Baking & Snack - February 2020 - 94

SNACK PROCESSING

ADDING PROCESS DEVELOPMENT
TO A WINNING R&D FORMULA

Snack producers are taking a more holistic approach
to creating new products, and it's paying off in profits.
"From experimenting with new ingredients to developing groundbreaking processing technologies, innovation
is extensive," noted Shayne De la Force, chief marketing
officer, TNA Solutions. "As such, there is a real need and
place for creativity in our industry."
Specifically, he pointed to the advancement of preprocessing technologies, including blanching that
enhances the structural quality and the nutritional
value of snacks.
New product collaboration now involves pooling
resources. Reading Bakery Systems' (RBS) Science &
Innovation Center allows customers to test new product
shapes, formulas and processes on a continuous pilot
line. "The knowledge gained there is very scalable to
a full production line," said Ken Zvoncheck, director of
process technology, RBS. "This process both reduces the
cost of product development as well as speeds up development from benchtop to production."
Food technologists in Bühler Group's Richmond, VA,
innovation center and at its European ones in Vienna,
Copenhagen and in The Netherlands push the envelope
to invigorate innovation in the global snack market, noted
Patrick Lamprecht, global business development manager, Bühler Group. "These centers allow us to create a
wide variety of traditional snacks as well as better-for-you
ones," he said. "Each can create different products with
various textures and different fillings."
Handtmann engages its equipment application specialists with a bakery's product developers to refine recipes
along with new processes to meet product goals, operational demands and business needs, noted Cesar Zelaya,
the company's bakery sales and technology manager.
Meanwhile, Clextral USA's pilot facility in Tampa, FL, is
equipped with a twin-screw extruder and other equipment for initiating product creation. "We work with snack
processors to optimize their equipment and processes,
to produce conventional and BFY snacks on the same
extruder, making entirely different products with different
formulations without an additional capital investment,"
said Julie Prost, process engineer and pilot plant manager, Clextral USA.
Heat and Control's 10 centers worldwide assist in streamlining operational and new product specification issues,
and they provide factory acceptance testing for equipment
prior to its delivery, said Lucas Bell, general manager of
Spray Dynamics, a Heat and Control product brand.

94 Baking & Snack February 2020 / www.bakingbusiness.com

Automated Seasoning Control (TASC), which performs
real-time adjustments to seasoning flow rates based on
mass-flow data from the company's Ishida weigher dispersion cone. "With TASC, seasoning coverage is collected in real time and used automatically to make adjustments while product is currently in-flight instead
of hours or shifts later," said Blake Svejkovsky, general
manager, product handling systems, Heat and Control.
The company is also working on an improved dry seasoning applicator that will be gravimetrically controlled
and deter even the toughest seasonings from bridging
in the hopper, according to Lucas Bell, general manager,
Spray Dynamics, a Heat and Control product brand.
Heat and Control is also pursuing advancement of its
pulsating and continuous liquid application systems to apply the precise amount of liquid. "We are constantly looking for ways to improve our existing product offerings, as
well as pushing the boundaries and developing innovative
liquid and dry seasoning applicators," Mr. Bell said.
Capable of handling wet and dry seasonings in a
single drum, TNA's intelli-flav OMS 5.1 incorporates
technologies such as a variable mass seasoning system,
an optional high-capacity stainless-steel drum, a heated
oil circulation system and an integrated bulk powder fill
technology system to season hot or cold snacks.
Mr. De la Force noted that the company's on-machine
seasoning (OMS) system allows one production line to
feed several OMS systems, meaning that multiple flavors
can be applied at any one time. He added the systems can
be cleaned for changeovers without stopping production.
Overall, more advanced equipment may be needed
when seasoning or spraying BFY products that carry
health or nutrition claims, suggested Norm Searle, sales
and marketing, GOE/Amherst Stainless Fabrication. "To
meet labeling requirements, the system must accurately
deliver the specified amount to each product regardless
of its location or speed of the conveyor," he said. "Both
a BFY and conventional snack will be sprayed using the
same system, but one possibly being more automated
than the other. The more automated the system, the less
likely you are to produce an inferior product."
That's because a more automated system requires less
operator intervention, ensures setpoints are maintained
and alarms when not. In addition, records are maintained documenting all activity. Mr. Searle added automated cleaning and sanitizing minimizes the chance of
timing, temperature and valve-motor sequencing issues
on spraying systems.

