatbreads), breakfast cereals, ready-to-eat snacks, confectionery, pre-made cookie dough, baby foods, full-fat soy, textured vegetable protein, certain beverages, and dry or semi-moist pet foods.

In today’s globalized market, consumers demand healthy and affordable food options. Extrusion systems offer a flexible and cost-effective solution to meet these evolving requirements. The extrusion process integrates several key operations, including mixing, cooking, kneading, shearing, shaping, and forming. This versatility, combined with its cost-efficiency, productivity, and environmentally friendly attributes, has made food extrusion increasingly popular.

Extrusion is also valued for its ability to create products with complex cross-sectional profiles and handle brittle materials without generating waste. By using compressive and shear stresses rather than tensile forces, extrusion minimizes material damage, making it an ideal method for producing a wide range of food products efficiently and with minimal waste.

How does the Increasing Demand for Convenience Food and Growing Personal Disposable Income Surge the Growth of the Food Extrusion Market?

As consumer lifestyles become increasingly hectic and urbanization accelerates, rising demand for convenience foods. This trend is driven by the need for quick and easy meal solutions that fit into busy schedules. Food extrusion plays a crucial role in meeting this demand by providing a versatile method for producing a wide range of convenient food products, such as snacks, breakfast cereals, and pasta. The technology enables manufacturers to produce high-quality, ready-to-eat items efficiently, thereby supporting the growth of the food extrusion market. The increase in personal disposable income, particularly in emerging economies, has a significant impact on the food extrusion market. As economic conditions improve, consumers are more inclined to spend on processed and packaged foods. This shift towards higher spending on convenience foods and ready-to-eat products is fueling the expansion of the food extrusion market. With more disposable income, consumers are increasingly able to afford and choose extruded food products that cater to their evolving tastes and preferences.

 The food extrusion market is being propelled forward by continuous technological advancements. Innovations in extrusion technology, such as the development of advanced extruders and enhanced processing techniques, have significantly improved the efficiency and capabilities of the extrusion process. These advancements enable the production of high-quality food products with superior texture, flavor, and nutritional content. As technology evolves, it supports the growth of the food extrusion market by facilitating the creation of diverse and high-value food products. Growing health consciousness among consumers is driving the demand for extruded food products that offer better nutritional profiles. As people become more aware of their dietary choices, there is an increasing preference for healthier snack options, fortified cereals, and functional foods. Food extrusion technology allows for the production of such health-oriented products, meeting consumer demands for nutritious and beneficial food items. This shift towards health and nutrition is a key factor driving the growth of the food extrusion market.

 The expansion of urban areas and the rapid pace of industrialization, especially in developing nations, are significant contributors to the food extrusion market’s growth. Urbanization leads to higher demand for processed and packaged foods as more people move to cities and seek convenient food solutions. Food extrusion technology supports the mass production of affordable and high-quality foods, catering to the needs of urban populations and driving market expansion. The processed food sector is experiencing robust growth due to changing consumption patterns and an increasing preference for convenience. Food extrusion is central to this growth, as it enables the production of a variety of processed food items, from snacks and bakery products to protein-enriched foods. The rise in demand for processed foods is a major driver of the food extrusion market, highlighting the technology’s importance in meeting evolving consumer needs.

 Innovations in packaging and food processing systems are enhancing the efficiency and shelf life of extruded products. Modern packaging solutions and advanced processing equipment contribute to the overall growth of the food extrusion market by improving product quality and extending its market reach. These advancements ensure that extruded foods remain fresh and appealing to consumers, further driving market demand. Ongoing research and development efforts in food extrusion technology are crucial for market growth. These efforts lead to the creation of new and improved products that cater to emerging consumer trends. The continuous innovation in extrusion technology supports the development of novel food products, driving the food extrusion market by addressing the evolving needs and preferences of consumers.

How the Unpredictable Climatic Conditions and the Instability of Raw Material Prices Impede the Growth of Food Extrusion Market?

Unpredictable climatic conditions significantly disrupt the production of raw materials essential for food extrusion, such as grains and vegetables. Extreme weather events, fluctuating temperatures, and other environmental factors can adversely affect crop yields and the quality of raw materials. This volatility in raw material availability poses a substantial challenge to the food extrusion market by causing supply chain disruptions and increasing raw material costs. The food extrusion industry faces challenges due to the instability in raw material prices. Variations in the cost of key ingredients, such as grains and legumes, can impact production costs and profitability. These price fluctuations are influenced by factors like climatic conditions, market demand, and geopolitical events. Consequently, manufacturers must navigate these uncertainties, which can strain budgets and affect market growth.

