Extruded Pellet Products

We offer an assortment of extrusion dies that can be cut at different lengths to deliver a wide variety of shapes and sizes.

The split pea and small ball shapes, also know as micro pellets, are designed for expansion in pressure puffing systems that determine the finished product shape.

We are developing several exciting new shapes, so if you don't see exactly what you have in mind here, just ask us.

We will also work with you to develop and secure custom extrusion shapes.

We can use almost any of our die shapes to extrude almost any formula.







Shells

Note: clicking a product photo will give a high quality zoomed in view

Large Shell

The large shell, shown here in multi-grain, adds dimension and bag fill in snack applications with great scoop-ability.

The large shell shape works well with formulas based on potato, whole ground, or multiple grains all of which compliment compliment savory topical seasonings.

Main ingredients as shown wheat, corn, rice
Flavor neutral grain
Texture light and crunchy
Dimensions with higher expansion grains fried product measures 3" x 1.5" or 75 x 35mm. The dimension can be varied by the cut length.
Dimensions with lower expansion grains fried product measures 2.375" x 1.25" or 60 x 30mm. The dimension can be varied by the cut length.
* The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months recommended
Package size 20 pound poly lined carton (typical)

Small Shell

This versatile shell shape adds variety to cereals, snacks, and mixes.

Formulas based on whole ground, or multiple grains work well with this shape, as do corn and rice bases. Including a light sweetness makes a great cereal.

Main ingredients as shown wheat, corn, rice
Flavor neutral grain
Texture light and crunchy
Dimensions with higher expansion grains fried product measures 1.25" x 1" or 30 x 20mm. The dimension can be varied by the cut length.
Dimensions With lower expansion grains fried product measures 1" x 0.875" or 25 x 22mm. The dimension can be varied by the cut length.
* The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months recommended
Package size 50 pound poly lined carton (typical)

Chips

Note: clicking a product photo will give a high quality zoomed in view

Tapioca Chips

The chip die is one that can be cut in different lengths to generate different shapes.

The ingredient base used for the chip determines the texture and expansion in the finished product. The combination of rice and tapioca yield an almost white color and very high expansion.

Main ingredients as shown tapioca, starch, shrimp
Flavor a light shrimp flavor
Texture open cell structure, light and crispy
Dimensions the fried product will measure about 2" x 1.25" or 51 x 32mm. The dimension can be varied by the cut length.
* The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months recommended
Package size 20 pound poly lined carton (typical)

Corn Chips

The chip die is one that can be cut in different lengths to generate different shapes.

The ingredient base used for the chip determines the texture and expansion in the finished product. Whole ground corn makes an excellent base for salty or savory snack applications.

Main ingredients as shown whole ground corn
Flavor toasted corn
Texture light and crunchy
Dimensions the fried product will measure about 1.5" x 5/8" or 40 x 15mm. The dimension can be varied by the cut length.
* The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months recommended
Package size 20 pound poly lined carton (typical)

Ridges

Note: clicking a product photo will give a high quality zoomed in view

Ridged Chips NEW

The ridge die is one that can be cut in different lengths to generate different shapes including a fry, a wedge, and a chip.

Potato whole and multiple grains are commonly used as the primary ingredient in chips. Vegetables such as spinach, carrots or tomato can be added to a variety of chip bases.

Main ingredients as shown rice, potato, corn, vegetable powder.
Flavor a blend of potato and vegetable
Texture full bodied crunch
Dimensions with higher expansion grains fried product measures 1.875" x 1.25" or 45 x 33mm. The dimension can be varied by the cut length.
Dimensions With lower expansion grains fried product measures 1.25" x 1" or 32 x 25mm. The dimension can be varied by the cut length.
* The hot air popped/baked version of each will be somewhat less expanded.
Storage life 12 months recommended
Package size 20 pound poly lined carton (typical)

Potato & Veggie Ridged Sticks

The ridge die can be cut in lengths to form fries, wedges or chips.

The ingredient base used will determine the texture and expansion in the finished product. Potato makes an excellent base for strips yielding a sturdy pellet.

Main ingredients as shown potato, rice, corn and vegetable powder
Flavor light spinach, tomato and carrot
Texture tight cell structure, light and crunchy
Dimensions with higher expansion grains fried product measures 3.5" x 0.375" or 88 x 9mm. The dimension can be varied by the cut length.
Dimensions with lower expansion grains fried product measures 2.625" x 0.25" or 67 x 6mm. The dimension can be varied by the cut length.
* The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months recommended
Package size 20 pound poly lined carton (typical)

Strips & Ribbons

Note: clicking a product photo will give a high quality zoomed in view

Potato & Veggie Sticks

The ribbon die can be cut in lengths to form strips, ribbons, or large scoops.