FYI on BFY
By diversifying their product portfolios, snack producers face the conundrum that comes with adding complexity to their operations. "Some technology options


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Baking & Snack - February 2020

Table of Contents for the Digital Edition of Baking & Snack - February 2020

Baking & Snack - February 2020
Contents
Editorial - What can bread learn from the little black dress?
Newsfront
People/In Brief
2020 Baking Hall of Fame - The history makers
2020 BAKING HALL OF FAME - The teacher
2020 BAKING HALL OF FAME - The engineer
2020 BAKING HALL OF FAME - The architect
2020 BAKING HALL OF FAME - The helper
Industry Confi dence Survey - Weathering the storm
Kwik Trip - Land of opportunity
Donuts - A hole in one
Health and wellness - Impacting consumer health
Protein - Blend for balance
Probiotics - Good for the gut
Snack processing - Story of the decade
Pan glazing - Life in the fast lane
Depositing - Bull's-eye
Production management - ERP software 101
Trays & baskets - Stacked for food safety
Meeting preview: ABA - A gold mine of information
Events
Innovations - Contents
Featured innovation center
Ingredients & formulating
Equipment & packaging
Patents
New on the shelf
Marketplace
Ad index
New product spotlight
Baking & Snack - February 2020 - Baking & Snack - February 2020
Baking & Snack - February 2020 - Baking & Snack - February 2020
Baking & Snack - February 2020 - 2
Baking & Snack - February 2020 - 3
Baking & Snack - February 2020 - 4
Baking & Snack - February 2020 - 5
Baking & Snack - February 2020 - 6
Baking & Snack - February 2020 - Contents
Baking & Snack - February 2020 - 8
Baking & Snack - February 2020 - 9
Baking & Snack - February 2020 - Editorial - What can bread learn from the little black dress?
Baking & Snack - February 2020 - 11
Baking & Snack - February 2020 - 12
Baking & Snack - February 2020 - 13
Baking & Snack - February 2020 - Newsfront
Baking & Snack - February 2020 - 15
Baking & Snack - February 2020 - People/In Brief
Baking & Snack - February 2020 - 17
Baking & Snack - February 2020 - 18
Baking & Snack - February 2020 - 19
Baking & Snack - February 2020 - 20
Baking & Snack - February 2020 - 2020 Baking Hall of Fame - The history makers
Baking & Snack - February 2020 - 2020 BAKING HALL OF FAME - The teacher
Baking & Snack - February 2020 - 23
Baking & Snack - February 2020 - 2020 BAKING HALL OF FAME - The engineer
Baking & Snack - February 2020 - 25
Baking & Snack - February 2020 - 26
Baking & Snack - February 2020 - 2020 BAKING HALL OF FAME - The architect
Baking & Snack - February 2020 - 28
Baking & Snack - February 2020 - 2020 BAKING HALL OF FAME - The helper
Baking & Snack - February 2020 - 30
Baking & Snack - February 2020 - Industry Confi dence Survey - Weathering the storm
Baking & Snack - February 2020 - 32
Baking & Snack - February 2020 - 33
Baking & Snack - February 2020 - 34
Baking & Snack - February 2020 - 35
Baking & Snack - February 2020 - 36
Baking & Snack - February 2020 - 37
Baking & Snack - February 2020 - Kwik Trip - Land of opportunity
Baking & Snack - February 2020 - 39
Baking & Snack - February 2020 - 41
Baking & Snack - February 2020 - 40
Baking & Snack - February 2020 - 42
Baking & Snack - February 2020 - 43
Baking & Snack - February 2020 - 44
Baking & Snack - February 2020 - 45
Baking & Snack - February 2020 - 46
Baking & Snack - February 2020 - 47
Baking & Snack - February 2020 - 48
Baking & Snack - February 2020 - 49
Baking & Snack - February 2020 - 50
Baking & Snack - February 2020 - 51
Baking & Snack - February 2020 - 52
Baking & Snack - February 2020 - 53
Baking & Snack - February 2020 - Donuts - A hole in one
Baking & Snack - February 2020 - 55
Baking & Snack - February 2020 - 56
Baking & Snack - February 2020 - 57
Baking & Snack - February 2020 - 58
Baking & Snack - February 2020 - 59
Baking & Snack - February 2020 - 60
Baking & Snack - February 2020 - 61
Baking & Snack - February 2020 - 62
Baking & Snack - February 2020 - 63
Baking & Snack - February 2020 - 64
Baking & Snack - February 2020 - Health and wellness - Impacting consumer health
