FLAVOUR APPLICATION SYSTEMS Doug Hanify Spray Dynamics Ltd.
Flavour application systems Seasoning systems most commonly used in savoury snacks: Conveyor based dusting system (typically salt) Drum based single-stage dry flavour application Drum based two-stage oil and dry flavour application Drum based slurry (may have dry) Flavour and especially colour may be added to the base formulation Frying or drying temperatures may change flavour profile Colour added to base can help with sight appeal Flavour application systems The key to great seasoning coverage is consistent flow with process control. Oil flavour addition Coating drum Product feeding Dry flavour addition What is the right system? Dry only systems are used on products that have natural tack Fried potato chips and crisp Fried pellet snacks Oil and dry systems are used on snacks that do not have natural tack Tortilla chips Corn chips Mini rice cakes or other dry puffed products Popcorn Baked chips and crisp Extruded snacks Slurries Extruded snacks Popcorn Puffed snacks
What is the right layout for your product? In-kitchen seasoning systems Large capacity Minimal flavour changes Two stage or slurry systems On-machine seasoning systems One stage coating Many flavour changes Belt coating systems Used primarily for salt only application Single stage dry seasoning In-kitchen seasoning systems On-machine seasoning systems Belt coating systems In-kitchen or process seasoning systems Large coating drum Seasoning metering device Seasoning spreader device
In-kitchen or process seasoning systems In kitchen seasoning systems are ideal for core products on process lines that change flavours once a shift or less Can have custom design Normally wash down design Great for high volume products These systems are designed for continuous product flow PPM Technologies high volume dry ingredient applicator In-kitchen or process seasoning systems Ideal for large production lines that have a few flavour changes Most consistent seasoning System can be rolled in and out of the line Typically less expensive Cleaning time between flavour changes can be long Must also clean conveyer to packaging Line must be stopped for sanitation KMG seasoning system On-machine seasoning systems (OMS) On-machine seasoning is seasoning application at the weigher (sometimes referred to as on head) Pre-assembled and mounted to a platform prior to shipping Quickly set in place and connected to utilities at the plant so production can begin without delays Ease of operation, sanitation, cleaning and simple to use New designs providing excellent coverage Heat and Control on-machine seasoning system
On-machine seasoning systems (OMS) Allow to run different flavour on each bagger Flyers continue to run during flavour change-overs Multiple flavours at one time which leads to smaller warehousing requirements Higher packaging equipment efficiency Can provide better seasoning coverage depending on product and equipment On-machine seasoning systems (OMS) Requires more space in packaging Product fluctuation (gate, film change) Throughput variation (big bag, small bag) More expensive investment depending on sophistication of equipment requested Possible allergen concerns Seasoning coverage may be different from in kitchen On-machine seasoning systems (OMS) Heat and Control Revolution Onmachine seasoning system Applies seasonings to snacks just before they enter the weigher to increase production versatility. TNA intell-flav OMS 5 Provides both powder flavouring and liquid oil in a single drum to deliver consistent coverage and flavour to your product
In-kitchen versus OMS seasoning Kitchen seasoning 5 seasonings are produced each week Each seasoning takes a day to produce Product with first four flavours must be stored until Friday On machine seasoning 5 seasonings are produced each day First afternoon the first truck is able to be loaded A saving of 4 days of shelf life A saving of warehouse space Key parameters to consider when selecting a drum based system Drum flight design Flights designed for product shape and density/volume Even turning product bed - No pulsing unless desired for breaking up clumps - Retention in coating zone (4 or more turns) Drum diameter and length Length is based on number of coating zone and length of coating zone Slurries can have soak time and use spirals in addition to flights Diameter is based on volume - Bed less than 18% fill - Weight of bed Dust-on / over the belt (Typically used for salt only) Inexpensive Small footprint Simple to use One sided coverage Process control is difficult Spray Dynamics metermaster salt applicator Dispenses powdered and granulated salt over-product on a moving belt with consistent and repeatable accuracy
Two stage seasoning - both oil and dry flavour When the natural or process induced tack is not present on the product to be flavoured, oil is sprayed on prior to adding the dry flavour Temperature of the product is very important to how much oil stays on the surface Dry flavour coverage is totally dependant on oil coverage Complete in kitchen system Oil applied in kitchen and dry flavour applied on the head Both oil and dry flavour applied on the head Two stage seasoning in-kitchen All in one package Handles large volumes Flexible placement if temperature is critical Best choice for high absorption products Long flavour change overs Line must be stopped for cleaning Two stage seasoning oil in-kitchen dry flavour on head Short dry flavour changes Oil spraying confined to the kitchen area Allows for time adjustments between oil and dry More flavours can be produced at one time May not work well for low fat or high absorption products More expensive to implement (floor space and cost)
Two stage seasoning oil and dry flavour on head (OMS) Short flavour changes Works well with low fat and high absorption products More flavours can be produced at one time New concept for production Potential oil mist in packaging area More expensive to implement (floor space and cost) Coating zones are limited Application systems dry dust applicators There are various types of dry flavour applicators that can be used for applying seasoning to snack products: piccolo tube dispensers Scarf plate dispenser / powder feeders Electrostatic systems Applications systems piccolo tube dispensers The piccolo tube dry spice dispenser has been used since the 1970s Screw feeder has long conveying tube The conveying tube has slots cut in the spreading (dispensing section) An outer tube with slots is used to adjust the dispensing opening
