Tna: Achieving Efficiency To Innovate A Tasty And Guilt-Free Snack Experience

Tuesday, November 26th, 2019 | 2190 Views

Egyptian snack manufacturer, Future Foods, has successfully launched a new pretzel range after collaborating with tna to successfully install a seasoning, processing and packaging line. This launch has helped Future Foods achieve 100 percent productivity at high speeds of up to 165 bags per minute (BPM).

With pretzels being the fastest growing segment in the savoury snacks category and expected to achieve a CAGR of 5.8 percent during 2016–2020, Future Foods decided to invest in a high-quality pretzel range that delivers a healthy, guilt-free snacking experience, to its consumers.

To maximise the opportunities this flourishing sector offers, Future Foods required equipment to optimise seasoning application, capitalise on packaging efficiency and minimise waste to ensure the successful launch of its new range.


Precise seasoning control

Gaining consumer acceptance at the very first bite is vital when launching any new product. In addition, application accuracy was a key consideration for the snack manufacturer. Opting for seasoning technology featuring a responsive variable mass seasoning mechanism with dynamic vibratory weigher, the tna intelli-flav OMS 5, Future Foods can precisely control seasoning application within the drum. This enables an accurate, proportional amount of seasoning to be evenly applied to the product for consistent coverage and flavour dispersion, meeting the need for a high-quality, evenly seasoned end-product.


Smooth product transfer

When it came to choosing a distribution system for the new range, minimising product breakage and ease of cleaning were critical factors. The company opted for equipment that aided a gentle transfer and chose the tna roflo HM 3 horizontal motion conveyor to ensure a smooth product transfer through the line, while keeping product damages to a minimum, as there is no vertical lifting or bouncing of the product and no flavour build-up in the pan.

The conveyors also offer significant maintenance benefits due to their overall mechanical simplicity, resulting in greater equipment reliability and therefore lower total cost of ownership over the lifespan of the system. The tna roflo HM uses a single linear servo motor and there is almost zero maintenance as there are no big drives, shafts, belts or pulleys.


High-speed, efficient packaging

Offering a new range of pretzels in 16g, 35g and 100g pillow-style bags, Future Foods was looking for a system that would deliver consistently high speeds. Beyond this, quick changeovers to maximise throughput and reduce downtime were also a necessity.

With the installation of two tna robag FX 3ci vertical form, fill and seal (VFFS) packaging systems, the production line offers flexibility and improved performance in a compact, easy-to-clean set up. With their rotary double jaws, the new baggers were quickly able to deliver speeds of up to 165 BMP, while quick-release formers ensure that Future Foods is able to change between bag sizes in less than three minutes.

“As a new company it was essential for Future Foods to work with a reliable partner that could ensure a smooth start up, achieve the line efficiencies we were looking for and deliver the best return on investment in the long term”, said George Soussou, Vice-Chairman & Operations Director at Future Foods.


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