Complete line solution developed for pork snack maker

tna solutions has worked in collaboration with US pork snack company Benestar Brands to develop an efficient processing and packaging line for the company’s ‘rinds and cracklins’ products.

Installed in 2019, the new line from tna solutions has helped the snack company improve its product quality tenfold and extend snack shelf life, while reducing energy use and enhancing efficiency.

“tna solutions has been a fantastic partner throughout the process,” commented Jose Gomez, Chief Technical Officer at Benestar Brands. “The company’s experts have a deep understanding of our industry, while being open to listening to our specific challenges and finding out-of-the-box solutions. The accommodation of our specific needs, from footprint restrictions and frying demands to intricate seasoning, helped facilitate our partnership with tna and develop an excellent product to satisfy every pork fan.”

From feeding to baggers — complete line solution

Working collaboratively since 2005, Benestar Brands and tna’s engineers have developed an advanced approach to pork rind manufacturing. Every piece of the process, from feeding and frying to distribution systems and packaging, is optimised to ensure better products and a faster return on investment. The tna batch-pro 12 frying technology is designed to reduce rejects to less than 3%, while its fryer design minimises oil use, which contributes to product and material savings.

In addition, the tna batch-pro 12 fryer system provides direct-fire heating for improved energy efficiencies and lower operating costs, while the flexible tna intelli-flav OMS 5.1 seasoning system allows for consistent coverage without costly ingredient losses, further contributing to a healthy bottom line. Last but not least, the tna robag 3e vertical form fill and seal (VFFS) packaging system enabled Benestar Brands to efficiently pack both its pork rinds and cracklins on the same line at a high speed.

Testing the quality first

With a portfolio of protein-rich and keto-friendly snacks, Benestar Brands puts specific emphasis on delivering consistently high-quality product for its customers.

tna was involved in the optimisation of processing and packaging from the outset, with the pork rinds and cracklins being fully tested at its technical centre facility in Texas prior to the equipment purchase. The toughest products were put to the test to ensure a consistent texture, seasoning and flavour. tna provided guidance and technical support throughout the entire manufacturing process to help ensure the product could be brought to market quickly and efficiently.

“Our partnership with Benestar Brands has been very exciting and has fuelled the engineering innovation of our team,” said Adam Holloway, tna Regional Sales Manager, North America. “Pork rinds have very different product characteristics to traditional snacks we have been working with, such as potato and tortilla chips. We brought the years of processing experience in terms of treating food products in oil baths, while Benestar Brands contributed specific application knowledge — two key ingredients for a successful outcome.”

Improving resource efficiency

Achieving efficiency gains and reducing environmental impact were high on the agenda for Benestar Brands when selecting a new production line, driven by regulatory changes and increasing pressures from retailers and consumers. tna helped Benestar Brands to replace direct heating with heat exchanger technology, reducing energy use in the most energy-intensive process — frying. tna installed a LO NO_x burner, reducing harmful nitrogen oxides (NO_x) emissions and helping the company comply with Californian regulatory requirements.

Thanks to its three-stage oil filtration system, the continuous frying technology from tna is designed to ensure efficient oil management and turnover, eliminating the need to discard oil on a daily basis after every single production run, saving costly material. The fryer can also lower fatty acids levels, which can help to enable an end product with the desired taste, colour, texture and nutritional profile.

What the future holds

With increasing pressures throughout the entire supply chain to do more to protect the environment, Benestar Brands is looking to further collaborate with tna experts on ways to reduce energy consumption, film and product waste, achieving a more sustainable production.

“The opportunities for future collaborations are endless,” Holloway said. “To meet market demands for energy-efficient and sustainable processing and packaging technologies, tna continuously invests in technological innovation, and we look forward to building a greener, more sustainable snacks industry together with Benestar Brands and Jose Gomez personally.”

Image credit: iStock.com/dontree_m