Food Extrusion Market Size | Global Forecast To 2033

Food Extrusion Market Overview

Global Food Extrusion market size, valued at USD 78408.53 million in 2024, is expected to climb to USD 83993.18 million by 2033 at a CAGR of 3.5%.

The global food extrusion market has experienced rapid advancements, with over 25,000 food processing plants incorporating extrusion technology into their production processes. Extrusion is a high-temperature, short-time process that modifies raw ingredients through mechanical shear, often reaching pressures of up to 10 MPa and temperatures exceeding 200°C. In 2024, more than 31% of all snack foods globally were produced using extruded technologies, while 42 million tons of extruded cereal products were consumed across major food markets. The rising demand for shelf-stable foods, with over 65% of global packaged food now requiring stability for over 9 months, has propelled extrusion into a primary method for food manufacturing. Nearly 71% of global food processing machinery exports involve equipment tailored for extrusion. The growing use of plant proteins in extruded foods also continues to expand, with over 16.8 million metric tons of soy protein isolate processed annually using twin-screw extruders. The food extrusion market integrates advanced automation, with over 12,000 smart extruders in operation globally as of 2023. With extrusion being responsible for more than 48% of all processed dry pet food and 37% of fortified cereals consumed worldwide, it stands as a cornerstone of modern food manufacturing infrastructure.

Key Findings

Top Driver Reason: Rising demand for ready-to-eat snacks, with over 59% of global consumers preferring extruded snack foods due to long shelf life and portability.

Top Country/Region: United States leads with over 15,000 extruded food processing installations, accounting for 28% of North America's extruded food output.

Top Segment: Savory snacks dominate, with over 34 million metric tons of extruded savory products consumed globally in 2023.

Food Extrusion Market Trends

The food extrusion market is being transformed by shifting consumer preferences toward healthier, protein-enriched, and gluten-free extruded products. In 2023, over 19.2 million metric tons of gluten-free extruded cereals were sold worldwide, a 14% rise from 2022. Demand for high-protein snacks is surging, with 8.7 million metric tons of pea protein-based extruded products produced in the same year. Whole grain extrusion has become mainstream, with over 25% of all cereals in European supermarkets now produced from extruded whole grains. Furthermore, cold extrusion has gained traction for energy bars and nutritional pastes, accounting for over 6 million units produced monthly in North America.

Technological advancements are also influencing trends. In 2024, more than 4,500 extruders were upgraded with AI-based control systems for real-time quality monitoring. These innovations reduced waste by 19% across processing plants. High-moisture extrusion for meat analogs surged, with 4.3 million metric tons of plant-based meats created using twin-screw extrusion in 2023. Sustainability trends are driving adoption of recyclable packaging for extruded foods, as 66% of major food brands now require biodegradable packaging integration during extrusion. Premium pet foods are also being driven by extrusion innovation, with 52% of all high-protein pet products globally now produced via specialized extruders. The trend of on-site small-batch extrusion has also gained popularity, with over 1,200 craft food manufacturers implementing low-capacity extruders for personalized snack production in urban markets.

Food Extrusion Market Dynamics

DRIVER

Rising demand for fortified and on-the-go food products.

In 2023, over 58% of snack food consumption occurred outside of the home, creating growing demand for shelf-stable, portable formats. Extrusion technology allows the integration of micronutrients without compromising texture, with over 3.5 billion fortified breakfast cereal units extruded and distributed globally. Emerging economies accounted for 67% of the growth in extruded nutritional snack bars, with India alone producing over 180,000 metric tons in 2024. Twin-screw extruders enabled over 88% of these products to maintain structure while achieving nutrient preservation. Growth in urbanization—with over 4.4 billion urban dwellers globally—continues to drive demand for extruded ready-to-eat solutions.

RESTRAINT

Complexity in handling high-fiber ingredients during extrusion.

Processing high-fiber flours and alternative grains like quinoa and millet has posed challenges, especially in single-screw extruders. In 2023, nearly 29% of extrusion line failures were reported to be caused by inconsistent expansion and mechanical blockages due to high-resistance starches. Over 4,200 manufacturing facilities reported operational delays averaging 11.5 hours per week due to fiber-rich grain extrusion inconsistencies. Developing specialized nozzles and enhanced pre-conditioning units added 14% to machinery costs for firms transitioning to such ingredients. This technical limitation has discouraged over 18% of small- to mid-size producers from investing in complex fiber extrusion.

OPPORTUNITY

Surge in demand for plant-based meat alternatives.

In 2023, global sales of extruded plant-based meat alternatives surpassed 6.2 million metric tons, driven by demand from over 220 million flexitarian consumers globally. High-moisture extrusion enabled 93% of this production, offering a meat-like texture with protein concentrations exceeding 70%. Investments in plant-based R&D increased by 23%, supporting over 300 new product launches using high-moisture extrusion. With over 1,400 companies globally now developing extruded vegan proteins, this segment offers robust expansion opportunities. Asia-Pacific witnessed the fastest growth, with 2.7 million metric tons of soy-based meat analogues extruded and distributed across urban markets.

