Is your snack production keeping up with consumer demands?

The global savory snack market is projected to reach $263bn by 2027, driven by evolving consumer demands and emerging technologies that enhance the efficiency of snack processing. But as consumers seek healthier and more indulgent options, snack manufacturers are under pressure to innovate both their products and production processes.

In today's market, two major trends are influencing snack production: health consciousness and sensory indulgence. According to Mintel, 68% of UK consumers and 74% of Canadians claim to eat healthily most of the time. However, these consumers also desire indulgent experiences, leading to the rise of what market researcher GlobalData calls ‘Restrained Hedonism’ – where healthier snacks are sought without sacrificing taste.

These trends have been further reinforced by government regulations that encourage better-for-you products. At the same time, economic pressures have introduced a new dynamic, with ‘Value Scepticism’ emerging as consumers become more price-sensitive due to rising costs from supply chain disruptions, inflation and climate change.

This landscape presents an opportunity for snack manufacturers to innovate their processing technologies, balancing consumer expectations for health, indulgence and cost-effectiveness.

In conversation with Twan van den Berg, group solution specialist, Processing, for TNA Solutions, Bakery&Snacks learnt of some key advancements that are reshaping the industry.

According to Van den Berg, “Efficiency is the name of the game today. Manufacturers need to invest in systems that not only increase throughput but also minimize waste and ensure high-quality output. The right technology can help achieve all of this while reducing the total cost of ownership.”

Leveraging technology to enhance efficiency

One area of innovation is the development of advanced defatter systems. These are designed to recover oil from pre-fried items such as potato sticks and hash browns, leading to significant cost savings.

“Defatters can recover between 1.5% and 2.0% of oil relative to the line's output,” explained Van den Berg.

“This recovered oil can then be reheated and reintroduced into the fryer, significantly reducing the amount of new oil needed. Given the current high cost of oil, the return on investment for these systems is typically realized within a year.”

In addition to recovering oil, defatter systems prevent contamination in distribution and packaging systems, which helps reduce cleaning time and improve overall efficiency. This focus on sustainability not only helps manufacturers meet environmental goals but also lowers operational costs, making it a win-win solution.

Recent advancements in frying technologies also play a crucial role in creating healthier snacks.

Van den Berg told us that “Continuous vacuum frying and batch frying allow manufacturers to fry at lower temperatures, which reduces the formation of acrylamide – a chemical that forms during high-temperature cooking and is considered harmful.”

By lowering oil absorption during the frying process, these technologies make it possible to produce low-fat snacks with extended shelf lives. Additionally, advanced oil filtration systems help extend the lifespan of the frying oil, improving product quality by minimizing the risk of off-flavors caused by old oil.

Pulsed Electric Field (PEF) technology

Beyond frying, technologies such as PEF treatment are increasingly being integrated into medium and large-scale processing lines.

PEF offers numerous benefits for the production of savory snacks, particularly potato chip manufacturing.

“With PEF, you get more accurate cuts, less feathering, and fewer broken chips,” said Van den Berg.

“It also allows for better diffusion during blanching, which helps reduce oil absorption. These small improvements ultimately lead to a healthier snack that maintains the same crispiness and taste that consumers expect.”

PEF technology is especially valuable for its ability to improve cutting quality and increase the lifespan of cutting blades, which contributes to overall cost efficiency.

“In an industry where margins are tight, any advancement that can lower waste or reduce maintenance downtime is significant,” he added.

Future-proofing snack production with versatile lines

As consumer preferences shift, manufacturers are increasingly looking for flexible production solutions that can adapt to changing market demands. The ability to efficiently switch between different snack products is becoming a key factor in maintaining competitiveness.

This is where technologies like on-machine seasoning systems are coming to the fore.

“These systems allow for precise control of both powder and liquid flavoring, with the ability to switch between products quickly,” said Van den Berg.

“They also provide consistent seasoning coverage, whether you’re applying a dry powder or a slurry, and help minimize seasoning waste, which reduces costs.”

The use of dynamic vibratory weighers and responsive variable mass controls ensures that the right amount of seasoning and oil is applied to each product, maintaining high standards of quality across different snack varieties. This flexibility allows manufacturers to respond quickly to trends without overhauling their production lines, making it easier to launch new products or cater to seasonal demand.

Embracing smart technology

In addition to process improvements, smart technologies such as augmented reality (AR) and virtual reality (VR) are gaining traction in the snack manufacturing space.

“These tools enable remote training, commissioning and maintenance, which significantly reduces downtime and enhances overall productivity,” said Van den Berg.

In a global market where competition is fierce, even small reductions in downtime can translate into significant cost savings.

By integrating smart technologies, producers can stay agile in a fast-paced environment, making it easier to adapt to changing consumer preferences, whether it’s for healthier options or more indulgent flavors.

As the global snack market gets more crowded and competitive, manufacturers must leverage cuttingedge technologies to remain competitive. The future of snack processing is all about efficiency, sustainability and adaptability.

“The ability to meet consumer demands while managing operational costs will be the key to success in the snack industry. The companies that invest in advanced processing solutions today will be the ones that thrive tomorrow,” said Van den Berg.