In the snack category, flexibility is the name of the game when it comes to processing. 

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'Innovation is key in the snack market, so snack makers need flexible equipment to make different varieties of snacks or even completely new products without the need for capital expenditures,' said José Coelho, president, Clextral USA. 'Extruders offer this flexibility, combined with versatility to run different products on the same production line, giving processors the ability to make new products or line extensions, and quickly scale to full production.'

This is especially true for smaller snack manufacturers, who are often those working with the latest, trendiest ingredients and developing new product lines all the time hoping to break through the noise of mainstream producers. 

'We see lots of activity with smaller producers who want to expand their product lines,' said John McIsaac, vice president of strategic business development, Reiser. 'Our challenge is to make their machinery multipurpose. The same machine that forms and portions a high protein cookie must also be able to produce bars or fill tubs. Bakers can add our new tunnel rounders to also produce bite-size balls of product.'

The flexibility of twin-screw extruders make them well-suited for direct expanded snacks made with alternative ingredients, Mike Shaw, sales account manager, snacks/cereals, Bühler Inc., noted, especially as those products begin to overlap into new formats as well. 

'The market trend to create hybrid products between snacks and crackers is also well-suited for the extrusion platform due to the wide range of possible process parameter adjustments and ancillary set-up,' he said. 'The screw pushout device on Bühler twin-screw extruders ensures that changeover from shutdowns is as fast as possible.'

When it comes to using the latest ingredients, much of the flexibility that aids innovation also addresses some of the challenges that come with alternative bases. Extruders designed with flexibility have the capability to offer a precise level of control over parameters. 

'When working with different raw materials and blends, you need equipment with the ability to generate the precise level of thermo-mechanical cooking to achieve the desired snack structure and product density,' Mr. Coehlo said. 'These two elements are linked as they dictate the mouthfeel and crunchiness level. ' The twin-screw extruder is a very versatile processing tool with almost unlimited parameter adjustments, and we rely on our expertise to find the right combination to reach our customers' product goals.'

Christian Hüttner, process engineer, food extrusion, Coperion GmbH, pointed out, alternative snack ingredients require different levels of mechanical energy and screw speeds in order to process through the extruder correctly. Being able to adjust to those needs quickly is critical for snack manufacturers to extrude a snack piece that will be the proper weight and texture. Coperion's ZSK Mv Plus Food Extruder can incorporate different capabilities to adapt. 

'The addition of steam directly into the extruder's process section as well as the possibility of high screw speeds allows the extruder to produce all the necessary energy so that no preconditioner is needed,' he said. 'Intensive degassing possibilities help get rid of excess moisture so that even raw materials with a high moisture content can be processed.' 

The ZSK Food Extruder can be individually configured to meet a snack's processing challenges due to its modular design and the combination of free-screw volume, screw speed and torque, Ms. Hüttner explained. 

In addition to adjusting to a snack's different processing parameters, the machine itself needs to be able to swap out tooling, pre-feeders and other accessories quickly and easily to enable flexible processing. 

'Coperion equips the ZSK Food Extruder with numerous features that speed up changeovers of recipes and ingredients,' Mr. Hüttner said. 'Feed hoppers, degassing domes and atmospheric ventings are equipped with quick-release clamps.'

Even a co-extruder with its added complexity needs to be able to make a quick change. Rheon designed its co-extruders to feature five main assemblies that can be added or removed from the machine in just a few minutes. 

'These assemblies are the only parts of the machine that come in contact with the food product, so cleaning of the main machine body is not necessary during a changeover,' said John Giacoio, vice president, sales and marketing, Rheon USA. 'These assemblies need to be washed and reassembled, but we can also offer duplicate assemblies that can be used on the machine while the other parts are being cleaned.' 

When it comes to innovating new products, Handtmann features real-time 3D shape design through its control panel. This feature allows snack manufacturers to set and test shapes immediately and then quickly change and test the next iteration. The Handtmann VF can quickly change configurations for different lanes and attachments as well as a variety of dough viscosities. 

'The flexibility and rapid set up of Handtmann coextrusion solutions also offers new product development opportunities that allow simplified R&D and high-volume production with very accurate outer and inner coextruded weights that dramatically reduce giveaway,' explained Paul W. Hill, national bakery sales manager, Handtmann Canada. 

Reiser aims to design its changeovers to be as tool-less as possible, and for those smaller manufacturers, they've added an XY Table so operators can automatically load pans full of product with the click of a footswitch. 

Nico Roesler, North American pretzel and snack equipment sales manager, Reading Bakery Systems (RBS), noted that RBS's low-pressure extruder has historically been one of the company's most dynamic pieces of equipment. 

'Whether it's gluten-free or wheat-based, it's the same general process,' he said. 'Its flexible design features tool-free disassembly and the die and compression head are easily removeable.'

