World’s largest controlled puffing operation starts up in Iowa

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World’s largest controlled puffing operation starts up in Iowa

19 Aug 2024

Joanie Spencer

Since 2008, Joanie Spencer has covered the retail and wholesale sides of the baking industry.
Serving associations such as the American Society of Baking (ASB) and BEMA, Joanie is also in demand as an industry presenter on bakery operations and trends. She holds a bachelor’s degree in communication from Rockhurst University and a master’s degree in journalism from the University of Missouri.

When she’s not running or playing soccer, Joanie spends her time with her husband and 11-year-old son.

DYERSVILLE, IA — Grainwell Puffed Grains, previously known as Ancient Brands, has started up a new full-scale puffed grain production plant. This marks the first controlled puffing facility in North America, as well as the world’s largest, according to the company.

The new multi-line, 105,000-square-foot operation produces high-quality, custom-puffed grains and legumes at scale. Using controlled Cerex puffing technology, combined with Grainwell’s proprietary methodology, the operation is touted as a more sustainable method of puffing at scale.

According to Dylan Kollasch, PhD, Grainwell’s VP of innovation and product development, the process reaches up to 95% efficiency, as opposed to an industry average of around 70%.

“Our closed, continuous batch process tightly controls every aspect of the complex puffing process, enabling calibration of the grain color, texture, size, moisture content and flavor profile,” Dr. Kollasch said. “We create less waste and use less water and energy to create a superior product. Many of our grain and legume capabilities are simply not possible with traditional puffing methodologies.”

The new operation inspired the renaming of the brand, which focuses on the health benefits that come with puffed products that can be made through this process.

“Our new name better reflects our unique capabilities and marketplace value,” said Wolfgang Buehler, CEO of Grainwell. “Better-for-you foods continue to gain market share globally. Puffed ancient and contemporary grains, produced properly, bring huge potential to create innovative new products and improve existing ones.”

Prior to Grainwell, Buehler was the owner and CEO of Organic Milling in San Dimas, CA. In that role, he experienced the need in the marketplace for improved puffed grain solutions. This led to Ancient Brands and an initial small-scale facility that was soon at capacity.

“Better-for-you foods continue to gain market share globally. Puffed ancient and contemporary grains, produced properly, bring huge potential to create innovative new products and improve existing ones.” — Wolfgang Buehler | CEO | Grainwell Puffed Grains

Plans for the greenfield facility began in late 2022, and almost year later the company moved to its new location, which has 14 times the capacity potential and provides greater product control, production efficiency, and grain diversity.

“Our team works with brands’ R&D, food science and product marketing people to tailor puffed grain and legume solutions,” Buehler said. “That opens up possibilities for innovative products and to improve existing ones.”

Grainwell provides samples and development support to food companies’ R&D, product development and food science teams on a wide array of components that can help create innovative new products or enhance existing offerings. The company also established a leading position in brand name, uncoated puffed grain cereals, claiming more than 80% of the production in this growing category.

“What’s old … is now what’s new,” said Chris Bekermeier, VP of sales and marketing for Grainwell. “Puffed ancient grains such as amaranth, quinoa and Kamut are being rediscovered. Puffed grains are single-ingredient, clean-label, non-GMO, wholesome sources of nutrition, in foods including cereals, baked goods, bars and snacks. And these grains taste amazing.”

To learn more about the company’s operation and the variety of puffed grains it produces, visit the Grainwell Puffed Grains website.

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