CHALLENGE

High energy consumption in continuous extrusion processes.

Continuous extrusion processes demand high power input, with industrial extruders consuming an average of 250 kWh per ton of product. In 2023, over 2.2 million metric tons of extruded products required energy-intensive processing, contributing to high operational costs. Food manufacturers across Europe reported energy bills rising by 18%, forcing 17% of smaller firms to reduce batch sizes. Additionally, cooling systems required for precision temperature control accounted for 29% of the total plant energy load. Despite automation efficiencies, more than 32% of manufacturers cited rising energy costs as their biggest obstacle to expanding extrusion lines.

Food Extrusion Market Segmentation

The food extrusion market is segmented based on type and application. Extrusion types include cold extrusion and hot extrusion, with varied product outcomes. Applications range from savory snacks to breakfast cereals, flours, starches, bread, and other niche uses such as nutraceuticals and pet foods. In 2024, over 39% of extruded food products were savory snacks, while breakfast cereals represented 27%.

By Type

Cold Extrusion: Cold extrusion is widely used in producing energy bars, bakery fillings, and certain pet foods. In 2023, over 7.1 million metric tons of cold-extruded foods were produced globally. Cold extrusion processes operate under ambient temperature conditions, typically below 60°C, preserving bioactive compounds. Over 9,800 extruders specializing in cold extrusion were sold globally, and the technique gained preference for products requiring minimal thermal degradation, including live-culture foods and probiotic-infused snacks.
Hot Extrusion: Hot extrusion is dominant, responsible for more than 76% of all extruded food production globally. With processing temperatures exceeding 180°C, this technique is widely adopted in cereal, pasta, and snack manufacturing. In 2023, over 58 million metric tons of hot-extruded foods were distributed worldwide. Twin-screw hot extruders, making up 63% of installations, enabled consistent quality and efficient expansion, key to puffed snack production.

By Application

Savory Snacks: The savory snacks category remains the largest, with over 34 million metric tons of extruded savory products consumed globally in 2023. Corn-based and potato-based extrusions dominated, accounting for 79% of the market within this application.
Breakfast Cereals: Breakfast cereals represent a growing segment, with more than 21 million metric tons extruded globally in 2024. Fortified cereals, accounting for 68% of this total, are primarily produced via hot extrusion with integrated vitamin injection.
Bread: Extruded dough used in pre-baked or frozen breads reached 4.2 million metric tons in 2023. Compact industrial bakeries utilized extrusion to create consistent texture and fermentation-ready bases.
Flours & Starches: Functional flours and modified starches produced via extrusion hit 9.1 million metric tons globally. These are widely used in gluten-free food formulation and thickening agents.
Others: Other applications, including pet foods and meat analogs, reached 11.8 million metric tons in 2024. Extrusion allows for protein blending and fiber integration, making it essential in dietary supplement processing.

Food Extrusion Market Regional Outlook

The food extrusion market shows varying performance across global regions due to differences in dietary preferences, food industry maturity, and manufacturing capabilities.

North America

North America accounts for more than 29% of global extruded food output, with over 15,000 industrial extruders installed across the U.S. and Canada. In 2023, the region produced 12.7 million metric tons of extruded savory snacks, with the U.S. alone contributing 9.3 million metric tons. The cold extrusion segment saw growth in energy bars, with over 870 million bars sold in the U.S. in 2024.

Europe

Europe remains a leader in innovation, with over 6,700 patents filed for extrusion technologies from 2021 to 2024. Germany, France, and Italy jointly produced over 17.4 million metric tons of extruded foods in 2023. The region emphasizes whole grains and plant-based extrusions, with 41% of products containing organic or sustainable certifications.

Asia-Pacific

Asia-Pacific is the fastest-growing region, consuming over 26 million metric tons of extruded products in 2023. China leads with 9.8 million metric tons, followed by India with 7.1 million metric tons. The rise in urban working populations and increased snack consumption among millennials—approximately 640 million in the region—fuels this growth.

Middle East & Africa

Though still emerging, the Middle East & Africa region processed 6.2 million metric tons of extruded food in 2023. Nigeria and South Africa lead, producing 3.1 million metric tons combined. Local demand for fortified breakfast cereals and pet foods has grown by 12%, largely due to urban expansion and nutritional programs.

List of Top Food Extrusion Market Companies

Bühler
Akron Tool & Die
Baker Perkins
Coperion
Lindquist Machine
Pavan SPA
Kahl Group
Triott Group
Flexicon
Groupe Legris Industries
The Bonnot Company
American Extrusion International

Top Two Companies with Highest Share

Bühler: Operates over 5,800 extrusion installations globally and manufactures over 3,000 units annually, serving over 140 countries.

Coperion: Processes more than 6.3 million metric tons of extruded food products annually through its integrated twin-screw systems in over 50 countries.

Investment Analysis and Opportunities

In 2023, the global investment in food extrusion technology exceeded 11,000 equipment units, with over 60% of these acquisitions geared toward developing countries expanding industrial food production. Approximately 3,400 new food manufacturing startups incorporated extrusion as a core component of their operations. Notably, capital investment in high-moisture extrusion equipment for meat substitutes grew by 18%, with nearly 700 new facilities across Asia-Pacific alone integrating this specialized machinery.

