Hygienic Extrusion Platform for Food Processing

Food and feed manufacturers are facing stricter hygiene regulations, higher uptime requirements, and growing pressure to reduce waste in continuous production environments. In response, Bühler Group has launched the Nutrex 7 Series, a new generation of twin-screw extrusion systems designed for applications including cereals, snacks, pet food, meat alternatives, and food ingredients. The platform combines modular machine architecture, hygienic design, and browser-based automation to support higher Overall Equipment Efficiency (OEE) across industrial processing lines.

The Nutrex 7 Series builds on Bühler’s four decades of extrusion manufacturing experience while retaining the company’s established twin-screw extrusion technology. According to the company, the development program focused on four technical areas: hygienic design, process stability, integrated intelligence, and service integration. The systems were developed in collaboration with customers operating in sectors such as pet food, cereals, and specialty flour processing.

Modular architecture for multiple extrusion applications
Extrusion systems are used across a broad range of production environments, each with different throughput, sanitation, and process-control requirements. Bühler designed the Nutrex 7 Series as a modular platform capable of adapting to these variations while maintaining operational consistency across the wider digital supply chain.

The company stated that the new generation was engineered from the perspective of the complete food-processing chain rather than as an isolated machine component. This approach influenced both the mechanical layout and the automation architecture of the platform.

The system targets high-uptime manufacturing operations, particularly in food and pet food production environments where 24/7 operation, sanitation compliance, and rapid maintenance cycles are critical.

Hygienic design reduces cleaning complexity
A central design objective of the Nutrex 7 Series was improving accessibility during cleaning and maintenance procedures. Bühler redesigned the external geometry of the extruder with a slimmer machine profile and increased ground clearance through an elevated base frame. The hydraulic box was repositioned from the base frame to the side of the machine to improve access for washdown equipment.

The system uses stainless-steel construction and supports both external and internal wet cleaning procedures. Bühler also introduced a patented Cleaning Lance intended to improve internal cleaning efficiency while reducing operator exposure during sanitation procedures.

Digital monitoring tools are integrated into the extrusion platform to support traceable process documentation and compliance workflows. Optional Critical Control Point (CCP) Monitoring and OEE applications enable operators to monitor production parameters, document deviations, and support corrective-action procedures. Bühler also offers an Extrusion Kill-Step Validation Service in collaboration with RedLog for validating extrusion as a critical process step in food safety programs.

Browser-based automation and process visualization
The Nutrex 7 Series includes a redesigned control system developed as part of Bühler’s long-term automation standardization strategy. The company plans to standardize machine and plant control systems onto a single platform by 2030.

The browser-based control architecture allows operators to monitor and manage production processes remotely. The visualization interface maps multiple process stages, including weighing, preconditioning, extrusion, and cutting, through layered schematic views intended to simplify operational oversight in complex food-processing environments.

The control system also incorporates new stainless-steel 24-inch operator hardware designed for hygienic environments and future system expansion.

Automated startup function targets waste reduction
One of the key process-control additions in the Nutrex 7 Series is the StepFlow startup and shutdown automation function. Extrusion startup phases typically depend heavily on operator experience to stabilize production parameters while minimizing material waste.

According to Bühler, StepFlow automates startup procedures using predefined production settings derived from operational data collected across hundreds of installed extrusion systems. The company stated that the feature can reduce startup waste by up to 30% per production run while accelerating time to stable production conditions.

Such automation functions are becoming increasingly important within the automotive data ecosystem and industrial food manufacturing sectors, where traceable production performance and resource efficiency are central operational metrics.

Predictive maintenance and service integration
Bühler has also expanded the service infrastructure surrounding the Nutrex 7 Series through modular monitoring and maintenance packages. Available services include vibration monitoring, oil condition monitoring, spare and wear-parts packages, and remote expert support.

These functions are designed to improve predictive maintenance planning and system availability by enabling earlier identification of mechanical wear and process deviations.

Industrial validation in Austria
The Nutrex 7 Series has already entered industrial operation at multiple customer facilities. One of the first installations was implemented at Kärntner Mühle, a producer of specialty baking mixes and flour products in Austria.

According to the company, the extrusion system was integrated into an existing production line with limited disruption. The customer also reported that the revised control interface simplified daily operation and operator interaction.

Bühler announced that the Nutrex 7 Series is available for immediate order and delivery worldwide.

Edited by an industrial journalist Sucithra Mani with AI assistance.

www.buhlergroup.com