Salt roasted pellets
Salt roasted pellets
RoastR is developed for producing tomorrows fresh, vegetable-based, snack pellets. The gentle roasting process makes sure that nutrients are preserved in the finished product, where the content of vitamins and dietary fibers can be kept high. At the same time the fat content in the finished product is as low as 0% and the protein content ranges up to 40 %. A wide range of today’s standard pellets can of course also be produced with RoastR.
A RoastR-line provides undiscovered possibilities for product development, with seasonings and vitamins to be used for your specific market requirements.
Snack pellets are traditionally cooked & expanded using frying oil or hot air as heat transfer media. With our patented RoastR, heat is applied through salt with infrared heat – the next step in snack innovation.
To produce a high-quality product when roasting snack pellets you will need a complete processing line that can ensure an even flow of product throughout the process.
When cooking and expanding snack pellets, heat is applied. RoastR utilizes the outstanding heating thermal conductivity in salt. This classic snack ingredient has proven to be an excellent heating media providing expansion and perfect crispiness for snack pellets. By roasting pellets in salt, a crispy and crunchy snack is produced with 0% fat.
Since we use a specific shape and size of granulated vacuum salt, heat is gently applied from electrical elements and the steam evaporated from the pellets is easily transferred out from the exhaust. The measured salt uptake in the product is not more than 0,1-0,4 %, which is related to the raw pellet formula and surface smoothness level after roasting.
The processing steps
In the first step of our pellet roasting line we make sure to transport the right amount of pellets towards the RoastR and this is made with an Infeed Elevator. It is important to feed an even flow of product already from start. When we have ensured an even amount of pellets, we want to separate them before the fryer, so that each pellet can get the necessary energy and room to expand.
Through the patented design in RoastR, salt is transferred in a mechanical loop through a 2-way processing auger. The unique design allows the pellets to be expanded in a bath of hot salt in one direction and the salt to be re-heated in the other. The expanded pellet goes out and the salt falls to an internally reversed auger. Any excess of salt on the products surface are shaken off before entering the cooling part of the process.
The pellets are now fully expanded and needs to be cooled off before the seasoning can be applied. Since this area is very clean and that there is no heating element left on the product, the cooling time is relatively short.
The final step is to apply seasoning to the product. To make this process as accurate as possible, the flow of product must be even and consistent so that no seasoning goes to waste. To make sure the whole surface area of each pellets gets covered in seasoning, we have designed the SEABASE system that measures both product and seasoning. Also, our seasoning dum allows the pellet to turn multiple times whilst being seasoned and at the same time it is transported forward towards the packing area.