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 are designed for expansion in popping 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.







Shells

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

Formulas based on potato, whole ground, or multiple grains work well with this shape, and compliment savory topical seasonings.

This is a commercial die shape

Main ingredients as shown wheat, corn, rice
Flavor neutral grain
Texture light and crunchy
Dimensions with higher expansion grains fried product measures 3. x 1-1/2. or 75 x 35mm.
Dimensions with lower expansion grains fried product measures 2-3/8. x 1-1/4. or 60 x 30mm.
* The hot air popped/baked version of each will be somewhat less expanded.
Storage life 12 months
Package size 20#/9kg bag

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.

This is a commercial die shape

Main ingredients as shown wheat, corn, rice
Flavor neutral grain
Texture light and crunchy
Dimensions with higher expansion grains fried product measures 1-1/4. x 1. or 30 x 20mm.
Dimensions With lower expansion grains fried product measures 1. x 7/8. or 25 x 22mm.
* The hot air popped/baked version of each will be somewhat less expanded.
Storage life 12 months
Package size 50#/22.7kg bag

Chips

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Potato & Veggie Ridged Chips

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

Potato or whole ground corn is commonly used as the primary ingredient in chips. Vegetables such as spinach, carrots or tomato can be added to a variety of chip bases.

The ridged chip is not yet a commercial die shape.

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 1-7/8. x 1-1/4. or 45 x 33mm.
Dimensions With lower expansion grains fried product measures 1-1/4. x 1. or 32 x 25mm.
* The shorter dimension can be varied by cut length.
** The hot air popped/baked version of each will be somewhat less expanded.
Storage life 12 months
Package size 20#/9kg bag

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.

This chip is a commercial die shape.

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 1-4. or 51 x 32mm. The shorter dimension can be varied by the cut length.
* The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months
Package size 20#/9kg bag

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.

This chip is a commercial die shape.

Main ingredients as shown whole ground corn
Flavor toasted corn
Texture light and crunchy
Dimensions the fried product will measure about 1-1/2. x 5/8. or 40 x 15mm. The shorter dimension can be varied by the cut length.
* The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months
Package size 20#/9kg bag

Strips & Ribbons

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Potato & Veggie Ridged 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.

The ribbon is not yet a commercial die shape.

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 3-1/2. x 3/8. or 88 x 9mm.
Dimensions with lower expansion grains fried product measures 2-5/8. x 1/4. or 67 x 6mm.
* The shorter dimension can be varied by the cut length.
**The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months
Package size 20#/9kg bag

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.

The ribbon is not yet a commercial die shape.

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 3-1/2. x 3/8. or 88 x 9mm.
Dimensions with lower expansion grains fried product measures 2-5/8. x 1/4. or 67 x 6mm.
* The shorter dimension can be varied by the cut length.
**The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months
Package size 20#/9kg bag

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.

The ribbon is not yet a commercial die shape.

Main ingredients as shown potato
Flavor french fried potato
Texture tight cell structure, light and crunchy
Dimensions with higher expansion grains fried product measures 3-1/2. x 3/8. or 88 x 9mm.
Dimensions with lower expansion grains fried product measures 2-5/8. x 1/4. or 67 x 6mm
* The shorter dimension can be varied by the cut length.
** The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months
Package size 20#/9kg bag

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.

The ribbon is not yet a commercial die shape.

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 3-1/2. x 1-1/8. or 88 x 28mm.
Dimensions with lower expansion grains fried product measures 2-5/8. x 1. or 67 x 25mm.
* The shorter dimension can be varied by the cut length.
The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months
Package size 20#/9kg bag

Twists

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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.

The single principle twist is a commercial die shape.

Main ingredients as shown whole ground corn
Flavor toasted corn
Texture tight cell structure, bold and crunchy
Dimensions fried product measures 1-3/4. x 3/4. or 45 x 19mm
* The longer dimension can be varied by the cut length.
** The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months
Package size 20#/9kg bag

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.

The single principle twist is a commercial die shape.

Main ingredients as shown rice, tapioca
Flavor neutral, depends on topical seasoning
Texture medium cell structure, light and crispy
Dimensions fried product measures 2-1/2. x 1-1/16. or 65 x 27mm
* The longer dimension can be varied by the cut length.
** The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months
Package size 20#/9kg bag

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.

The single principle twist is a commercial die shape.

