Complete processing lines for savoury snacks: challenges and opportunities

The global savoury snack market faces several challenges and opportunities. While it is projected to grow at a CAGR of 5.2%, reaching USD 263 billion by 2027, climate change is increasingly impacting the supply of raw materials, such as potatoes, leading to volatile prices. This volatility, combined with the cost-of-living crisis and inflation, puts pressure on both manufacturers and consumers, highlighting the need for snack brands to balance product attributes with affordability.

Supporting the market growth, consumer habits are shifting from traditional meals to all-day snacking, with over two-thirds of consumers globally snacking at least once a day. This trend is intertwined with the health and wellness movement, driving demand for healthier snack options. According to GlobalData’s global consumer survey, 81% of the global population are concerned about their physical fitness and health.

To meet these challenges, snack brands are turning to complete processing line solutions that maximise output, ensure flexibility, minimise downtime, and reduce the total cost of ownership. Partnering with an end-to-end solution provider like TNA is crucial for optimising productivity across the entire production process, from receiving, destoning, washing, peeling, inspecting, slicing, blanching, dewatering, frying (continuous-/ vacuum-/batch-), de-oiling, sorting, distribution, seasoning, and even packaging.

Addressing ever-changing consumer preferences

As consumer preferences shift towards exciting flavours, snack producers must be flexible in catering to diverse tastes. International flavours, particularly Mexican and Asian, are gaining popularity globally, with churro, turmeric, and Korean BBQ standing out. Even as consumers seek more nutritious ingredients, they still desire enjoyable snacks. Mintel’s research indicates that 37% of snackers feel unique flavours make healthier snacks feel like a treat, highlighting the importance of balancing taste and health.

To meet these evolving demands, snack producers require flexible production lines capable of accommodating a wide range of products and flavours. TNA offers solutions that enable precise recipe control and quick changeovers. The tna intelli-flav^® OMS 5.1, the next-generation on-machine seasoning system, provides both powder flavouring and liquid oil in a single drum and delivers consistent coverage and flavour to a variety of products, including wet, dry and slurry applications. Features such as independent scarf feeders and separate tumble drums are essential to accommodating alternative product varieties on a single production line. Responsive variable mass controls and a dynamic vibratory weigher allow for accurate flavour and oil application, essential for maintaining product quality, minimising seasoning waste, and reducing costs.

tna intelli-flav OMS 5.1

The growing demand for better-for-you snacks with lower salt and fat content drives the industry towards more automated, recipe-driven approaches. The intelligent OMS 5.1 seasoning with integrated controls and monitoring ensures the precise application of ingredients, enhancing transparency and efficiency. Digitally enabled systems allow manufacturers to quickly adapt recipes and follow trends, seamlessly switching between healthier and standard products by simply selecting a pre-set recipe for each batch.

Creating healthier snacks with technology

Oil quality is crucial in the snacks sector for producing healthier, better-for-you products. Recent advancements in frying technologies, such as Continuous Vacuum Frying and Batch Frying, have made it possible to lower frying temperatures, resulting in snacks with improved health benefits and extended shelf life. For example, the tna conti-pro PC 3, a continuous chip frying system, lowers acrylamide formation and oil absorption, producing healthier, low-fat snacks with natural colour and texture.

Batch Frying, such as the tna batch-pro-12, equipped with a unique thermal fluid heating system, provides consistent frying conditions that ensure uniform product quality. The system’s rapid temperature recovery minimises the impact of product loading, maintaining optimal frying temperatures for evenly cooked products with consistent texture, colour, and taste. Additionally, the advanced oil filtration system extends the lifespan of the oil by removing contaminating particles, reducing overall costs, and improving product quality by lowering the risk of off-flavours or spoilage from old oil.

 

tna batch-pro-12

Beyond different frying technologies such as batch frying, vacuum frying or continuous frying, technologies such as pulsed electric field (PEF) are increasingly being introduced in medium to large size processing lines for savoury snacks. More accurate cutting, better cutting quality, increased blade lifespan, smoother chip surfaces, less breakage and feathering, better diffusion processes during blanching (if needed) and less oil absorption are the most important results of the PEF treatment of raw, whole potatoes when making chips. These innovations create healthier snacks while preserving the crispiness that consumers love, ensuring that the products remain both competitive and appealing.

Efficiency is king

With the snack market growing at 5.2% annually, and rising energy costs and financial pressures on consumers, efficient production processes are essential to stay competitive. For optimal productivity, partnering with an end-to-end solution provider like TNA, that is experienced in the entire production process, is crucial. A partner with expertise across the entire production line —from receiving to packaging — can help producers achieve the perfect balance between consumer satisfaction and profitability.

End-to-end solution providers have the capabilities and expertise to support customers from a project’s inception to its completion and beyond. An integrated setup not only streamlines the production process but also boosts efficiency and reduces the likelihood of errors or inconsistencies.

Choosing the right partner goes beyond selecting food processing equipment; it involves access to trend insights and expert knowledge across the production process. By investing in complete line solutions, snack producers can transform an initial idea into a complete eating experience that keeps consumers coming back for more.

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About TNA Solutions

TNA Solutions is a global leader in food processing and packaging solutions, committed to helping people succeed responsibly in a changing world. With over 40 years of experience, TNA’s global team of experts have installed more than 16,000 systems in over 130 countries. The company creates and sustains solutions that help customers realize goals and exceed their expectations, with performance, responsibility, and a customer-centric approach at the core of the business. A collaborative, consultative approach ensures measurable results and lasting success, with solutions designed to evolve and perform over time. As an inclusive partner, TNA supports a growth agenda that goes beyond business, emphasizing its commitment to people, prosperity and the planet in harmony. TNA is a powerful advocate of social justice, and aims to support children in disadvantaged communities through education, healthcare, and social enterprise programmes, through the humanitarian initiatives undertaken by the Nadia and Alf Taylor Foundation.

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Visit www.tnasolutions.com or contact tnateam@tnasolutions.com to learn more.

Top image caption: TNA Solutions Full Line for Potato Chips.