Application systems piccolo tube dispensers Fits in small openings Medium cost option Dispensing holes plug Must adjust tube and motor speed to change rates Application systems scarf plate feeder/spreader Bias cut on a vibratory or horizontal motion conveyor Screw feeder is used to feed the spice at the desired rate Spray Dynamics Scarf plate distributor PPM Technologies Scarf plate dispenser + powder feeder Application systems scarf plate feeder Easy to operate Easy to clean Can work with most products Creates a very consistent curtain Bulky, need large coating drum opening Powders may stick to the surface (flavour bombs) Cost KMG Heat and Control Fastback Excalibur
Application systems electrostatic application The technique works by applying a static charge to the powder, oil or slurry as it is being sprayed onto the base product As the flavourings and coatings become negatively charged, and repel each other making a nice curtain or spread of seasoning Application systems electrostatic application Reduction in dry powder usage Even coverage Cleaner working environment Must use a stainless steel coating drum that is well grounded Complexity Cost Practical considerations for dry seasoning applicator Humidity All types of spreading devices are susceptible to humidity A scarf spreader with a cover seems to work the best in these conditions Keep flavour stored in dry environment and always place the cover on the screw feeding device Screw feeders Bridging and tunnelling can occur - Paddles - Agitators - Vibrators and air hammers Cleaning - Auger removable - Unused spice recovery Linearity versus hopper level Loss-in-weight system
Spray applicators Pulsing spray Continuous oil sprays 1. Air assist 2. Pressure orifice Spray applicators pulsing sprays Piston pump with adjustable cavity size One nozzle per pump, nozzle has spring value to open orifice Operates up to 500 strokes per minute (250 more common) Long history in the industry (1950s) Cost Simplicity Very accurate Small foot print Not recommended for high oil rates (>300Kg per hour of oil) Requires manual adjustment for high turndown ratios Must keep pulse rate above 150 PPM Spray applicators continuous air assist Low pressure liquid is atomised using air Air added around the annulus or internal mixing chamber Typically air is low pressure Can be used with a flow meter Continuous stream of oil Works well with PD pump and flow meter Good for high oil rates Mist is a challenge to control Uneven application from nozzle to nozzle at low rates Cost KMG liquid spray unit
Spray applicators continuous oil spray systems PPM Technologies continuous flow oil applicators Delivery precise, repeatable spray patterns with a variety of light to medium viscosity liquids, oils and oil/water solutions Spray Dynamics MSIII continuous oil spray applicator Designed for use inside a coating drum, in a blender, or across a belt TNA intelli-flav CLO 3 series For the application of oil and injected flavour or just oil, requiring no mixing tanks and minimal equipment contaminated with flavour Spray applicators practical considerations for oil applicators Coverage Getting an even coating of oil on each piece is key to flavour adhesion and appearance Use as many nozzles as practical to apply to more pieces at once (4 turns or more) If using a pulsing system keep rate above 150 pulses per minute Make sure continuous systems have balanced pressure to each nozzle Always spray on tumbling product Spray on tumbling bed Slurry applicators When product specifications call for more oil than seasoning, a slurry is typically used Oil is more an 60% of the slurry weight Mixing and use tanks are required Many ingredients including salt will not dissolve in oil and constant mixing is required Most slurry applications require a soak, time for the oil seasoning mix to be absorbed in the base product
Slurry applicators over two stage coating Allows mixing of several liquid and dry powder ingredients in proportion Works well on extruded and pellet type products as well as popcorn Challenges Can be messy if not properly installed Selecting the correct pump can be a challenge Nozzle and line blockage may occur Spray Dynamics Slurry spray system For snack and other applications to maximise coverage and minimise waste Slurry applicator mixing systems Flo-Mech Flo-Flavour Slurry mixing and application systems Spray Dynamics master series tank system Engineered mix/use liquid blending and supply station TNA Intelli-flav cls 3 Tumble drum flavour slurry spray system Slurry applicators practical considerations Spread out application zone to reduce the dependency on piece to piece contact Using a longer drum allows more piece to piece contact and allow the slurry to soak in Match the pump to the system Centrifugal pump requires a constant head to be linear PD pump is linear but has clearance issues with large particles (salt does on dissolve in oil) Flow meter can be used to control the rate
Summary Seasoning topology: In-kitchen/or process seasoning On-machine seasoning Dry seasoning applicators: Screw dispenser Scarf plate with screw feeder Electrostatic application with screw feeder and vib Wet seasoning applicators: Spray applicators (pulse and continuous oil application) Slurry applicators What s likely in the next 2-3 years? Dry only applications For on machine seasoning, more integrated solutions such as dust collection and powder refill More verification for both in kitchen and OMS (loss-in-weight systems) Oil and dry applications More options for OMS to include split drum and all in one More verification for in kitchen (flow meter for oil, loss-in-weight for dry) Better control of coating bed (opportunity to coat an individual piece) Slurry applications Continuous mixing slurry systems Emulsions that require post drying Practical aspects The coating drum is the heart of the system Creates rolling bed to coat Must have 4 to 7 turns of product in applications zone Poor coverage? If using oil, adjust oil application for more complete coverage Spray onto rolling bed, never on coating drum 4 to 7 turns in the coating zone If dry only make sure seasoning is falling onto rolling product bed and make sure you are getting 4 to 7 turns in the coating zone How to test coating zone turns? Dwell time length of drum and RPM
Practical aspects Breakage? Most likely caused by wrong flight profile in the coating drum Too much or too little product in coating drum Cross-contamination Implement dust extraction systems to avoid cross contamination Thank you Any Questions?