 The food extrusion market is also constrained by stringent food safety and quality regulations, particularly in developed countries. These regulations are designed to ensure consumer safety but can impose additional compliance costs and operational challenges for extrusion manufacturers. Adhering to these regulations requires significant investments in quality control, testing, and certification processes, which can be particularly burdensome for smaller and medium-sized enterprises. Establishing an extrusion facility involves substantial capital investment, which can be a significant barrier for small and medium-sized enterprises (SMEs). The costs associated with purchasing advanced extrusion equipment, setting up production lines, and implementing quality control systems can be prohibitive. This high initial investment requirement may limit the entry of new players into the market and constrain the growth potential of existing SMEs.

 The extrusion process is energy-intensive, which poses a challenge for manufacturers concerned with rising energy costs and environmental sustainability. The need for high temperatures and continuous operation during extrusion leads to substantial energy consumption. Managing these energy requirements while maintaining cost-efficiency and minimizing environmental impact is a key challenge for the food extrusion industry. The COVID-19 pandemic has impacted the food extrusion market by disrupting the hospitality sector and reducing demand for packaged food products. With restaurants and foodservice establishments facing closures or reduced operations, there has been a shift in focus from restaurant supply chains to retail channels. Although there has been a rise in online sales of certain food products like breakfast cereals and meat-based items, the overall manufacturing sector experienced a downturn. The pandemic has underscored the vulnerability of the food extrusion market to external shocks and changing consumer behaviors.

Category-Wise Acumens

How the Sophisticated Advancements in Food Processing Technology, and Complex Electronic System Surge the Growth of Twin-Screw Extruders Segment?

The twin extruders segment showing significant growth in the food extrusion market. Twin-screw extruders represent a sophisticated advancement in food processing technology, utilizing a complex electronic control system, such as a Programmable Logic Controller (PLC) extrusion computer or cabinet. These control systems are designed to display and monitor all critical parameters of the extrusion process in real time, including current, voltage, temperature, torque, and rotational speed. This immediate feedback allows for precise adjustments and optimal control over the extrusion process. Twin-screw extruders can effectively adjust the combination of screw elements, making them highly adaptable to various plastic material compounding needs. This adaptability is further enhanced by the use of a mixed accurate metered feeding hopper, which ensures precise ingredient feeding for consistent product quality. The benefits of twin-screw extruders include their low production cost, ease of operation, superior control over process parameters, exceptional mixing technology, and high level of process flexibility. These attributes contribute to the increasing demand for twin-screw extruders in the food processing industry.

Renowned for their high processing rates, twin-screw extruders are capable of producing a diverse range of food products with specific properties and textures. They are extensively used in the production of pasta, baby food, meat substitutes, and other food items that require meticulous control over the finished product’s texture and composition. Large-scale food producers often prefer twin-screw extruders due to their greater efficiency and throughput compared to single-screw extruders. Technological advancements in twin-screw extrusion technology have further fueled revenue growth by enabling the creation of systems that can handle increasingly complex food formulations while maintaining consistent quality at a lower cost. These innovations have expanded the capabilities of twin-screw extruders, making them an essential tool for modern food processing, where the demand for precision, efficiency, and versatility continues to rise.

How the Efficient Processing Capabilities, High Temperature and Heat-Sensitive Energy Transfer Foster the Growth of Hot Extrusion Segment?

The Hot Extrusion segment is demonstrating significant growth within the Food Extrusion Market, owing to its efficient processing capabilities characterized by a short period, high temperatures, and substantial energy transfer. The method is highly effective in preventing the degradation of heat-sensitive food ingredients while enhancing the digestion of proteins and carbohydrates. Additionally, hot extrusion is adept at removing anti-nutrients such as hemagglutinins, gossypol, and trypsin inhibitors, as well as undesirable enzymes like lipoxidases, lipases, and various microorganisms, which further drives the adoption of this process.

Hot extrusion involves the processing of raw food materials under baro-thermal conditions, where the ground material is subjected to shear energy from a rotating screw and additional heating from the barrel. This process heats the food material to its melting point, facilitating a change in its rheological state. Under high pressure, the heated material is forced through a die or a series of dies, expanding to its final shape.

This transformation results in extrudates with markedly different physical and chemical properties compared to the raw materials used. The high temperatures and pressures involved in hot extrusion ensure a rapid and thorough cooking process and improve the texture, flavor, and nutritional value of the final product. These benefits make hot extrusion a preferred method for producing a wide range of food products, from snacks and breakfast cereals to meat substitutes and baby foods. As consumer demand for high-quality, nutritious, and convenient food products continues to rise, the hot extrusion segment is poised to experience sustained growth, driven by its ability to meet these evolving preferences efficiently and effectively.

Gain Access to Food Extrusion Market Report Methodology

Country/Region Wise Acumens

How Well-Established Snack Food Sector Surges the Growth of the Food Extrusion Market in Europe?

Europe substantially dominates the food extrusion market driven by the well-established snack food sector that provides a substantial consumer base. This region holds promising growth potential due to the increased consumption of processed food products, particularly in Eastern and Southeastern European countries. As demand for snack products rises, producers are compelled to import extruded snack goods from other parts of the world to ensure a steady supply of raw materials. Domestic production in these areas is often insufficient to meet the high demand from Europe’s food industry.

