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34 MACHINERY UPDATE JANUARY/FEBRUARY 2015 www.machineryupdate.co.uk Feature: Snacks Processing new snacks for future Machinery Update looks at the latest processing equipment available that offers value added options to NPD projects Baker Perkins has developed a new 16-stream die to increase the output capability of its co-extrusion systems for snacks containing two components – a cereal outer and a centre filling. At the same time, the company notes that high-protein snacks are an emerging niche sector into which companies can easily move with an existing twin-screw extrusion line. These Co-Ex Master systems provide a wide choice of outputs with die sizes now ranging from four to 16 streams – the previous maximum was 12. The systems also include a cream feeder which supplies the die and a pillowcrimper where the product stream from the die is cut to length and sealed. In operation, fillings with contrasting tastes and textures are incorporated into a cereal tube emerging from a twinscrew extruder. This tube is formed into individual pillows, tubes, bars or wafers to create high added value products in sizes ranging from small bite-size up to larger sticks. Fillings can be of virtually any colour or flavour –savoury creams and cheese are typical, and new snacks can be developed using different flavours in the filling and coating. In addition to familiar, conventional flavours, Asian, Middle Eastern and Hispanic tastes are increasingly popular, explains Keith Graham of Baker Perkins. Chilli, paprika, teriyaki, guacamole, sweet and sour, black bean sauce and a wide family of curries can be used individually or in combination to produce snacks with high consumer appeal. In terms of new product development, high-protein snacks are an emerging niche sector and extruded snacks can be quickly re-formulated to add a highprotein element, creating a profitable new line to widen the appeal of an existing range. “For newcomers to the snacks sector, this is an innovative route to market,” says Graham. PROTEIN MARKET EXPANSION The protein market is moving rapidly beyond body building into the mainstream to meet a variety of needs, including balancing diet and weight loss. A high-protein extruded snack typically involves the addition of proteins such as whey or soy in powdered form to an existing formula. Whole grain or multigrain formats could also be chosen to make a positive contribution to the nutritional profile, and strengthen the ‘feel good’ factor. SUMMARY PROCESS TRENDS ■ ■ Two component variants ■ ■ Cereal outer and a centre filling ■ ■ High-protein an emerging sector ■ ■ Root vegetable colour matching ■ ■ Gentle handling of healthier options These processes can be verified as commercially viable in the Baker Perkins Innovation Centre in Peterborough. This Centre allows Baker Perkins to support customers from initial concept development through to maximising performance of installed plant. Development and pilot scale equipment is available to create new products and processes, produce samples for evaluation, conduct feasibility trials and train staff. At the same time, the company has launched a colour-change system for packs of assorted extruded snacks that allows changeover between colour variations of extruded product to be made ‘on the run’ with minimal waste. This
www.machineryupdate.co.uk JANUARY/FEBRUARY 2015 MACHINERY UPDATE 35 Feature: Name here The hot oil batch-pro 12 series from Foodesign This system has been installed for cashews The SBX Master extruder from Baker Perkins provides a wide choice of outputs system can match the colour of vegetableflavoured snacks such as carrot, beetroot, tomato, broccoli or peas in a single pack. Also suitable for root and other vegetable products such as potato, carrot, beetroot and parsnip crisps is the automated hot oil batch-pro 12 series of cookers and fryers from tna company Foodesign. With heat capacities ranging from 90 to 272kg per hour, this batch fryer optimises output while offering reliable performance. Foodesign says this system delivers both <strong>efficiency</strong> and sustainability for the processing of root vegetable products. Coupled with the machine’s high <strong>efficiency</strong> burner design, production can be increased while consistency maintained. For example, a batch-pro 12 system allows batch-by-batch cooking of thicker potato slices for higher quality, crunchier crisps. Precise temperature profiling systems and quick heat recovery capabilities safeguard consistency in both flavour and colour in every batch. The system has been designed with waste reduction in mind. A continuous oil filtration system helps remove both fine and large particles while during cooking, potato slices take on only 23% of the oil. The remaining 77% of oil is subsequently filtered out and blended with fresh oil to return levels to 100%. Alongside this continuous oil circulation system, full temperature control is also maintained through constant and zone control systems, offering ultimate heat regulation in the cooking and frying process. Extruded snacks can be quickly reformulated to add a high-protein element, creating a new line Meanwhile, growing interest in the healthy snack foods market has led to the installation of a Revtech unit in the UK by Holmach for the processing of ready to eat cashew nuts for the health food and bakery aisles. This follows two machines being installed in Japan for puffing rice and barley for use in snack foods and the recent accreditation of Revtech’s proof of process for a five log reduction on microbial populations by the California Almond Board. Using special patented spiral vibratory technology, Revtech’s units pasteurise and toast & roast grains, cereals, seeds or nuts and are able to process from 300 to 13,000kgs per hour. Decontamination is achieved using the Joule effect, comprising a combination of dry radiant heat with a steam cycle to sterilise the product. Food is handled gently during treatment to allow nuts such as brazils, almonds and walnuts to be processed without chipping or any damage to their final appearance. Not using steam to heat during the first stage of the cycle ensures that the essential oils of the raw foodstuffs are not stripped, reducing the risk of rancidity, and that its moisture content is controlled. Only once the product is at temperature does the steam cycle of the process begin, allowing the natural defences of nuts and seeds to be preserved, thus retaining an extended shelf life. Homogenous treatment of foodstuffs is integral to the process, with the option to toast & roast dry ingredients to EBC levels as high as 1500 without the risk of fire. Crucially, the product is discharged cool and ready for immediate packing. W www.bakerperkins.com W www.foodesign.com W www.holmach.co.uk
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