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

Oil flavour

addition

Product

feeding

Coating

drum

Dry flavour

addition

Flavour application systems

The key to great seasoning coverage is consistent flow with process control.

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

Advantages

• 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

Disadvantages

• 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)

Advantages

• 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)

Disadvantages

• 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® On-

machine 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)

Advantages

• Inexpensive

• Small footprint

• Simple to use

Disadvantages

• 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

Advantages

• All in one package

• Handles large volumes

• Flexible placement if temperature is critical

• Best choice for high absorption products

Disadvantages

• Long flavour change overs

• Line must be stopped for cleaning

Two stage seasoning – oil in-kitchen dry flavour on

head

Advantages

• 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

Disadvantages

• 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)

Advantages

• Short flavour changes

• Works well with low fat and high absorption products

• More flavours can be produced at one time

Disadvantages

• 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

Advantages

• Fits in small openings

• Medium cost option

Disadvantages

• 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

PPM Technologies®

Scarf plate dispenser +

powder feeder

Spray Dynamics®

Scarf plate distributor

Application systems – scarf plate feeder

Advantages

• Easy to operate

• Easy to clean

• Can work with most products

• Creates a very consistent curtain

Disadvantages

• Bulky, need large coating drum opening

• Powders may stick to the surface (flavour bombs)

• Cost

Heat and Control

Fastback® Excalibur™

KMG

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

Advantages

• Reduction in dry powder usage

• Even coverage

• Cleaner working environment

Disadvantages

• 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)

Advantages

• Long history in the industry (1950s)

• Cost

• Simplicity

• Very accurate

• Small foot print

Disadvantages

• 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

Advantages

• Continuous stream of oil

• Works well with PD pump and flow meter

• Good for high oil rates

Disadvantages

• 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

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

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

Spray on

tumbling bed

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

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

Advantages 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?