PRODUCTION PROCESS

Discover our production process, and how we create the best affordable savoury snacks.

 

Production processes

CRACKERS

STEP 1 : Dough production
The dough is prepared from a mix of ingredients kneaded for several minutes. It is then placed in the oven under set conditions of temperature and humidity to soften and facilitating working of the paste during the next stage.

 

STEP 2: Shaping the dough
Casting rolls shape a sheet of dough, which will then be layered with other sheets, then rolled until the correct biscuit thickness is obtained. It is then cut into shapes and decorated according to the recipe.

 

STEP 3: Cooking
The shapes are placed on the oven tray (75m long) to achieve the correct colouring, moisture and development.

 

STEP 4: Spraying/cooling
The cooked biscuits are then sprayed with rapeseed oil, then placed on an inspection and cooling conveyor.

 

STEP 5: Packaging
The biscuits are then spread over weighing scales that will weigh out the desired quantity of product and transfer this amount to bags. These bags are then transferred to cartoners to be packed.

SNACKS (PELLETS)

STEP 1 : Expansion
Frying in sunflower oil for 20 to 30 seconds at 190oC followed by draining of the product.

STEP 2: Flavouring
Product is passed through a revolving tube to flavour it according to a set recipe using flavouring and salt, without the addition of any fat.

STEP 3: Bagging
The fried snacks are then spread over weighing scales that will weigh out the desired quantity of product and transfer this amount to bags.

STEP 4: Packaging
These bags are then packed into a cardboard box either by an operator or by means of an automated process.

SNACKS (EXTRUDED)

STEP 1: Mixing of flours
Based on the recipe, preparation of a mix of flour (potato starch, maize, wheat, etc.) and water.

 

STEP 2: Extrusion and drying
The mix is passed through an extruder to achieve the desired shape and size of product using a nozzle and a knife. The product then passes through a drying oven to remove as much water as possible and make it crispy.

 

STEP 3: Flavouring
On leaving the oven, the product enters a revolving tube to be flavoured using flavourings, salt and fat (sunflower oil) or peanut paste, according to the recipe.

 

STEP 4: Bagging
The fried snacks are then spread over weighing scales that will weigh out the desired quantity of product and transfer this amount to bags

 

STEP 5: Packaging
These bags are then packed into a cardboard box either by an operator or by an automated process

STACKED CHIPS

STEP 1: Dough Preparation
Mixing of solid and liquid raw materials to form a sheet of paste from which oval dough shapes are cut

 

STEP 2: Frying
The raw dough is passed through a fryer containing moulds, which give the product its rounded shape

 

STEP 3: Flavouring
Sprinkling of salt or flavouring over the crisps as they leave the fryer

 

STEP4: Packing in tubes
Collection of flavoured stacked chips on conveyors prior to packing them in tubes

 

Step 5 : Packaging
Once the stacked chips are packaged in tubes, the tubes are sent for packing and palletization.

POPPED SNACKS

STEP 1 : Supply
Supply of production line with micro-pellets packed in cardboard

 

STEP 2 : Mixing
Damping and mixing of micro-pellets

 

STEP 3: Popping
Expansion of micro-pellets by press-forming combined with heat

 

STEP 4 : Flavouring
Coating of products according to the recipe

 

STEP 5 : Bagging
The popped snacks are then spread over weighing scales that will weigh out the desired quantity of product and transfer this amount to bags

HANDCOOKED CRISPS

STEP 1: Preparing the potatoes
All potatoes are washed and transferred to peelers. Once peeled, they are sliced to a certain thickness depending on the recipe.

 

STEP 2: Frying Process
The sliced potatoes are conveyed into the fryer at 150°C for about 5 minutes. During the frying process the crisps are continuously stirred to achieve a better frying and to avoid the crisps to stick together.

 

STEP 3: Flavouring
The handcooked crisps are conveyed on a deoiling belt to the flavouring drum, where the flavour is evenly sprinkled.

 

STEP 4: Bagging
Once flavoured, the handcooked crisps are spread over the weighing scales that will weigh out the desired product quantity and transfer this amount to bags.

STANDARD CRISPS

STEP 1: Preparing the potatoes
All potatoes are washed and transferred to peelers. Once peeled, they are sliced to a certain thickness depending on the recipe.

 

STEP 2: Washing & Drying
Sliced potatoes are washed to remove most of the starch. The washed potato slices are then dried through air pressure and conveyed to the fryer.

 

STEP 3: Frying Process
The potato slices are passing through the fryer for 5 minutes at 150°C to be then conveyed to the flavouring drum.

 

STEP 4: Bagging
Once flavoured, the crisps are then spread over the weighing scales that will weigh out the desired quantity of product and transfer this amount to bags.

POPCORN

STEP 1: Oil Popping
In this stage the corn kernels, the sugar and the oil are poured into a popper kettle at 190°C for 6 minutes. Eventually this process converts the corn kernels into Butterfly Shape popcorns.

STEP 2: Sifting
Butterfly popcorns are then conveyed to a drum sifter, where unpopped corn kernels separate from the popped popcorn.

STEP 3: Flavouring
The Butterfly popcorns are conveyed into the flavouring drum where flavour/salt is evenly sprinkled on the popcorns as per recipe.

STEP 4: Bagging
Once flavoured, the popcorns are then spread over the weighing scales that will weigh out the desired quantity of product and transfer this amount into bags.

TORTILLAS

STEP 1: Soaking
All the know-how of the production lies in the beginning of the process. The most important step happens when the corn is soaked in water tanks.

STEP 2: Forming the triangle shape
After remaining in a certain amount of time in water, the corn is then crushed and mixed to create a uniform dough. This dough will then be flattened, cut into its famous triangular shapes and sent into the toasting oven.

STEP 3: Frying Process
Once toasted, the triangular shaped snack is conveyed on a cooling belt before going in the fryer. After being fried, the tortilla is transported on a deoiling belt to the flavouring system

STEP 4: Bagging
Once flavoured, the tortilla is conveyed to the packaging unit. They are then spread over the weighing scales and transfer a specific amount into bags.

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