The presence of a demanding and sophisticated food market offers the European food extrusion market a robust consumer base, with ample entrepreneurial development opportunities. The growth of the food industry in this region is propelled by the expanding consumption of processed product categories in Eastern and Southeastern Europe. The surge in snack product consumption further necessitated the sourcing of extruded snack products globally, as local production keep pace with the burgeoning demand.

Furthermore, the well-established food and beverage industry in Europe is subject to strict government regulations regarding food safety standards. These stringent regulations, coupled with the rising consumption of snack products, have pushed producers to seek extruded snack products from other regions to maintain a continuous supply of raw materials. The inability of domestic production to meet the high demand from the European food industry underscores the importance of global sourcing in sustaining the market.

How Dense Population and Rapid Urbanization Enable the Growth of Food Extrusion Market in Asia Pacific During the Forecast Period?

Asia Pacific is anticipated to witness the fastest growth in the food extrusion market during the forecast period. The rising population and rapid urbanization in countries like China and India are leading to increase in food and beverage consumption. This growth is creating a larger market for food extrusion products, particularly in urban areas where convenience foods are in high demand. The Asia Pacific region, characterized by its dense population and rapid urbanization, is experiencing a significant increase in food and beverage consumption. This surge presents a unique opportunity for the food extrusion market to solidify its position within the food and beverage industry by introducing innovative products that cater to the evolving preferences of both manufacturers and end consumers. The region’s growing inclination towards ready-to-eat and fast-food products, coupled with globalization, westernization, and changing lifestyles, are key drivers of this market expansion.

Asia-Pacific is projected to exhibit the highest compound annual growth rate (CAGR) during the forecast period, largely due to stringent government regulations on food safety standards, the expansion of the food and beverage industry, and the rising preference for convenient food options. Emerging economies such as India, China, and Indonesia are at the forefront of this growth, fueled by increasing disposable incomes and the demand for processed and ready-to-eat food products. The region’s youthful demographic and millennial population are also significant contributors to this trend, driving demand for new and innovative food products.

With economic development and increasing disposable income, consumers in the Asia Pacific region are more willing to spend on processed and ready-to-eat food products. This shift is driving demand for a variety of extruded food products that offer convenience and quality. As dietary preferences evolve, there is a growing demand for healthier food options. The market is witnessing a shift towards extruded snacks made from whole grains and other nutritious ingredients. This trend is supported by the increasing awareness of health and wellness among consumers in the region.

Strict government regulations regarding food safety and quality standards are pushing manufacturers to adopt advanced food extrusion technologies. These regulations ensure that the food products meet high safety and quality standards, which in turn boosts consumer confidence and demand. The food extrusion market in the Asia Pacific region is also driven by continuous innovation and product development. Manufacturers are leveraging advanced extrusion technologies to create new and appealing food products that meet the changing expectations of consumers. The globalization of food cultures and the influence of Western dietary habits are contributing to the expansion of the food extrusion market. Consumers are increasingly seeking diverse and convenient food options, further driving market growth.

Competitive Landscape

The food extrusion market is characterized by a mix of established industry giants and specialized equipment manufacturers. While competition is intense, there’s room for innovation and differentiation.

The organizations are focusing on innovating their product line to serve the vast population in diverse regions. Some of the prominent players operating in the food extrusion market include:

Akron Tool & Die, Baker Perkins, Coperion, GEA, The Bonnot Company, American Extrusion International,Groupe Legris Industries, Triott Group, Flexicon, KAHL Group, Wenger Manufacturing.

Latest Developments

• In July 2021, Flexicon Corporation Pty Ltd expanded its assembly and sales operations. It will ensure the organization’s growth in Asia.
• In January 2021, Bühler worked with DIL to improve the long-term manufacture of healthy extruded meat alternatives. Bühler will leverage its extrusion expertise to provide bespoke solutions using extrusion technology that it has developed.
• In 2021, Bühler Holding AG announced the launch of the innovative Polycondensation System, a high-performance recycling solution for PET (polyethylene terephthalate) plastic. This unique method recycles PET flakes into high-quality, high-value items like food-grade packaging material.
• In 2021, Coperion GmbH announced the launch of a new extrusion technique called the STS 25 Mc11 extruder, which is specifically suited for the pharmaceutical business. This technology is capable of producing a wide range a variety of pharmaceutical preparations, including capsules, tablets, and granules.

Report Scope

Food Extrusion Market, By Category

Product Type

• Savory Snacks
• Breakfast Cereals
• Bread
• Flours & Starches
• Textured Protein
• Functional Ingredient

Extruder

• Single Screw Extruders
• Thin Screw Extruders
• Contra Twin Screw Extruders

Process

• Hot Extrusion
• Cold Extrusion

Region

• North America
• Europe
• Asia-Pacific
• South America
• Middle East & Africa

Research Methodology of Market Research: