Egyptian snack manufacturer, Future Foods, has successfully launched a new pretzel range after collaborating with tna, a leading solutions provider in the food processing and packaging industry, to successfully install a seasoning, processing and packaging line. This launch has helped Future Foods achieve 100% productivity at high speeds of up to 165 bags per minute (BPM).
Founded in 2016, in Giza, Egypt, Future Foods prides itself on bringing new and innovative products to the market. With pretzels being the fastest growing segment in the savoury snacks category, the company decided to invest in a high-quality pretzel range that delivers a healthy, guilt-free snacking experience, to its consumers.
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.
The chosen distribution system, the tna roflo HM 3 horizontal motion conveyor, ensures 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.
Unlike traditional conveyors that use mechanical gates, the patented ‘true’ gateless design of the tna roflo HM 3 helps protect the pretzels from damage with servo controlled ‘virtual gates’ that simply open up a gap between the pans where the product is discharged. The risk of any potential damage to the product is significantly reduced and practically eliminates any loss of flavour. With the installation of several tna systems, including the tna roflo HM 3 and tna intelli-flav OMS 5, breakage level from seasoning to packaging is less than 0.5%.
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, tna reports.