Nice textures & selected flavours presented in attractive shapes
Raw-materials: Most savoury snacks are made from corn. Sometimes other raw-materials like potato powder, wheat or rice grits are used to impart an identifiable and attractive taste to the base product. Pulses or beans may be added to cater to distinctive local tastes. Similarly materials with high fiber content may be added to increase specific nutritional values.
Process: The process can be divided into 3 stages.
Pre-extrusion - Single or a homogeneous blend of various raw-materials is moisturised to a pre-determined level with water or water containing materials, prior to extrusion. The moisturisation is done either in batch mode during blending or continuously. The moisturised raw-material is still free-flowing and is metered into the extruder, sometimes together with other additives, usually with the help of volumetric screw dosing units.
Extrusion - The raw-materials, being fed at a certain rate into the extruder, so long as their major component is starch or protein, are extruded (formed into a cooked dough under heat and pressure) and finally expanded into a shaped base extrudate. Schaaf TURBO-extruders offer the possibility to control the expansion of the extrudate through various means to control the texture of the final product.
Schaaf also offers a large number of possibilities in terms of product shapes by the use of different dies. It is also possible to produce 3D product shapes using Schaaf’s patented cutting system. Some products may be imparted special characteristics in terms of colours, textures and shapes by the use of various optional accessory equipments.
Post-extrusion - Though fully cooked, when it comes out of the extruder, the extrudate must be dried to reduce its moisture level to allow it to be preserved for a longer time. By the use of drum driers with infrared heating systems, Schaaf is not only able to achieve efficient drying of the product but is also able to impart special effects like roasting or toasting to enhance the taste of some components favourably. After the extrudate is properly dried, it develops a crispy bite, but often still lacks an attractive taste. Hence usually a slurry of fat and seasoning is sprayed on to the product as it rolls inside and slowly moves down the coating drum. The slurry to be sprayed is prepared in a system with two heated vessels, one of which is used to vigorously mix the various components off-line and pump the slurry to the other vessel which is only a holding tank connected online. After seasoning the product is ready-to-eat. It is then either suitably stored intermediately, protected from atmospheric moisture, or immediately packed suitably.