SNACK FOOD TECHNOLOGY Second Edition

SNACK FOOD TECHNOLOGY Second Edition

Samuel A. Matz

President Pocoloco, Inc. P.G. Box 384

Villa Park, Illinois

• aVI A VI PUBLISHING CGMPANY, INC.

Westport, Connecticut

© Copyright 1984 by THE AVI PUBLISHING COMPANY, INC. Westport, Connecticut

Softcover reprint of the hardcover 2nd edition 1984

All rights reserved. No part of this work covered by the copyright hereon may be reproduced or used in any form or by any means-graphic, e1ectronic, or mechanical, including photocopying, recording, taping, or information storage and retrieva1 systems-without written permission of the publisher.

Library of Congress Cata10ging in Publication Data

Matz, Samue1 A. Snack food techno1ogy.

Bibliography: p. Includes index. 1. Snack foods-Patents. I. Title.

TP451.S57M37 1984 664/.6 84-18523

ISBN-13: 978-94-010-9780-2 e-ISBN-13: 978-94-010-9778-9 DOl: 10.1007/978-94-010-9778-9

ABCDE 543210987654

Contents

Preface xi

PART I SNACK FOOD INGREDIENTS 1

1 Popcorn and Other Cereal Products 3

Popcorn 3 Other Corn Products 8 Wheat-based Ingredients 15 Rice 15 Rye 16 Sorghum 16 References 16

2 Fats, Oils, Emulsifiers, and Antioxidants 18

Natural Fats and Oils 19 Processing Vegetable Oils 23 Analytical Tests Applied to Shortenings 25 Specifications and Quality Assurance 28 Frying Fats 29 Emulsifiers 30 Antioxidants 32 References 34

3 Sweeteners 37

Invert Syrups 40 Molasses 41 Brown Sugar 41 Other Sweeteners 47 References 48

4 Dairy Products 50

Fluid Milk Products 50 Concentrated Milk Products 51 Dried Milk Products 52

v

vi CONTENTS

Cheese 55 References 61

5 Salt 63

Manufacture of Salt 63 Salt with Additives 69 Storage and Packing 70 Salt Requirements for Snacks 71 References 74

6 Water 75

Public Health Service Drinking Water Standards 77 Analyses of Water 78 Water Treatment 79 References 81

7 Nuts and Fruits 83

Nuts 83 Fruits 92 References 98

8 Vegetable Ingredients 100

Potatoes 100 On ions 103 Other Plant Products 104 References 104

9 Flavors and Colors 106

Flavors 106 Colors 115 References 117

PART II PRODUCTS AND PROCESSES 119

10 Potato Chips 121

Potato Chip Processing 121 Quality Factors 127 Storage Stability 127 References 128

11 Meat-based Snacks 130

Popped Pork Rinds 130 Pickled Snacks 133 References 136

CONTENTS vii

12 Snacks Based on Popcorn 138

Factors Affecting the Quality of Popcorn 138 Popping Procedures 144 Caramel Corn and Other Formulated Popcorn Snacks 146 References 148

13 Puffed Snacks 150

Formulations and Procedures 151 Addition of Flavors and Colors 160 References 163

14 Corn Chips and Simulated Potato Chips 166

Corn Chips 166 Simulated Potato Chips 169 References 172

15 Baked Snacks 173

Salty-savory Baked Snacks 173 Sweet Baked Snacks 182 References 191

16 Nut-based Snacks 192

Peanuts 192 Other Nuts 196 Sugared and Spiced Nuts 198 References 198

PART 111 EQUIPMENT 201

17 Extruding Equipment 203

Extruder Function 203 Using Extruders to Make Snacks 204 Extruder Design and Operation 210 Commercially Available Extruding Equipment 213 Complete Plants 225 Special Processes 226 References 228

18 Equipment for Frying, Baking, and Drying 231

Heat Transfer Mechanisms 231 Ovens 234 Electronic Ovens 239 Driers 240 Toasting Ovens 242

viii CONTENTS

Frying 243 Specialized Snack-frying Equipment 246 References 250

19 Specialized Equipment for Popcorn Processing 251

Poppers 252 Sifters 255 Coaters 257 Caramel Corn Plants 257 References 262

20 Specialized Equipment for Potato Chip Processing 263

Receiving and Cleaning Potatoes 263 Peelers 264 Slicers 266 Slice Washers and Conditioners 267 Fryers 269 Vacuum Finishing of Potato Chips 271 Microwave Drying 271 Addition of Salt and Seasonings 271 Sorting Potato Chips by Size 272 Protecting the Environment 273 References 275

21 Packaging Materials 276

Types of Containers 276 Special Features Required in Certain Snack Packages 287 Testing Films 289 Legal Considerations 290 References 291

