Seasoning kale chips more effectively

Due to increased demand from consumers for healthier alternatives to potato chips, Brandneu Foods has seen the popularity of its kale chips soar. The company therefore needed to reassess its production capabilities to meet this demand and stay competitive in an increasingly crowded marketplace.

The Canadian-based company significantly reduced lead times for its range of kale chips by 75% after installing the high-performance tna intelli-flav OMS 5 at its plant in Toronto. In addition to cutting production lead times from 60 days to just 15, the new installation enabled Brandneu to consolidate work space, meaning it can better respond to customer demands for its products. To ensure a smooth installation, tna provided total project management services — from start to finish — offering Brandneu complete peace of mind to concentrate on its day-to-day business objectives. 

Brandneu had previously experienced issues with inconsistent flavouring, which had an impact on taste and resulted in significant seasoning losses. The company found that tna’s intelli-flav OMS 5 on-machine seasoning system was the solution. Providing both powder flavouring and liquid oil in a single drum, the system features a variable mass seasoning system with a dynamic vibratory weigher to directly control oil spray. This means only the right amount of oil is applied to each chip — an essential feature for Brandneu, which was keen to maintain the healthy profile of its kale chips.

Thanks to the system’s application accuracy, Brandneu was able to minimise seasoning losses in the production process, reducing raw material waste and increasing profitability. In addition, the intelli-flav OMS 5 offers improved coverage and flavour dispersion, enabling Brandneu to apply minimal salt and flavouring without compromising on the overall quality and taste of its kale chips.

The tna intelli-flav OMS 5 system features a simple touch screen that is user-friendly and easy to program for simple operation. This helps plant managers save time in training staff, while also providing total peace of mind.

To meet the high demand for its product, Brandneu needed complete flexibility to change flavours quickly and easily. Addressing this need, tna suggested a second drum that can be changed on the line in less than 15 min. The addition of the second drum means Brandneu can meet orders more quickly and reduce production lead time considerably.

Image credit: ©stock.adobe.com/au/wjarek