GEA Unveils High-speed Bake Extruder for Industrial Biscuit Production

GEA has launched its new high-performance Bake Extruder at IBA 2025 in Düsseldorf, introducing a flexible, high-speed solution tailored for medium- to large-scale biscuit and cookie manufacturers. The system is designed to handle high-volume production with precision, supporting a wide variety of formats including wirecut, co-extruded, filled, and continuous extruded products.

Developed in response to customer feedback, the Bake Extruder prioritises performance, versatility, and hygiene. “From customer interviews, we learned that the industry demands higher performance, greater flexibility, easier cleaning, and enhanced product variety,” said Matteo Pasquali, Application Manager Soft Dough at GEA. “The Bake Extruder is our response to those requests.”

The modular system features interchangeable dies and cutting tools, including a new wirecut system capable of up to 350 strokes per minute across a 1,700 mm width. It can achieve 130 cuts per minute for filled cookies and up to 250 for continuous extruded formats. Optional lobe pumps enhance dosing precision for soft or aerated doughs with inclusions, such as chocolate chips or fruit pieces.

Powered by brushless motors and servo-driven axes, the extruder ensures tight control over extrusion speed and cut timing, maintaining consistent product size and quality. A newly developed HMI with standalone control box supports intuitive operation, advanced recipe management, and ERP system integration. Predictive maintenance is also enabled through performance data analysis.

The design meets strict hygiene standards, with a removable hopper, open-head configuration, and photoelectric safety barriers allowing quick, safe cleaning. Stainless steel parts and easily accessible components further reduce maintenance downtime and wear. The GEA Bake Extruder can be deployed as a standalone unit or integrated with existing oven systems.