Personalized snacks cater to a greater diversity of nutrition priorities, lifestyles and diets, portion sizes and flavor combinations. Either wire-cut or molded, new and changing cookies are demanding flexible systems to support large-scale production.
Biscuits and cookies are a thriving market, estimated to grow from last year’s value of USD 135.21 billion to USD 181.83 billion by 2031 (Mordor Intelligence, Global Biscuits Market). Consumers increasingly favor indulgence in their snack time and better-for-you formulations, with premium and single-serve offerings. European consumers are particularly fond of biscuits, driving the continent’s market share to 27.55% in 2025. But they are popular around the world, with South America on track to become the fastest-growing market over the next five years, according to Mordor’s research. Coming in any type of flavor, filling, shape and size combinations, wheat-based biscuits make up for the vast majority of the market (84.74%); at the same time, free-from alternatives make an enticing, growing niche.
“Our latest improvements focus on enhancing flexibility, accuracy, and productivity in soft dough bakery production.”
GEA specialists
Extruded cookies
Last year, GEA also introduced a new extruder at iba ’25. The GEA Bake Extruder was developed for high-volume and high-speed applications, with a hygienic design. It was designed to have the flexibility to support a range of industrial baking needs, for various production styles including wirecut, co-extruded, filled, continuous extruded, and like-deposited products (cookies that replicate the texture and appearance of traditionally deposited, hand-crafted products). These formats are commonly used in the production of cookies, bars, and biscuits with varied textures, fillings, and inclusions.
“The new E-Bake electric tunnel oven is part of the ‘GEA Add Better’ portfolio, optimizing energy efficiency. It can help lower energy consumption by up to 40%, compared with gas-fired models.”
GEA specialists
“GEA identified current needs in a customer survey and aligned its engineering accordingly,” said Matteo Pasquali, Application Manager Soft Dough at GEA. “From customer interviews, we learned that the industry demands higher performance, greater flexibility, easier cleaning, and enhanced product variety. The Bake Extruder is our response to those requests.”
This modular system features interchangeable dies and cutting mechanisms, including a fully redesigned wirecut system that can operate at speeds of up to 350 strokes per minute across a maximum working width of 1,700 millimeters. For specific product formats, the machine delivers a performance of 130 cuts per minute when producing encapsulated cookies, and up to 250 cuts per minute for continuous extruded products, GEA details.
To push its versatility one step further, the GEA Bake Extruder comes with customizable filler blocks and can be configured with optional lobe pumps, which provide gentle and accurate dosing for delicate or aerated doughs. “These lobe pumps are particularly well-suited for processing aerated and softer doughs that may contain inclusions such as chocolate chips or dried fruits, ensuring accurate dosing and maintaining product integrity,” the specialist details.
This extruder is powered by brushless motors, meaning that the extrusion speed and cut timing can be very accurately controlled. Its servo-driven axes ensure high repeatability and minimal deviations in product size and shape.
For the Bake Extruder, GEA developed a new HMI with an independent control box, offering intuitive operation, multi-level access, and improved recipe management. The system can be integrated with the facility’s ERP system and includes performance analysis tools for predictive maintenance.
For added digital service, including remote monitoring, GEA recently upgraded its platforms: GEA Smartcontrol, InsightPartner and RemotePartner. They can provide real‑time performance data, remote diagnostics, and expert support without needing on‑site visits.
As the company anticipates greater reliance on digital tools in the future, it also provides preventive maintenance and audits via its Bakery Health Check program, alongside service agreements and tailored support packages that combine maintenance planning, spare parts, and consulting to optimize uptime, efficiency, and product quality.
With a multitude of new developments, the quest for new cookie creations does not need to have any technical limitations. The segment retains a loyal consumer base – the only condition for success is meeting their preferences.