Bühler launches Nutrex 7 Series to boost extrusion efficiency, hygiene and digital control

Bühler has launched its Nutrex 7 Series extrusion platform, introducing a new generation of systems designed to improve hygiene, efficiency and digital integration for food and feed manufacturers.

• Bühler has introduced the Nutrex 7 Series extrusion systems, focusing on hygiene, process stability, digital integration and service to improve overall equipment efficiency.
• The platform has been developed with customers and is already operating at industrial sites, including Kärntner Mühle in Austria.
• New features include a modular design, automated StepFlow function and digital monitoring tools to reduce downtime and improve productivity.

The Swiss processing equipment supplier reported that the new platform responded to increasing industry demands for food safety, reduced downtime and more user-friendly operation. The first systems have already been deployed at customer sites, where they have demonstrated reliability alongside enhanced functionality.

Bühler stated that food and feed manufacturers were operating in a rapidly evolving environment, where stricter hygiene standards and the need to minimize production interruptions were becoming increasingly critical. The company said its engineering teams had focused on improving process hygiene, boosting productivity and integrating advanced digital technologies, while retaining its established twin-screw extrusion technology.

“We focused on a holistic approach based on four main categories: hygienic design, process stability, integrated intelligence, and service excellence, all with the aim of increasing Overall Equipment Efficiency (OEE) for our customers,” said Stefanie Hardtmann, Product Manager Value Nutrition at Bühler.

The Nutrex 7 Series has been developed as a modular system to accommodate a wide range of applications, from cereals and snacks to pet food, meat alternatives and food ingredients. Bühler reported that the design allowed manufacturers to tailor the system to specific process requirements, while maintaining high levels of safety, uptime and performance.

David Meile, Project Manager R&D at Bühler, said the development drew on decades of experience and emphasized a system-wide perspective. “Here, we drew on four decades of experience based on hundreds of installed systems around the world. A decisive factor was viewing the extrusion system as a whole in the context of the food processing chain,” he said.

Hygienic design formed a central pillar of the new platform. Bühler reported that the system had been engineered to simplify cleaning and reduce downtime, with features including a slimmer extruder design, increased ground clearance and an integrated hydraulic box to improve accessibility. These changes were intended to allow faster cleaning and quicker return to operation.

The system also incorporated new cleaning technologies, including a patented Cleaning Lance designed to improve internal cleaning while enhancing operator safety. Bühler stated that the machine was constructed from stainless steel and designed for both internal and external wet cleaning.

Digital tools were integrated to support monitoring and compliance. Options such as Critical Control Point monitoring and an Overall Equipment Efficiency app allow operators to track performance, document deviations and implement corrective actions. Bühler reported that these tools could help reduce the workload associated with audits and validation. The company also offered an Extrusion Kill-Step Validation Service in collaboration with RedLog to support assessment of extrusion as a critical process step.

A revised control system formed a core component of the platform’s digital capabilities. Bühler reported that the system aligned with its broader automation strategy to standardize machine and plant control systems on a single platform by 2030. The browser-based interface enables remote monitoring and control, allowing operators to oversee processes such as preconditioning, weighing, extruding and cutting from different locations.

“An extruder is not simply a machine, but an integrated process step in the food industry. Our new visualization concept does justice to this complexity and maps the various processes – such as preconditioning, weighing, extruding, and cutting – schematically across various levels. In addition, the control system is completely browser-based, meaning the processes can be monitored and controlled from anywhere,” said Adrian Staerkle, Team Manager R&D Automation Software at Bühler.

The system also introduced StepFlow, an automated function designed to optimize start-up and shutdown procedures. Bühler reported that the feature used predefined production values based on its operational experience to streamline processes and reduce reliance on operator expertise.

“The StepFlow function allows the fastest start-up procedure to be achieved automatically, based on pre-defined production values,” said Staerkle.

According to Bühler, the feature can reduce waste by up to 30% per run, while improving process consistency and efficiency.

Beyond the core system, Bühler highlighted its service offering as a key component of the Nutrex 7 Series. The company reported that its service network provided modular packages including vibration monitoring, oil condition monitoring, spare parts and expert support. These tools are intended to enable predictive maintenance, improve system availability and support long-term operational reliability.

The development process involved collaboration with customers across multiple sectors, including pet food, extruded flours and cereals. Bühler reported that this approach allowed the systems to be tested under industrial conditions before launch.

Kärntner Mühle in Austria was among the first companies to operate the system. Martin Kropfitsch, owner and Managing Director, said the company had been closely involved in its development.

“As the first customer of Nutrex 7 Series, we were closely involved in the development process. The collaboration with Bühler was partnership-based and practical. We were particularly impressed by the simple integration into our existing line and the significantly simplified handling. The intuitive control system makes day-to-day operation noticeably easier,” he said.

Additional units have since been installed at other customer sites. Bühler reported that the Nutrex 7 Series is now available for order and delivery.

Hardtmann said the launch marked a continuation of the company’s long-standing focus on process innovation. “For 166 years, Bühler has been launching new processing technologies with the goal of making its customers more successful. With Nutrex 7 Series, we are seamlessly continuing this tradition and offering food and feed producers worldwide a system that equips them for the challenges in their markets. It can be used flexibly, meets the highest hygiene requirements, and is equipped with the latest control technology for smooth and efficient operation,” she said.