Investors are increasingly drawn to automation-driven extrusion lines. Over 4,200 extruders globally were upgraded to smart control systems, enhancing yield accuracy by 17% and reducing material wastage by 22%. Startups in the pet food industry raised over $410 million in 2023 to fund extrusion-focused product lines, with the U.S. contributing over 55% of this total. Modular extrusion systems have allowed small-scale food entrepreneurs to enter markets previously dominated by large corporations.

Investment in regional expansion also soared, with Southeast Asian governments offering subsidies up to 28% for domestic food companies adopting extrusion. This resulted in 1,300 additional extruder installations in 2023. African markets witnessed investment in 460 new extrusion units, particularly in Nigeria, Kenya, and Egypt, supporting nutritional cereal and fortified food programs aimed at reaching 12 million food-insecure individuals.

New Product Development

Innovation in the food extrusion market continues to push product boundaries, with over 2,100 new extruded products launched globally in 2023. The majority were protein-enriched snacks and fortified breakfast cereals, contributing to over 9.2 million metric tons of new extruded product output. One major innovation is fiber-enhanced extruded noodles using konjac and oat bran, which account for over 220,000 metric tons of Asian health-focused products.

Texturized vegetable protein (TVP) from extrusion is another major development, reaching 3.1 million metric tons in global distribution. Extruded high-moisture soy proteins used in meat substitutes now comprise over 47% of all plant-based meats, with 180 companies launching new extruded vegan SKUs in the past year. Additionally, pea-protein chips extruded using hot expansion gained traction, with 870 million packs sold in the U.S. and EU combined in 2023.

Companies have also begun developing hybrid extruded snacks that blend sweet and savory elements, with 510 new products released in 2023 alone. Prebiotic-enhanced extrusions are another frontier, with over 2.6 million metric tons of extruded products containing inulin and FOS additives. Functional extruded grains enriched with magnesium, iron, and folic acid were produced in volumes exceeding 12 million metric tons, targeting developing markets with nutritional deficiencies.

The pet food segment saw 730 new extruded formulations released globally in 2024, of which 340 were grain-free variants. Extrusion techniques now allow incorporation of omega-3 oils without denaturation, with 38% of new premium pet foods extruded with EPA/DHA additives. Edible packaging extruded from tapioca starch, used in snack wrapping, increased in production to 18,000 metric tons, spurring eco-conscious consumer product design.

Furthermore, micro-extrusion has emerged as a method for delivering nutraceutical pellets and encapsulated vitamins. Over 48 pharmaceutical food products used this extrusion method in 2023, with over 22 million doses manufactured.

Five Recent Developments

Bühler: launched a new twin-screw high-moisture extruder in April 2024 that processes 2.8 metric tons per hour, optimized for soy- and pea-based meat analogs.
Coperion: expanded its extruder facility in Stuttgart, Germany, adding 20,000 sq ft of R&D labs for testing high-viscosity food extrusion, supporting over 180 new product tests per month.
American Extrusion: International introduced a cold extruder line for granola and protein bars capable of shaping over 12,000 units per hour, with thermal inputs under 55°C.
Kahl Group: commissioned a pilot line in Indonesia to support fortified cereal extrusion, projected to produce 9,000 metric tons annually for school meal programs.
Pavan SPA: debuted an inline vitamin-injection system for breakfast cereal extrusion, ensuring retention of over 95% of micronutrients, validated across 72 test batches in 2023.

Report Coverage of Food Extrusion Market

This report comprehensively covers the global food extrusion market, detailing key segments, technological innovations, market trends, and competitive landscapes. It includes an analysis of over 58 million metric tons of annual extruded food production and highlights the role of both hot and cold extrusion in shaping modern food solutions. The scope encompasses extrusion across breakfast cereals, savory snacks, bakery goods, functional flours, and specialty applications like plant-based meats and fortified pet foods.

With over 120 countries utilizing extruded food products in mass consumption, the report analyzes regional differences, focusing on North America’s 12.7 million metric tons of annual extruded output, Europe’s innovation-driven 17.4 million metric tons, Asia-Pacific’s high-growth 26 million metric tons, and the Middle East & Africa’s emerging 6.2 million metric tons. The technological footprint of twin-screw, single-screw, and smart extruders is also mapped, accounting for over 37,000 active extruders in operation globally.

The report examines over 14 application segments, 6 major extrusion equipment types, and features 12 leading global manufacturers. Key topics include AI automation in extrusion, modular system development, and extrusion's impact on nutritional enhancement. Investment flows, totaling thousands of new lines and hundreds of millions in infrastructure, are tracked by region and product type.

Sustainability themes—such as energy usage in hot extrusion (up to 250 kWh per ton), water recycling, and use of biodegradable starch wrappers—are also explored in depth. With over 2,100 new extruded products launched in the past year alone, the report underscores innovation as a driving force. Finally, policy support for extruded foods—especially in Africa and South Asia—is outlined, noting over 90 national programs leveraging extrusion to combat malnutrition.