Bioeconomy
Teesside University collaborated with leading UK snack manufacturer, KP Snacks, to optimise production processes, resulting in healthier crisps and significant efficiency savings. Supported by Innovate UK and the National Horizons Centre, this £2 million project achieved a reduction in oil content, lower acrylamide levels, and improved food quality control.
The snack industry faces increasing pressure to produce healthier products and comply with evolving food safety regulations. Acrylamide, a naturally occurring chemical in fried foods, poses health concerns, prompting manufacturers to seek innovative solutions to reduce its levels while maintaining product quality and efficiency.
Teesside University researchers tackled key areas of the production process to address these challenges. They began by optimising the potato washing process to reduce sugar levels, a critical factor in acrylamide formation. Extensive trials revealed that using a double cold wash, instead of a cold followed by hot wash, was more effective for most potatoes. This approach significantly reduced sugar content while preserving the crisp's taste and quality, as confirmed by taste panel results. The research team also focused on the frying process, identifying temperature variations as a major contributor to increased acrylamide production. By developing an innovative control strategy, the team ensured simultaneous regulation of fryer exit temperature and crisp moisture levels. This solution minimised operator intervention, effectively managed production line start-ups, and maintained consistent quality, even during load variations.
The collaboration delivered measurable benefits for the manufacturer. An 8% reduction in oil content and lower acrylamide levels made the crisps healthier without compromising flavour or quality. The refined control strategies also improved production efficiency, reducing manual adjustments and ensuring consistent output. Taste panel feedback confirmed that the product maintained its high consumer appeal, demonstrating the success of these innovations.
