Snack Food Moisture Applications
Moisture, Oil, & Fat/Protein Measurement
to Create Instant Quality Control
Measure Moisture, Oil, Fat/Protein Content and More … with one device!
Why Are We Different?
Leader in Moisture Measurement & Control
Over 40 Years of Experience and Top Quality Local Support in Your Area – We Can Measure Moisture, Oil, Fat Content & More
Zero Drifting or Re-Calibrations
Guaranteed Not to Drift or Need Re-Calibrations Over Time – Forget Any Yearly Maintenance Too!
Cutting Edge Technology
A Non-Contact Option Utilizing Near-Infrared Technology Provides Superior Data Results
Efficiency Improvements
Increase Production Efficiency by 400% or More With a Moisture Measurement & Control System from MoistTech
Software & Communications
MoistTech Does Not Require Any External Hardware and Also Provides Software Free of Charge with Unlimited Licensing Capabilities
The Importance of Moisture Measurement and Control During Production
The moisture content requirements in snack food manufacturing dictate many of the product outcomes: taste, consistency, quality, and shelf life. Utilizing an experienced moisture management system will allow the user to have full control over the manufacturing process to create a reduction in waste and downtime, improve plant efficiency and product quality, save energy through proper dryer control and allow for full product inspection.
Snack foods play a significant role in the global food market, generating billions of dollars in revenue each year.
- Potato Chips or Crisps
- Tortilla Chips
- Nuts
- Dried Fruits
- Granola
- Hand or Batch Cooked Chips or Crisps
- Corn Dough
- Popcorn
- Pretzels
- Puffed Corn
- Baked Potato Based Snacks
- Crackers
- Breadsticks
Ensuring consistent product quality and implementing efficient production methods are essential for the success of snack food products.
MoistTech offers multiple sensor options to suit your specific application needs including the standard IR3000 series and IR-3000-F series that is Nickel Plated to specifically allow for food environments where frequent wash downs occur and protects against corrosion and abrasion. The food grade sensor includes a Kel-F window in place of our standard glass.
Measure Moisture in Real Time Now!
Benefits of Proper Moisture Analysis
Our sensor calibrations, measurement wavelengths, algorithms and sensor optical requirements are pre-set at the factory. With impeccable accuracy and consistency, there are a multitude of benefits that are immediately seen with a proper moisture measurement and control system from MoistTech:
- Typical accuracy is about ±0.1% moisture
- Typical analog range is 0-10% moisture
- The outputs can be adjusted to optimize PLC or recording requirements
- Little to Zero Maintenance
- No need for re-calibration or yearly maintenance
- Can be installed anywhere on the line – even at an angle
- Made for harsh environments near ovens and sprayers
- RS232 and Ethernet compatible for real-time control
- Thousands of measurements per second
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MoistTech Corp. manufactures the diamond standard in moisture measurement sensors, service, and support. With over 40 years of experience, our equipment stands above the competition providing continuous, reliable readings with zero maintenance, a one-time calibration with a non-drift optical design that allows operational personnel to confidently make line adjustments based on real-time measurements.
Near-Infrared Moisture Detection is State-of-the-Art
The precision of NIR moisture sensors can help increase the quality of your product resulting in less lost time and money.
Combining our long experience with improvements suggested by our customers, we’ve designed a better, more precise and more accurate NIR moisture sensor.
More Precision Than Other Technologies
The 3000 Series Near Infrared moisture sensor is designed to not only be more accurate but to be low maintenance as well. An initial calibration is all it takes, and our NIR moisture sensor is ready to go. The IR-3000 uses NIR technology to take precise measurements in percentage wet and percentage dry, allowing you to make real time adjustments either automatically or manually. Our NIR moisture sensor will help you achieve a better, more consistent product.
Instant ROI
The most “bang for the buck” happens when you can control the moisture in the process through an automatic, feed-back-loop control system. A feed-back-loop changes the process based on the in-line measurement. If the collection and analysis of real-time data is the only purpose of the testing, but the analysis of the data has potential to define substantive future process changes, an in-line solution may have a high potential ROI.
Avoid Downtime with Quick Measurements
Enjoy immediate adjustments to your process based on real-time measurements from our online NIR sensors. Avoid costly downtime and excessive scrap by catching any out-of-tolerance readings as quickly as possible. Immediate changes can be made to your production line to stop extra waste and keep the line moving. Connect our sensors directly to your PLC by RS232 or Ethernet for complete software control of your line.
Unbeatable Accuracy & Reliability
Our non-drift optical design gives you repeatable results in the most accurate measurements available. Calibrated from the factory, the sensor requires no further maintenance to maintain their accuracy. Results are unaffected by heat or humidity.
Utilizing NIR
By utilizing NIR analysis at the oven exit, plant operators can receive immediate feedback, allowing them to make necessary adjustments to the oven temperatures and optimize moisture levels, typically within a 0.5% range. This results in a more consistent product quality, reduced energy and ingredient costs, and a decrease in out-of-specification products. In fact, in many manufacturing plants, focusing solely on moisture control can lead to a payback period of less than 6 months when using a MoistTech analyzer.
Incoming raw ingredients, such as flour, corn, wheat, and rice, can vary significantly in composition and quality. Surprisingly, many manufacturers do not implement proper quality control measures for these critical ingredients. By analyzing key parameters like protein, moisture, and others, manufacturers can ensure consistent quality from their raw materials. Implementing quality monitoring for raw ingredients results in more consistent products and reduces the need for rework and discarding.
Many snack foods undergo additional processes, such as the application of oil, cheese, or other coatings, after leaving the oven. NIR technology can be effectively utilized to ensure the consistent and uniform application of these coatings. This further enhances the overall quality of the final product.
Installation Tips
Some of the process points in a snack food plant where quality measurements can help control the process, saving money and improving consistency and quality include:
• Raw material testing to verify supplier integrity and ingredient quality
• Monitoring dough or masa for consistency • Monitoring moisture and fat levels at fryer or oven exit
• Monitoring and controlling oils, cheese or other ingredients sprayed on the product NIR analysis is a proven technique that provides simultaneous results for moisture, protein, fat and other parameters instantly.
Constant Return on Investment
Snack food production applications encompass the examination of both the initial components and the final product, facilitating the enhancement of the entire process. The rapid analysis speed enables a comprehensive measurement of all incoming ingredients and finished products, ensuring utmost precision. By verifying the suppliers of raw ingredients, the provision of high-quality materials can be ensured, thereby guaranteeing consistent production and product quality while minimizing the need for re-work.
The primary focus in analyzing snack foods is typically at the oven exit. It is crucial to control the moisture levels in the final products to maintain their quality. Excessive moisture can negatively impact the texture, mouthfeel, and even the microbiological and product stability aspects if left uncontrolled. On the other hand, over-drying the product can affect its palatability and lead to higher drying and ingredient expenses.
Client Testimonials
“Potato flake is mixed with oil, water, butter flavor, salt, milk powder and a mix of other minor ingredients. This is then dried and sent to packaging. Moisture measurement is important to ensure that we are in spec for quality and prevent spoilage. Our plant prefers MoistTech over other NIR sensors we have tried in the past … we have reduced our out of spec product due to moisture content.”
“The knowledgeable MoistTech Team provides our organization with outstanding support through the development and implementation process. We have worked together on a variety of different projects and applications; their experience has enabled our engineering team to properly evaluate and design systems that meet with our customer’s requirements.”
“The system is working very well with an efficiency improvement of 400-600 % improvement in moisture control. We are also looking at promoting this to a best practice suitable for our other plants and shingle lines.”