The ingredient base used will determine the texture and expansion in the finished product. Potato makes an excellent base for strips yielding a sturdy pellet.

Main ingredients as shown potato, rice, corn and vegetable powder
Flavor light spinach, tomato and carrot
Texture tight cell structure, light and crunchy
Dimensions with higher expansion grains fried product measures 3.5" x 0.375" or 88 x 9mm. The dimension can be varied by the cut length.
Dimensions with lower expansion grains fried product measures 2.625" x 0.25" or 67 x 6mm. The dimension can be varied by the cut length.
* The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months recommended
Package size 20 pound poly lined carton (typical)

Potato Sticks

The ribbon die can be cut in lengths to form strips, ribbons, or large scoops.

The ingredient base used will determine the texture and expansion in the finished product. Potato makes an excellent base for strips yielding a sturdy pellet.

Main ingredients as shown potato
Flavor french fried potato
Texture tight cell structure, light and crunchy
Dimensions with higher expansion grains fried product measures 3.5" x 0.375" or 88 x 9mm. The dimension can be varied by the cut length.
Dimensions with lower expansion grains fried product measures 2.625" x 0.25" or 67 x 6mm. The dimension can be varied by the cut length.
* The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months recommended
Package size 20 pound poly lined carton (typical)

Potato & Veggie Ribbon Sticks

The ribbon die can be cut in lengths to form strips, ribbons, or large scoops.

The ingredient base used will determine the texture and expansion in the finished product. Potato makes an excellent base for strips yielding a sturdy pellet.

Main ingredients as shown potato, rice, corn and vegetable powder
Flavor light spinach, tomato and carrot
Texture tight cell structure, bold and crunchy
Dimensions with higher expansion grains fried product measures 3.5" x 1.125" or 88 x 28mm. The dimension can be varied by the cut length.
Dimensions with lower expansion grains fried product measures 2.625" x 1" or 67 x 25mm. The dimension can be varied by the cut length.
* The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months recommended
Package size 20 pound poly lined carton (typical)

Twists

Note: clicking a product photo will give a high quality zoomed in view

Twist dies are available in single principle and three principle versions. Cut lengths yield very different shapes.

The ingredient base used will determine the appearance, texture and expansion in the finished product. Twist dies work well with many grains including multi or whole grains. A seasoning like chili/cheese turns this shape into a great savory snack.

Main ingredients as shown whole ground corn
Flavor toasted corn
Texture tight cell structure, bold and crunchy
Dimensions fried product measures 1.75" x 0.75" or 45 x 19mm. The dimension can be varied by the cut length.
* The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months recommended
Package size 20 pound poly lined carton (typical)

Twist dies are available in single principle and three principle versions. Cut lengths yield very different shapes.

The ingredient base used will determine the appearance, texture and expansion in the finished product. Twist dies work well with many grains including multi or whole grains. A seasoning like white cheddar turns this shape into a great savory snack.

Main ingredients as shown rice, tapioca
Flavor neutral, depends on topical seasoning
Texture medium cell structure, light and crispy
Dimensions fried product measures 2.5" x 1.0625" or 65 x 27mm. The dimension can be varied by the cut length.
* The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months recommended
Package size 20 pound poly lined carton (typical)

Twist dies are available in single principle and three principle versions. Cut lengths yield very different shapes.

The ingredient base used will determine the appearance, texture and expansion in the finished product. Twist dies work well with many grains including multi or whole grains. A seasoning like cinnamon sugar turns this shape into a great sweet treat.

Main ingredients as shown wheat, corn, rice
Flavor neutral grain
Texture light and crispy
Dimensions fried product measures 1.75" x 0.75" or 45 x 19mm. The dimension can be varied by the cut length.
* The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months recommended
Package size 20 pound poly lined carton (typical)

Circular Tubes NEW

Note: clicking a product photo will give a high quality zoomed in view

Thin Walled Tube

Wall thickness can have as much impact on the texture and appearance of the finished product as cut length. Cut lengths yield very different shapes from "churros" for snacks and desserts to O's for cereals.

The ingredient base used will determine the appearance, texture and expansion in the finished product. This thin walled circular tube dies work well with many grains including multi or whole grains. The shape is shown here in a "churro" cut with cocoa powder extruded into the pellet, and works well for a variety of targets and channels.

Main ingredients as shown Wheat, corn, rice, cocoa
Flavor Cocoa and lightly toasted grain
Texture light and crispy
Dimensions fried product measures 2.00" x 0.625" or 45 x 16mm. The dimension can be varied by the cut length.
* The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months recommended
Package size For long cut shown, 20 pound poly lined carton

Medium Walled Tube

Cut lengths yield very different shapes from "straws" for snacks and sweet treats to O's for cereals.