22 Packaging Equipment 293

Folding Cartons 293 Preformed Pouches 294 Form-Fill-Seal Equipment 296 Inner-lined Containers and Rotoseal Machines 305 Automatie Case Packaging for Flexible Bags 306 Milk Carton Types 306 Packaging Nut Meats 306 References 307

23 Miscellaneous Equipment 308

Nut-processing Equipment 308 Oil, Powder, and Granule Applicators 314 Transfer and Storage Equipment 318 Measuring and Weighing Equipment 323

CONTENTS ix

Weighing 324 References 332

PART IV TECHNICAL FUNCTIONS

24 Product Development

Introduction Mission and Objectives Administration of Product Development Systematizing New Product Development Conducting Development Work Packaging Development References

25 Quality Control

335

337

337 340 341 346 369 376 376

381

Quality Control or Quality Assurance? 381 The Mission of Quality Control 382 The Extent of the Concern of Quality Control 382 The Position of Quality Control in the Organization 383 Functions of a Quality Control Department 384 Promoting a Quality-conscious Attitude in Other Departments 388 Keeping Records 389 Establishing Standards and Writing Specifications 390 Sampling 393 Sanitation 394 Supervision of On-line Inspectors 395 HACCP Studies 395 Recalls 396 Compliance 397 Utilization of Outside Laboratories 398 References 399

26 Nutritional Supplementation 401

Recommended Daily Allowances 401 Vitamins 403 Minerals 404 Protein 405 Other Nutrients 407 References 408

Index 409

Preface

This book fills a need for a technological guide in a field that has experi­enced an almost explosive increase in the last two decades. No other book available to food scientists provides detailed coverage of the ingredients, processes, products, and equipment of nearly every type of snack food made today. Since publication of the First Edition, many changes have occurred in the snack industry, making necessary a thorough revision of all chapters. The text, illustrations, and bibliographies have all been brought up-to-date. My goal has been to provide an accurate and reasona­bly detailed description of every major snack processing method and prod­uct current in the United States. If any reader believes I have omitted an important topic, I would be glad to learn ofit, in the hope that there will be a Third Edition in which I can incorporate the suggested additions.

One of the main purposes of this volume is to provide a source for answers to problems that the technologist encounters in the course of his or her daily work. Extensive bibliographies, in which the emphasis is on recent publications (extending into 1983), should permit the reader to resolve more complex or new questions. With these bibliographies as guides, the food technologist can delve as deeply as he or she wishes into specialized aspects ofthe subject, while at the same time the reader who is interested in the broad overall picture will not be distracted by excess detail.

This book is not directed solely to food technologists working directly with snack foods. Scientists, technologists, and engineers connected with companies that supply ingredients, packaging materials, and equipment used in the industry should find the information helpful in guiding new product development and product improvement studies. Marketing and technical sales personnel should find the book of value in acquiring a better understanding of factors affecting product quality and customer requirements. Administrators and general management personnel who are not technically trained will find that the volume can make the reports of their research, development, and quality assurance departments more meaningful.

The plan of the book is to discuss ingredients, products and processes, equipment, and technical services in separate groups of chapters. In each

xi

xii PREFACE

ofthe chapters dealing with ingredients, the characteristics ofthe various raw materials are covered as weIl as the quality control tests applied to them, their effects on the finished product, bulk handling details (if ap­plicable), and the effects of storage conditions on quality. Products and the processes used to make them are discussed in the second set of chapters. In the next group, the specialized equipment of the snack food industry is described, its sources identified, and its effects on the product analyzed. Packaging material is also covered in the third section. FinaIly, a group of three chapters is devoted to technical functions and nutritional supplementation.

The following persons reviewed one or more chapters and in some cases provided valuable supplementary material.

David M. Strietelmeier Morton Salt Company

Charles E. Holaday National Peanut Research Laboratory, USDA

Charles Staff Fairmont Foods

Ray Mykleby Land O'Lakes, Inc.

James Moncrieff Glidden-Durkee

James E. Mack Peanut Butter Manufacturers and Salters Association

Richard J. Alexander Krause Milling Co.

Roy Shaw Red River Valley Potato Research Center

Ernest L. Semersky Clinton Corn Processing Co.

Edward E. Nuebel Associated Milk Producers, Inc.

Paul Perry Warner-J enkinson

Lee Brazier Milprint, Inc.

Dr. Ben Borenstein Roche Chemical Division

John Butler American Can Co.

A. V. Petersen Wright Machinery Division, Rexharn Machinery Group

Dr. Rulon Chappell Land-O-Lakes, Inc.

The individuals and companies that have contributed information and illustrations are far too numerous to be acknowledged here, but credit for their contributions is given at appropriate points in the text and in figure captions.

A special acknowledgment is owed to Mrs. Ludmila Ulanowski, who provided encouragement as weIl as important editorial assistance.

Samuel A. Matz

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