Main ingredients as shown wheat, corn, rice
Flavor neutral grain
Texture light and crispy
Dimensions fried product measures 1-3/4. x 3/4. or 45 x 19mm
* The longer dimension can be varied by the cut length.
** The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months
Package size 20#/9kg bag

Circular Tubes

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Cut lengths yield very different shapes from "churros" for snacks and deserts 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.

The circular tube is a commercial die shape.

Main ingredients as shown whole grain wheat, whole ground corn, brown rice
Flavor toasted grain
Texture light and crispy
Dimensions fried product measures 1-3/4" x 3/4" or 45 x 19mm
* The longer dimension can be varied by the cut length.
** The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months
Package size 50#/22.7kg bag or 2,200#/998kg super sack

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.

The circular tube is a commercial die shape.

Main ingredients as shown wheat, corn, rice
Flavor neutral grain
Texture light and crispy
Dimensions fried product measures 1-3/4" x 3/4" or 25 x 19mm
* The longer dimension can be varied by the cut length.
** The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months
Package size 50#/22.7kg bag or 2,200#/998kg super sack

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.

The circular tube is a commercial die shape.

Main ingredients as shown white corn, rice
Flavor lightly sweet corn
Texture light and crispy
Dimensions fried product measures 1/2" x 3/4" or 12 x 19mm
* The longer dimension can be varied by the cut length.
** The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months
Package size 50#/22.7kg bag or 2,200#/998kg super sack

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.

The circular tube is a commercial die shape.

Main ingredients as shown rice, tapioca
Flavor lightly sweet corn
Texture light and crispy
Dimensions fried product measures 1/8" x 3/4" or 3 x 19mm
* The longer dimension can be varied by the cut length.
** The hot air popped/baked version will be somewhat less expanded.
Storage life 12 months
Package size 50#/22.7kg bag or 2,200#/998kg super sack

Split Peas & Small Balls

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The small round shape we refer to as "split peas" are expanded by pressure 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. Double striking the die will yield a flatter "crisp/cracker" appearance.

The split pea and small ball are both commercial shapes.

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
Dimensions raw small ball is about 1/8" or 3mm diameter
Storage life 12 months
Package size 50#/22.7kg bag or 2,200#/998kg super sack

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.

The split pea and small ball are both commercial shapes.

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
Dimensions raw small ball is about 1/8" or 3mm diameter
Storage life 12 months
Package size 50#/22.7kg bag or 2,200#/998kg super sack

Rings

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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.

Rings are commercial shapes.

Main ingredients as shown potato and corn, with and without annatto for color
Flavor lightly onion
Texture light and crunchy
Dimensions 1-3/4 or 45mm diameter
The hot air popped / baked versions of either grid will be less expanded.
Storage life 12 months
Package size 20#/9kg bag

Grids

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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.

3x2 and 3x4 grids are commercial shapes.

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 3/8" 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 3/4" or 25 x 19mm when fried.
The hot air popped / baked versions of either grid will be less expanded.
Storage life 12 months
Package size 20#/9kg bag

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.

The circle grid is a commercial shape.

Main ingredients as shown whole grain wheat, whole ground corn, rice
Flavor toasted grain
Texture light and crunchy
Dimensions as shown 1-3/8" or 32mm diameter
The hot air popped / baked versions of either grid will be less expanded.
Storage life 12 months
Package size 20#/9kg bag

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.

The triangle grid is a commercial shape.

Main ingredients as shown corn, wheat, rice
Flavor light corn
Texture light and crunchy
Dimensions 1-3/4" or 45mm per side With whole grains 1-5/8" or 42mm.
The hot air popped / baked versions of either grid will be less expanded.
Storage life 12 months
Package size 20#/9kg bag

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.

This is a commercial die shape


Top Product

Main ingredients as shown wheat, corn, rice
Flavor neutral grain
Texture light and crispy
Dimensions with higher expansion grains fried product measures 1 5/8" x 5/8" or 40 x 15mm.
The hot air popped / baked versions of either grid will be less expanded.
Storage life 12 months
Package size 20#/9kg bag

Bottom Product

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 3/8" or 25 x 9mm.
The hot air popped / baked versions of either grid will be less expanded.
Storage life 12 months
Package size 50#/22.7kg bag or 2,200#/998kg super sack

Brands & Custom Shapes

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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
Storage life 12 months
Package size 20#/9kg bag, 50#/22.7kg bag