As a result, contract manufacturers with twin-screw technology are playing a significant role in the better-for-you landscape. Food processors of all sizes, especially brand marketers for whom production isn't a competency, hedge their risk by turning to contract manufacturers rather than investing in twin-screw extruders.
For the Inventure Group, Phoenix, it’s meant producing salty snacks under the TGI Fridays and Burger King brands.
"This whole better-for-you category has increased as a percentage of our business," says Steve Sklar, Inventure's senior vice president of marketing. In addition to those two restaurant brands, the company's regional salty snack brand, Boulder Canyon, has been adding varieties such as a Rice & Adzuki Bean chip, touted to have higher fiber, vitamins and proteins. "We’re working on introducing more multi-grain products, as well as low sodium and lower fat ones."
Processors also invest
Highly diversified in the salty snacks arena, Shearer's, has six plants producing traditional potato chips, kettle-style chips, tortilla chips and other sheeted products, pretzels and a variety of extruded snacks from cheese puffs to new whole-grain snacks. The company has its own brands, but most business is contract manufacturing for customers from small marketers to Fortune 100 brands.
The company this summer began operations at its sixth plant, in Massillon, Ohio, which claims to be the first snack food processor to gain platinum certification under the U.S. Green Building Council's Leadership in Energy and Environmental Design (LEED) program, which establishes guidelines for sustainable, environmentally friendly buildings.
Wiegmann says the company has invested "heavily" in twin-screw technology from extruder manufacturer Clextral "for its ability to make not just today's product, but tomorrow's… the ability to use different substrates together. It's just a smokin' process. It's magical!" he says. "When you think of all the little tweaks you can do with heat and pressure inside those barrels… how far we've come from the old 1980s single-barrel extruders to what we have today."
For example, conventional cheese puffs come off a single-screw machine – a twin-screw would be a waste of capital. But try to run whole-grain products on a single-screw and, says Wiegmann, "You'd clog that puppy up in a heartbeat. It just would not work."
Wyandot's McGrady says that while he can run a degerminated corn – just the starch component – all day long on a single-screw extruder, whole grains are "very, very difficult" to process without a twin-screw because of the floury endosperm component that's present along with the bran, and oil in the grain. A twin-screw unit can handle that, as well as many other products that come its way – and in flat, round, even wavy shapes, even different colors for different substrates.
"It's a machine that imparts energy into a dry blend or a substrate, if you will. It’s also a very effective mixer. And, from a processing standpoint, what you end up with is a technology that is able to form a food matrix out of flours, grains, meals and other components that you can shape into many forms, from a sheet to form a chip, a puff, a cereal piece, flat bread, shapes – even jelly chew shapes," says McGrady. While a single-screw can produce "garden variety" cheese puffs, the twin-screw has broader capability to handle blends of oats, rice, corn, wheat, and other fine flours.
What's next? Wyandot is pushing into functional foods, such as vegetable and fruit powders on chips, and antioxidants such as anthocyanins, which are found in blueberries and, closer to home, blue/purple corn.
At this July’s Institute of Food Technologists’ Food Expo, the Center for Innovative Food Technology and the Ohio Dept. of Development awarded research funding to Wyandot, Cincinnati-based supplier Sensus and Clextral, the Tampa, Fla.-based extrusion technology provider, to cooperatively develop a high-antioxidant/high-anthocyanin purple corn snack food that shows promise for its health benefits.