Formulation for Various Snack Bases

How is a pretzel seasoning different than a potato chip seasoning? Why are snack seasonings applied at different rates? For many reasons, different snack bases require different considerations when formulating seasonings. In this blog, culinologist Brian Duffy breaks it down for you and explains how formulation can differ depending on the base.

Over the years, many new snacks featuring different bases have been introduced to the market, and more are being developed each day.  The snack aisle is more diverse than ever. Some common snack bases we see on the market include crackers, cookies, chips, puffs, pretzels, and health foods. Each of these snacks use a seasoning to drive flavor, but those seasonings must be crafted specifically for the application process of each base.

Crackers and cookies are usually more dense than other snacks with a strong flavor of their own. Usually, seasoning is applied topically onto a product like this from 2-5%.  This is a lower usage level from a coverage standpoint, and therefore, the seasoning must be heavily concentrated in flavoring ingredients such as salt, spices, flavors and extracts. In addition, higher granulation materials can be used for visual effect such as granulated salts, sugars, and spices. This can help drive flavor perception through visual aids.

Chips are the most common snack in this space and are usually applied topically at 6-10%. Since chips are so light with a high surface area, coverage is very important. To achieve proper coverage, the flavoring components tend to be diluted with carriers such as sugar, dextrose, maltodextrin, whey, and rice flour. This dilution allows the flavoring ingredients to be evenly distributed across the surface of the chips. In addition, the granulation for a chip seasoning should be built on the smaller side to avoid key flavoring ingredients falling off the chip. Flow properties are also an important consideration for chip seasonings. Chip seasonings are usually applied by sprinkling the seasoning over freshly fried chips in a tumbler. So, ensuring the that the flow to dust ratio is in check, is very important. Too wet and heavy, the seasoning will not coat evenly. Too dusty, and the seasoning becomes not only a mess for the plant, but a health hazard to employees working in the surrounding area.  Flow is usually addressed through the native properties of the flavoring ingredients interacting with processing aids such as silicon dioxide, calcium stearate, oils, and more.

Puffs are also a very common snack base in which seasonings are typically applied in an oil slurry that has been sprayed onto the base. This oil slurry is usually in a 60:40 ratio oil to seasoning. This is a key point that a seasoning must be built towards. Ingredients should favor powdered ingredients. This will allow the seasoning to be evenly dispersed throughout the oil, limit separation, and avoid clogging the sprayer. In addition, flavors should be oil soluble to ensure that the slurry maintains a homogeneous mixture during course the spray.

Pretzels are products that can utilize another type of slurry: a water-based slurry. The seasoning is mixed with water and sprayed on the product. The base is then baked to dehydrate and set the seasoning onto the base. In a fat-based system, like chips and puffs, residual fat that sticks to the base acts as a glue to adhere the seasoning to the base and maintain coverage. In a water-based slurry, however, the seasoning would fall off. So, gums are included in a seasoning blend as functional ingredients to create that “glue.” So, when formulating for these applications, function must be taken into account to tailor the seasoning to the adhesion needs of each base according to its specific needs.

While all of these types of products require a different application method that demands different formulation tactics, clean label products often require more expertise to overcome flavor challenges. It is commonplace now to have snacks developed for the health food space. Often times, especially in the case of high protein bases, off flavors can be present as a result of the alternative material being used as the base such as whey protein, pea, and soy protein. When formulating for these snacks, it is important to pack the seasoning full of flavor to overcome these off notes. This can be done through higher levels of flavor and spices, but also, through new technology from flavor suppliers; flavor maskers and blockers.  Flavor maskers and blockers are a newer technology developed by flavor houses that are intended to occupy the taste receptor for common off notes, and let the other flavoring ingredients in a seasoning shine.

Snacks make up such a broad category that is showing innovation every day. Understanding each base and their specific requirements makes Fuchs a great partner across the category. Fuchs North America has established itself as an industry leader in snack seasonings for all applications and is committed to working as a partner with all of our customers to tailor each seasoning to their specific needs. If you have a new snack project and are in need of a flavor packed seasoning, our R&D experts are here to help.

Got a formulation question or a seasoning challenge? Contact us today to get innovating!