Food Beverages And Hospitality October 2018
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boost the shelf life of expanded snacks. Puffing<br />
these pellets into so-called “third-generation” (or<br />
3-G) snacks closer to the time and place of<br />
consumption — whether via hot air, frying or<br />
microwaving— helps ensure longer-lasting<br />
freshness.<br />
“A pellet is shelf-stable for up to a year in its 'raw' or<br />
unexpanded form,” states J.R. Short Milling Co., a<br />
Kankakee, Ill.-based pellet supplier, on its website<br />
(www.shortmail.com). “Pellets offer unique<br />
economies in shipping because until they are<br />
expanded, you are not shipping or storing air.”<br />
A number of snack food processors address shelf<br />
stability through packaging technology. Denverbased<br />
Oogie's Snacks, a manufacturer of branded<br />
and private label better-for-you popcorn, uses<br />
nitrogen flushing and particularly strong seals on<br />
its packaging to maximize shelf life.<br />
“Nitrogen fits in with our healthy, natural focus,”<br />
says Eric Thier, the company's president, who<br />
emphasizes that that the packaging Oogie's uses<br />
has barriers that are “the highest in the industry.”<br />
Herr <strong>Food</strong>s for some time has been using<br />
metalized film for many of its snack products<br />
(including all of its potato chips), not just those<br />
that that tout simple and natural ingredients, adds<br />
Clark. The foil-like bags help retain nutrients as<br />
well as freshness and crispness.<br />
Becoming certifiable<br />
Because many consumers of clean label snacks<br />
expect them to be free of gluten and genetically<br />
modified ingredients — and because more and<br />
more people today actually do suffer from food<br />
allergies, intolerances and sensitivities —<br />
manufacturers increasingly are jumping through<br />
extra hoops to obtain certifications that exceed<br />
federal and state regulations.<br />
For example, when products are certified by the<br />
Gluten-Free Certification Organization (GFCO),<br />
thereby ensuring that they are safe for individuals<br />
with celiac disease or gluten intolerance,<br />
manufacturers must take specific steps to prevent<br />
contamination. These protocols include adhering<br />
to equipment-cleaning schedules, documenting<br />
that they are followed, and validating their<br />
effectiveness with gluten-specific or proteinspecific<br />
swab tests performed at multiple locations<br />
after cleaning.<br />
“Even in facilities that are dedicated to gluten-free<br />
p r o d u c t i o n , p r o t o c o l s f o r p r e v e n t i n g<br />
contamination of the facility must be in place,<br />
including supplier vetting and control of what<br />
employees can bring into the plant,” says Laura<br />
Allred, regulatory and standards manager for the<br />
Gluten Intolerance Group (GIG), GFCO's parent<br />
organization. Among other requirements, the<br />
GFCO Standard mandates that all staff be trained<br />
on gluten risks and that employee hygiene<br />
protocols be implemented.<br />
“Gluten-free products can have different textures<br />
and consistencies that need to be accounted for<br />
both in production and packaging,” Allred adds.<br />
“While a processor may be able to use the same<br />
equipment for processes like shape molding,<br />
cutting or packaging, they may find that these<br />
processes need to be done under different<br />
conditions than they use for gluten-containing<br />
products.”<br />
Bright outlook<br />
Through more efficient operations, manufacturers<br />
can offset some of the added costs of free-from<br />
snack production.<br />
“There are lots of ways processes can be<br />
streamlined at every stage of the production line,”<br />
Johnson maintains. “For example, in many snack<br />
lines, seasoning can be more expensive than the<br />
actual base product, so reducing waste at this stage<br />
can make a huge difference to overall profitability.<br />
In fact, reducing the amount of giveaway through<br />
over-seasoning by only 1 percent can reduce the<br />
cost per bag by up to 10 percent.”<br />
In addition, technology that captures energy<br />
released by one process to fuel another offers<br />
further potential for savings, Johnson says. For<br />
example, one solution developed by TNA recovers<br />
energy from a fryer.<br />
“The hot exhaust gases and steam from the fryer<br />
are transferred through a heat exchanger that will<br />
produce warm or hot water (between 130° and 194°<br />
F),” Johnson explains. “This can then be used for<br />
other processes like hot washing.”<br />
Clark, for one, remains enthusiastic about the<br />
market potential of clean label snacks such as Herr<br />
<strong>Food</strong>s' Good Natured Selects brand. “We want to<br />
follow where the consumer wants to go, so we do<br />
see it as an opportunity,”<br />
www.kingsinfomedia.com<br />
<strong>October</strong> - <strong>2018</strong><br />
Focus <strong>Food</strong> <strong>Beverages</strong> & <strong>Hospitality</strong><br />
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