Advanced Co-Extrusion Technology
Automatic Core Filling Snack Production Line Solutions
Create premium Chocolate Pillows & Cream Bars with a crispy shell and melting center. Upgrade your portfolio with high-margin co-extruded snacks.
The Magic of Co-Extrusion:
Two Textures in One Bite
Standard extrusion creates a uniform texture. Co-Extrusion takes this a step further by combining two different materials into a single die head.
While the twin-screw extruder cooks and forms the Crispy Cereal Shell, a specialized core filler simultaneously injects a Soft Cream or Chocolate Center.
This precise synchronization creates the signature “Pillow” or “Bar” snacks that offer consumers a delightful contrast between crunchy and smooth mouthfeels.
High Profit Margin
Center-filled snacks are positioned as premium products in the market. They command a 30-50% higher retail price compared to standard plain corn puffs, significantly boosting your ROI.
Complex Mouthfeel
Consumers love complexity. The combination of a savory or sweet crispy outer shell with a smooth, melting filling (chocolate, cheese, fruit jam) creates an addictive sensory experience.
2-in-1 Production Line
This line is an “All-Rounder”. By simply turning off the core filler and changing the die mold, you can use the same machine to produce standard plain puffs (balls, rings), giving you maximum market flexibility.
The Co-Extrusion Process
A synchronized operation where the outer shell and inner filling meet at the die head, creating a perfectly sealed snack.
01
Raw Material Mixing
Grain flour (Corn/Rice/Wheat) is mixed with water for the shell. Simultaneously, the filling (Chocolate/Cream) is prepared in a separate melting tank.
02
Co-Extrusion Injection
The Twin Screw Extruder cooks the shell. At the die head, the Core Filler injects the fluid filling into the center of the extrudate before it expands.
03
Pinch & Cut Shaping
The filled tube enters the Shaping Cutter. It pinches the tube to seal the filling inside and cuts it into Pillows, Bars, or Sticks to prevent leakage.
04
Crisping Oven
The snacks pass through a multi-layer dryer at low temperature. This removes moisture from the shell to make it crispy without melting the filling inside.
05
Surface Seasoning
Even though it has a filling, the outer shell is often sprayed with oil and seasoning powder (like cocoa or milk powder) for extra flavor.
06
Automated Packaging
The finished products are cooled and then packed by vertical packaging machines into pillow bags, ready for retail distribution.
Machinery Behind the Magic
Producing center-filled snacks requires precise synchronization between the shell extrusion, core injection, and sealing cutter.
The Shell Creator
Co-Extrusion Host Machine
Unlike standard extruders, the host machine is fitted with a specialized Co-Extrusion Die Mold. It creates a hollow tube of cooked grain dough, providing the perfect channel for the filling to be injected.
Precise Temp Control
High Torque Gearbox
Touch Screen PLC
Easy-Change Dies
The Soul of Flavor
Automatic Core Filler
This vertical unit holds and pumps the filling (Chocolate, Cream, Jam). It features an Interlayer Heating System in the hopper and pump to keep the filling fluid, preventing solidification and blockage during operation.
Heating & Mixing Tank
Variable Speed Pump
Anti-Blockage Design
Sanitary Stainless Steel
The Leakage Stopper
Shaping & Cutting Machine
Ordinary cutters cause leakage. Our machine uses specialized rollers to “Pinch” the tube ends together before cutting. This seals the filling inside, creating perfect Pillow or Bar shapes without messy leaks.
Leak-Proof Pinching
Synchronized Speed
Versatile Shapes
Emergency Stop Safety
Inside the Crisp
From chocolate pillows to fruit bars. Our co-extrusion technology enables you to produce a wide variety of shapes with infinite filling possibilities.
Cocoa Filling
Chocolate Pillows
The market favorite. A crunchy cereal shell filled with rich, melting dark or milk chocolate.
Milk Cream
Cream Filled Bars
Long, stick-shaped snacks filled with sweet milk or vanilla cream. Easy to hold and eat.
Fruit Jam
Fruit Jam Bites
A perfect balance of sweet and tart. Filled with strawberry, blueberry, or orange jam.
Savory Cheese
Cheese Filled Balls
Savory option. Corn puff exterior with a salty, creamy cheddar cheese filling.
Dual Color
Dual-Color Snacks
Advanced extrusion allowing two colors on the shell (e.g., stripes) for enhanced visual appeal.
Yogurt Filling
Yogurt Oat Bites
Health-focused snacks using oat flour shell and low-fat yogurt filling. Popular in modern markets.
