Background:
A popular savory snack manufacturer approached us with a challenge. Their traditional snacks, including items like namkeen, chakli, and sev, had a shelf life of only one month. This limited their distribution capabilities, especially for international markets where longer shipping times and storage periods were necessary. The goal was to extend the shelf life of these products to at least 8 months while maintaining their crispiness, flavor, and overall quality, all without adding synthetic preservatives.
Objective:
The primary objective was to extend the shelf life of the savory snacks from 1 month to 8 months, ensuring the retention of key attributes such as crispiness, taste, and texture. The company emphasized maintaining the natural appeal of the product and avoiding synthetic preservatives.
Challenges:
- Oil Rancidity: High oil content in many savory snacks could lead to rancidity, especially over longer storage times. Preventing oxidation of the oil without altering the flavor was a significant hurdle.
- Moisture Absorption: Savory snacks tend to absorb moisture from the environment, leading to loss of crispiness. Proper moisture control was necessary.
- Microbial Growth: Though savories are typically low in water content, improper storage can still lead to microbial growth, particularly from molds.
- Packaging: The current packaging was insufficient for maintaining product freshness over an extended period.
Solution & Formulation by Food Research Lab:
Antioxidant Usage:
- To prevent oil rancidity, natural antioxidants were incorporated into the formulation. These natural ingredients helped slow down oxidation and kept the oil from going rancid over time.
- Additionally, frying techniques were optimized to minimize oil absorption, thereby reducing the risk of rancidity.
Moisture Control:
- We recommended reducing moisture content further during the production process. Low-temperature baking and dehumidifying steps were introduced in the final stage to achieve optimal moisture levels, ensuring the snacks remained crisp for an extended time.
- Ingredients that naturally have low moisture content and act as moisture barriers, like rice flour and gram flour, were optimized in the formulations.
Modified Atmosphere Packaging (MAP):
- Modified Atmosphere Packaging (MAP) was implemented, which involved flushing the packaging with an inert gas such as nitrogen. This technique reduces the presence of oxygen, preventing both oxidation and microbial growth.
- Multi-layered barrier packaging was used to ensure the product was protected from external moisture, light, and oxygen.
Vacuum Sealing:
- Vacuum sealing was also recommended for certain types of snacks that could tolerate this packaging method. This method drastically reduces the oxygen inside the packaging and extends shelf life by preventing oxidation and staleness.
Natural Preservatives:
- Natural preservatives with antimicrobial properties were incorporated into the seasoning mix. This acted as a natural preservative while enhancing the flavor profile of the product.
- Specific savory snacks, such as chakli, benefited from natural ingredients like garlic extract and turmeric, which have natural antioxidant and antimicrobial properties.
Storage Recommendations:
- A cold storage protocol was suggested for warehouses and distribution centers. The products were stored at a controlled temperature of 10-15°C to prevent any form of microbial growth or degradation in the quality of the oil.
- Detailed storage guidelines were created for retailers and consumers to ensure that the snacks remained in optimal condition until consumption.
Implementation:
After multiple rounds of testing and product trials, we successfully extended the shelf life of the savory snacks to 8 months. Stability testing was conducted at various intervals—1 month, 4 months, and 8 months—checking for any changes in sensory properties (taste, texture, and appearance) and microbiological safety.
Outcome:
The client was able to extend the shelf life of their savory products to 8 months while maintaining their signature taste and texture. The new extended shelf life allowed the client to:
- Enter new international markets where longer shipping and storage times were necessary.
- Increase their sales and market reach by supplying their products to regions with less frequent restocking.
- Reduce product wastage due to spoilage, improving overall profit margins.
Additionally, the client received positive consumer feedback for the retained quality of the snacks even after extended storage times, and the “natural preservative” approach resonated well with health-conscious customers.
Conclusion:
By utilizing natural antioxidants, moisture control techniques, advanced packaging solutions like MAP and vacuum sealing, and storage optimization, we successfully extended the shelf life of the client’s savory snacks from 1 month to 8 months. This approach allowed the client to maintain the quality and natural appeal of the snacks, expand their market, and improve profitability