Baking & Snack - February 2020 - 66
Baking & Snack - February 2020 - 67
Baking & Snack - February 2020 - 68
Baking & Snack - February 2020 - 69
Baking & Snack - February 2020 - 70
Baking & Snack - February 2020 - Protein - Blend for balance
Baking & Snack - February 2020 - 72
Baking & Snack - February 2020 - 73
Baking & Snack - February 2020 - 74
Baking & Snack - February 2020 - 75
Baking & Snack - February 2020 - 76
Baking & Snack - February 2020 - 77
Baking & Snack - February 2020 - 78
Baking & Snack - February 2020 - 79
Baking & Snack - February 2020 - 80
Baking & Snack - February 2020 - Probiotics - Good for the gut
Baking & Snack - February 2020 - 82
Baking & Snack - February 2020 - 83
Baking & Snack - February 2020 - 84
Baking & Snack - February 2020 - 85
Baking & Snack - February 2020 - 86
Baking & Snack - February 2020 - 87
Baking & Snack - February 2020 - 88
Baking & Snack - February 2020 - Snack processing - Story of the decade
Baking & Snack - February 2020 - 90
Baking & Snack - February 2020 - 91
Baking & Snack - February 2020 - 92
Baking & Snack - February 2020 - 93
Baking & Snack - February 2020 - 94
Baking & Snack - February 2020 - 95
Baking & Snack - February 2020 - 96
Baking & Snack - February 2020 - 97
Baking & Snack - February 2020 - 98
Baking & Snack - February 2020 - Pan glazing - Life in the fast lane
Baking & Snack - February 2020 - 100
Baking & Snack - February 2020 - 101
Baking & Snack - February 2020 - 102
Baking & Snack - February 2020 - 103
Baking & Snack - February 2020 - 104
Baking & Snack - February 2020 - 105
Baking & Snack - February 2020 - 106
Baking & Snack - February 2020 - Depositing - Bull's-eye
Baking & Snack - February 2020 - 108
Baking & Snack - February 2020 - 109
Baking & Snack - February 2020 - 110
Baking & Snack - February 2020 - 111
Baking & Snack - February 2020 - 112
Baking & Snack - February 2020 - 113
Baking & Snack - February 2020 - 114
Baking & Snack - February 2020 - Production management - ERP software 101
Baking & Snack - February 2020 - 116
Baking & Snack - February 2020 - 117
Baking & Snack - February 2020 - 118
Baking & Snack - February 2020 - 119
Baking & Snack - February 2020 - 120
Baking & Snack - February 2020 - 121
Baking & Snack - February 2020 - 122
Baking & Snack - February 2020 - Trays & baskets - Stacked for food safety
Baking & Snack - February 2020 - 124
Baking & Snack - February 2020 - 125
Baking & Snack - February 2020 - 126
Baking & Snack - February 2020 - 127
Baking & Snack - February 2020 - 128
Baking & Snack - February 2020 - Meeting preview: ABA - A gold mine of information
Baking & Snack - February 2020 - Events
Baking & Snack - February 2020 - 131
Baking & Snack - February 2020 - 132
Baking & Snack - February 2020 - Innovations - Contents
Baking & Snack - February 2020 - Featured innovation center
Baking & Snack - February 2020 - 135
Baking & Snack - February 2020 - 136
Baking & Snack - February 2020 - Ingredients & formulating
Baking & Snack - February 2020 - 138
Baking & Snack - February 2020 - 139
Baking & Snack - February 2020 - Equipment & packaging
Baking & Snack - February 2020 - 141
Baking & Snack - February 2020 - 142
Baking & Snack - February 2020 - 143
Baking & Snack - February 2020 - 144
Baking & Snack - February 2020 - 145
Baking & Snack - February 2020 - 146
Baking & Snack - February 2020 - 147
Baking & Snack - February 2020 - Patents
Baking & Snack - February 2020 - 149
Baking & Snack - February 2020 - New on the shelf
Baking & Snack - February 2020 - 151
Baking & Snack - February 2020 - Marketplace
Baking & Snack - February 2020 - 153
Baking & Snack - February 2020 - 154
Baking & Snack - February 2020 - 155
Baking & Snack - February 2020 - 156
Baking & Snack - February 2020 - 157
Baking & Snack - February 2020 - 158
Baking & Snack - February 2020 - 159
Baking & Snack - February 2020 - 160
Baking & Snack - February 2020 - Ad index
Baking & Snack - February 2020 - New product spotlight
Baking & Snack - February 2020 - 163
Baking & Snack - February 2020 - 164
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