The ingredient base used will determine the appearance, texture and expansion in the finished product. Circular tube dies work well with many grains including multi or whole grains. Fruit flavors and colors can make this a great shape for healthy snacks targeted to kids.

Main ingredients as shown whole grain wheat, whole ground corn, brown rice
Flavor toasted grain
Texture light and crispy
Dimensions fried product measures 1.50" x 0.625" or 38 x 16mm. The dimension can be varied by the cut length.
* The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months recommended
Package size 50 pound poly lined carton or 2,200 pound super sack (typical)

Short Cut Tube

The "short tube" is one of the popular shapes for bite-size snacks and snack blends.

The ingredient base used will determine the appearance, texture and expansion in the finished product. Circular tube dies work well with many grains including multi or whole grains. This shape works well with both sweet and savory topical seasonings.

Main ingredients as shown wheat, corn, rice
Flavor neutral grain
Texture light and crispy
Dimensions fried product measures 0.75" x 0.625" or 19 x 16mm
* The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months recommended
Package size 50 pound poly lined carton or 2,200 pound super sack (typical)

Mini Tube

The "mini tube" is one of the popular shapes for cereal snacks and snack blends.

The ingredient base used will determine the appearance, texture and expansion in the finished product. Circular tube dies work well with many grains including multi or whole grains. This shape works well with both sweet and fruit flavors, colors, and topical seasonings.

Main ingredients as shown white corn, rice
Flavor lightly sweet corn
Texture light and crispy
Dimensions fried product measures 0.5" x 0.625" or 12 x 16mm. The dimension can be varied by the cut length.
* The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months recommended
Package size 50 pound poly lined carton or 2,200 pound super sack (typical)

"O" Cut Tube

The "O" is one of the popular shapes for cereals and cereal snacks.

The ingredient base used will determine the appearance, texture and expansion in the finished product. Circular tube dies work well with many grains including multi or whole grains. This shape works well with both sweet and fruit flavors, colors, and topical seasonings.

Main ingredients as shown rice, tapioca
Flavor neutral
Texture light and crispy
Dimensions fried product measures 0.125" x 0.625" or 3 x 16mm. The dimension can be varied by the cut length.
* The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months recommended
Package size 50 pound poly lined carton or 2,200 pound super sack (typical)

Square Tubes

Note: clicking a product photo will give a high quality zoomed in view

Fry Cut NEW

The square tube is a popular shape for snacks and sweet treats.

The ingredient base used will determine the appearance, texture and expansion in the finished product. Square tube dies work well with many grains including multi or whole grains. This shape works well with sweet flavors such as cocoa or cinnamon, as well as with a variety of topical seasonings. Shorter cuts would work well for snack mix inclusions. This shape can be fried or air popped, and cut length may be impacted by the choice of expansion method.

Main ingredients as shown Wheat, brown rice, corn
Flavor lightly toasted rich grain
Texture Relatively bold and crunchy
Dimensions fried product measures 1.75" or 45mm. The dimension can be varied by the cut length.
* The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months recommended
Package size 20 pound poly lined carton or super sack (typical)

Split Peas & Small Balls (Micro Pellets)

Note: clicking a product photo will give a high quality zoomed in view

The small round shape we refer to as "split peas" are expanded by pressure, or compression, popping and can be formed into a variety of shapes and thicknesses depending on the shape of the die used in the pressure popping system.

This type of expansion system is used to produce rice cakes, triangles and multi-grain snacks. A variety of process options during expansion will significantly change the appearance and texture of the finished product from a cake to a crisp

Main ingredients in darker split peas whole ground wheat, whole ground corn, whole ground oats
Main ingredients in lighter split peas split peas; rice flour, toasted soy flour
Flavor rich grain and toasted grain respectively
Texture depends on expansion system
Dimensions raw split pea is about 3/16" or 4mm diameter. The dimension can be varied by the cut length.
Dimensions raw small ball is about 0.125" or 3mm diameter. The dimension can be varied by the cut length.
* The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months recommended
Package size 50 pound poly lined carton or 2,200 pound super sack (typical)

The small ball is slightly smaller than the split pea shape and works well in angular shapes. Both can be formulated with multiple grains and can include sweetness, natural or artificial colors, or flavors like marshmallow that when air popped in popcorn popping systems or fluidized air bake ovens become great tasting cereals or components for cereal or clustered snacks.

