tna delivers flexibility and productivity for Italian snack company

Italian snack manufacturer Pata specialises in the production of potato chips, popcorn and extruded snacks.

Pata needed a flexible packaging system that could handle different products and bag sizes for a wide variety of snacks, for their own brand and also for third parties. At the same time, the company was looking to optimise production by increasing bagging speeds and reducing waste.

Choosing packaging, weighing, seasoning and distribution systems — all from integrated packaging and processing solutions provider tna — has enabled Pata to reduce waste, simplify cleaning operations and improve overall production efficiencies.

The tna robag TX 3ci vertical form, fill and seal (VFFS) packaging system was able to offer Pata both production flexibility and improved performance in a compact, easy-to-clean system. The robag series is capable of delivering up to 160 bags/min on potato chips and can handle a wide variety of bag sizes and formats. Its rotary single jaws ensure seal integrity, preventing bursts and reducing waste.

The system was integrated with a tna intelli-weigh 0314S omega multihead high-speed scale. Capable of up to 200 weighs/min, the scale offers high accuracy, further improving performance by reducing product losses. In addition, the integration of a stainless steel metal detector ensured standards of hygiene and safety were maintained.

“Our robag range is completely upgradeable to different jaw sizes and configurations, enabling Pata to further speed up their production should their requirements change in the future,” commented Peter Pellizzari, regional sales manager, tna.

Seasoning is a key challenge for any snack manufacturer. Each type of snack-based product has its own attributes, product structure, surface and topography, which can challenge the application needs. For Pata, it was therefore important to find a seasoning system that was able to handle the versatile product range while ensuring even coverage and precise flavour diffusion.

The tna intelli-flav OMS 5 features a responsive variable mass seasoning system with a dynamic vibratory weigher, which enables an accurate, proportional amount of seasoning to be evenly applied to the product. With a simple, modular design, tna’s seasoning systems are fully enclosed for increased levels of hygiene and ease of cleaning, while their 90° pivoting drums improve accessibility for hard-to-reach areas.

Reduced product breakage and ease of cleaning were the deciding factors when Pata was choosing a conveyer. In the past, products would break easily when travelling along the conveyer, resulting in material waste. And the accumulation of crumbs in hard-to-reach places made cleaning time-consuming and labour-intensive.

tna roflo VM conveyors with an accumulation capability were installed to gently distribute products along the production line. Using a vibratory motion and a dimpled surface, the conveyors allow for smooth product flow, minimising the risk of product breakage and rejects. The easy-to-clean design of the conveyor reduces downtime and helps manufacturers to comply with food quality standards.