Technical Specifications
These models include the standard Core Filling System and Shaping Cutter. Capacity figures include both the cereal shell and the filling weight.
| Model | Output Capacity | Main Motor | Installed Power | Line Dimensions (L*W*H) |
|---|---|---|---|---|
| LY-65 | 120 – 150 kg/h | 22 kW | 75 kW | 18 x 1.2 x 2.2 m |
| LY-70 | 200 – 250 kg/h | 30 kW | 100 kW | 22 x 1.5 x 2.2 m |
| LY-85 | 400 – 500 kg/h | 55 kW | 150 kW | 30 x 1.5 x 3.0 m |
* Note: Line length is slightly longer than standard puff lines due to the addition of the Shaping Cutter and Cooling Conveyor.
Limited factory space? We can design a U-shape or L-shape layout to fit the longer co-extrusion line into your facility.
Get Customized LayoutStandard Puff vs. Core Filling
Should you invest in Co-Extrusion? While the Standard Line is cheaper, the Core Filling Line offers “2-in-1” capability and higher profit margins.
Best Value (2-in-1)
Core Filling Line
The versatile choice. Produces both premium filled snacks AND standard puffs by toggling the filling system.
Initial Investment
Medium (+ Filling Units)
Market Versatility
High (All Shapes)
Profit Potential
Premium Pricing
Capabilities:
✓ Chocolate Pillows / Bars
✓ Fruit Jam Bites
✓ Cheese Balls (Filling Off)
✓ Corn Curls (Filling Off)
✓ Fruit Jam Bites
✓ Cheese Balls (Filling Off)
✓ Corn Curls (Filling Off)
Entry Level
Standard Puff Line
Dedicated to simple direct-expanded shapes. Lower cost, but limited to plain texture snacks.
Initial Investment
Low (Basic Equipment)
Market Versatility
Basic Shapes Only
Profit Potential
Volume Based
Capabilities:
✓ Cheese Balls
✓ Corn Curls / Rings
✕ Chocolate Pillows
✕ Cream Bars
✓ Corn Curls / Rings
✕ Chocolate Pillows
✕ Cream Bars
Live Co-Extrusion Gallery
See the synchronization of extrusion and core filling in action.
Success Stories
From technical consultation to mass production, see why manufacturers choose our co-extrusion technology.
“
Your explanation was more complete than all the companies, even Fava and Pawan.
“
ممتاز، الجهاز يعمل بشكل قوي والمواد الغذائية ذات جودة عالية. شكرا لكم. من أول يوم والجهاز ما قصر. أوصي الجميع.
Why Choose Loyal?
Producing filled snacks is technically demanding. We solve the most common issues—leakage, blockage, and inconsistent ratios—so you can run 24/7 without downtime.
Zero Leakage
Leaking filling ruins packaging machines. Our Shaping Cutter uses a synchronized “Pinch & Cut” mechanism to seal the tube ends tightly before cutting, ensuring clean production.
No Blockage
Chocolate hardens if it cools. Our Core Filling system features a Double-Layer Heating Jacket on the tank, pump, and pipe to keep the filling at the perfect viscosity.
Precise Ratio Control
Want 30% filling and 70% shell? Our PLC system uses Inverter Control to precisely adjust the extruder and pump speeds, maintaining a consistent shell-to-core ratio.
Recipe Support
Filling too thin? It leaks. Too thick? It blocks. We provide Viscosity Guidelines and proven recipes for cream and fruit jams to ensure smooth injection.
Frequently Asked Questions
Expert answers on leakage prevention, filling types, and machine versatility.
How do you prevent the filling from leaking out?
We use a specialized Shaping Cutter designed for co-extrusion. Unlike standard knives, it uses a synchronized roller mechanism to “pinch” (seal) the ends of the snack tube together before cutting. This ensures the filling stays strictly inside the shell.
What kind of fillings can I use?
You can use any flowable filling that matches the viscosity requirements, such as Chocolate, Cream, Fruit Jam, or Peanut Butter. The filling must be smooth (no large particles) to avoid blocking the injection nozzle. We provide viscosity guidelines with the machine.
Can I use this line to make standard (non-filled) puffs?
Yes, absolutely. This is a “2-in-1” line. To make standard puffs (like cheese balls or corn curls), simply turn off the Core Filler, change the die mold, and run the extruder normally. You get two production capabilities in one investment.
Will chocolate harden and block the machine?
No. Our Core Filling System (Tank, Pump, and Injection Pipe) is equipped with a Double-Layer Heating Jacket. It circulates hot water or oil to keep the chocolate at a constant temperature (e.g., 40-50°C), ensuring it remains fluid throughout production.
What is the maximum filling ratio?
Typically, the filling accounts for 20% to 40% of the total product weight. You can adjust this ratio precisely using the PLC touch screen, which controls the speed of the injection pump relative to the extruder.
Need a Filling Recipe?
We provide proven recipes for chocolate and cream fillings to help you start production smoothly.
Get Recipe Support