Flexibility doesn't end after processing. The seasoning side of production often needs to be the most flexible of all, with new flavors providing the fastest way for snack manufacturers to add new products. For seasoning systems, cross-contamination is one of the biggest challenges during changeovers.

'Additional time is generally added to clean the line and reduce the chances of these occurrences,' said Josh Hughes, group marketing coordinator, Burford Corp. 

Burford designed its FD Sanitary Duster to be easily disassembled and cleaned to reduce the risk of cross-contamination. The hopper's back plate, agitating and dispensing mechanisms as well as other components have all been designed with tool-less removal for efficiency. 

To prevent cross-contamination, TNA designed its intelli-flav OMS 5.1 to meet IP65 (NEMA4) specifications for wet washdown environments. That means its hygienic design includes smooth food-grade stainless steel surfaces and specialized welded joints. The flavor kit is also designed for tool-less changeovers and the machine features a lightweight drum. 

'These advancements in seasoning equipment streamline the changeover process, enabling snack manufacturers to respond swiftly to consumer trends and demands,' said Elwyn Cope, group solution specialist, seasoning and spraying, TNA solutions. 'With efficient changeovers, manufacturers can keep up with market demands, reduce downtime and optimize production efficiency while ensuring consistent and even seasoning of their products.'

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On-machine seasoning (OMS) systems, Blake Svejkovsky, general manager, product handling systems, Heat and Control, pointed out, can offer flexibility in that they do not require the entire processing line to be turned off or even throttled back during flavor changes. This keeps production moving on the same base if only changing flavor profile. OMS systems once were limited to certain products, but that's no longer the case. 

'In the past, OMS was only applicable for certain products because of issues with seasoning quality,' Mr. Svejkovsky said. 'With the latest technology improvements incorporated into the FastBack Revolution Seasoning Systems' OMS, such as AccuFlavor tumble drums, performance auto feed adjust, dynamic tumbling action and totally automated seasoning control, the seasoning quality of OMS is equal to or better than traditional systems. Now both corn- and potato-based snacks, along with other snack products are candidates for OMS.'

With innovation back and consumers seeking snacks to satisfy their every need, snack manufacturers are searching for equipment to overcome their every challenge. With flexibility and control at the forefront of equipment design, they may find just what they're looking for from equipment suppliers.

This article is an excerpt from the August issue of Baking & Snack. To read the entire feature on Snack Processing, click here.     

What Are the Characteristics of Puffed Food Extruder?

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Puff snacks extruders are an essential piece of machinery in the snack food industry, used to produce a wide variety of puff snacks such as chips, crackers, and cereals. These snacks are made by heating and pressurizing a dough or batter mixture until it expands and puffs up, creating a light and airy texture. Puff snack extruders are highly efficient and can produce large quantities of snacks in a short amount of time. In this article, we will take a closer look at how puff snack extruders work and the various types available on the market.

Puff snack extruders consist of several key components, including a feeding system, an extrusion barrel, and a shaping die. The feeding system is used to introduce the dough or batter mixture into the extrusion barrel, which is typically heated to a high temperature to help the mixture expand and puff up. The extrusion barrel is equipped with a series of screws that rotate and mix the dough or batter as it is pushed through the barrel. The shaping die is a metal mold with a specific shape that determines the final shape of the snack.

There are two main types of puff snack extruders: single-screw and twin-screw. Single-screw extruders are the most common type and are used for producing a wide variety of puff snacks. They consist of a single screw that rotates and mixes the dough or batter as it is pushed through the extrusion barrel. Twin-screw extruders, on the other hand, have two screws that rotate in opposite directions and are typically used for producing more complex snack shapes or for incorporating multiple ingredients into the dough or batter mixture.

Puff snack extruders can be used to produce a wide variety of puff snacks, including chips, crackers, and cereals. Chips are made by extruding a dough or batter mixture through a shaping die with a thin, flat shape. Crackers are similar to chips but are typically made with a harder dough or batter mixture and have a more rigid texture. Cereals are made by extruding a dough or batter mixture through a shaping die with a small, round shape and are often flavored and sweetened.

One of the main advantages of using a puff snack extruder is the high level of efficiency and consistency it offers. These machines can produce large quantities of snacks in a short amount of time and can be programmed to produce snacks with very specific shapes and sizes. Additionally, puff snack extruders are highly versatile and can be used to produce a wide variety of snack flavors and textures by simply changing the ingredients in the dough or batter mixture.

In conclusion, puff snack extruders are an essential piece of machinery in the snack food industry, used to produce a wide variety of puff snacks such as chips, crackers, and cereals. These machines are highly efficient and offer a high level of consistency, and can be used to produce a wide variety of flavors and textures by simply changing the ingredients in the dough or batter mixture.

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