Main ingredients in light small ball shown rice, tapioca, white corn, vanilla
Flavor lightly vanilla
Texture depends on expansion system
Dimensions raw split pea is about 3/16" or 4mm diameter. The dimension can be varied by the cut length.
Dimensions raw small ball is about 0.125" or 3mm diameter. The dimension can be varied by the cut length.
Storage life 12 months recommended
Package size 50 pound poly lined carton or 2,200 pound super sack (typical)

Rings

Note: clicking a product photo will give a high quality zoomed in view

The ingredient base and expansion method used will have a dramatic impact on the size and texture of the finished product. The ring shape is classically positioned as an "onion ring" type snack for retail, vending, and foodservice. Another flavor option for this shape is a "calamari" type snack.

Main ingredients as shown potato and corn, with and without annatto for color
Flavor lightly onion
Texture light and crunchy
Dimensions 1.75" or 45mm diameter. The dimension can be varied by the cut length.
* The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months recommended
Package size 20 pound poly lined carton (typical)

Grids

Note: clicking a product photo will give a high quality zoomed in view

Grids: 3x2 Rectangle, 3x4 Rectangle

Shown as a 3 over 2 grid and available as a 3 over 4 grid.

The ingredient base and expansion method used will have a dramatic impact on the size of the finished product. This shape works well alone as a snack or as part of a snack blend. When formulated with whole grain wheat or whole ground corn and air popped, the shape yields a great tasting cereal shape with an excellent source of fiber.

Main ingredients as shown wheat, corn, rice
Flavor neutral grain
Texture light and crispy
Dimensions with higher expansion grains the 3 over 2 product will measure about 1.375" x 1" or 34 x 25 mm when fried. With lower expansion, higher fiber grains such as a multi or whole grain formulas, this shape will finish nearer 1" x 0.75" or 25 x 19mm when fried. The dimension can be varied by the cut length.
* The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months recommended
Package size 20 pound poly lined carton (typical)

Grids: Circle

The unique circle grid shape, ideal for a "light" snack.

The ingredient base and expansion method used can turn this unique shape into a cracker, a crisp, or a light and puffy snack. When formulated with a potato and vegetable base and air popped, the shape yields a light crunchy texture as a "veggie" crisp.

Main ingredients as shown whole grain wheat, whole ground corn, rice
Flavor toasted grain
Texture light and crunchy
Dimensions as shown 1.375" or 32mm diameter. The dimension can be varied by the cut length.
* The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months recommended
Package size 20 pound poly lined carton (typical)

Grids: Triangle

Unique triangle grid shape is ideal for a "light" snack.

The ingredient base and expansion method used can turn this unique shape into a crisp chip, or a puffy snack. When formulated with a whole ground corn base and air popped, the shape yields a bold crunchy texture as a "light" tortilla-type crisp.

Main ingredients as shown corn, wheat, rice
Flavor light corn
Texture light and crunchy
Dimensions 1.75" or 45mm per side With whole grains 1.625" or 42mm. The dimension can be varied by the cut length.
* The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months recommended
Package size 20 pound poly lined carton (typical)

Grids: Buttons



This unique "button" shape adds variety to snack or cereal mixes.

Formulas based on potato, grains, or combinations with vegetable/fruit can all be extruded in this shape.


Top Photo

Main ingredients as shown wheat, corn, rice
Flavor neutral grain
Texture light and crispy
Dimensions with higher expansion grains fried product measures 1.625" x 0.625" or 40 x 15mm. The dimension can be varied by the cut length.
* The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months recommended
Package size 20 pound poly lined carton (typical)

Bottom Photo

Main ingredients as shown whole ground wheat, whole ground corn, whole ground oats
Flavor toasted grain
Texture slightly denser, crunchy
Claims whole grain, good source fiber
Dimensions With lower expansion grains, when fried shape will finish nearer 1" x 0.375" or 25 x 9mm. The dimension can be varied by the cut length.
* The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months recommended
Package size 50 pound poly lined carton or 2,200 pound super sack (typical)

Brands & Custom Shapes

Note: clicking a product photo will give a high quality zoomed in view



Custom shaped snack pellets offer brand owners a unique opportunity to leverage the equity of their current brands. The combination of shape, multiple ingredients, flavors, colors and topical seasonings can be the basis for an entire product line.

Our R&D innovations team will work with you to develop a die that will extrude and expand to the shape you have in mind.

Plan 8 weeks in your development timeline for die manufacture

Main ingredients as shown the lighter, larger shape is a deep fried rice and wheat blend, while the darker shape is an air baked whole ground corn
Flavor the light color is a neutral grain while the darker is a toasted corn
Texture the lighter shape has a light and crispy texture and the darker is hearty and crunchy
* The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months recommended
Package size 20 or 50 pound poly lined carton (typical)