Food Additives

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Aitzaz Gahuri Dear Sir/Madam! My name is Aitzaz Ghauri and I am working as Factory Manager in Pakistan’s Largest Snack Food Manufacturing Company "Tripple –Em (pvt) Limited" and we are located in Pakistan’s 2nd largest city Lahore.



Our Company is engaged in the manufacturing of Potato Chips, Potato based Pellet Products, Fried Nuts & Corn Based Extruded Products.



The reason for contacting you is to seek help / guidance from you to resolve our one issue.



One of our leading products is a corn based extruded product (Snacks). You may say it Cheese Curls. The process of manufacturing of this product is as follows.



Homogenized Mixing of Fine & Coarse Grade Corn Gritz and the mixture is called "meal" and at the time of mixing we maintain a moisture level of 14~17 % in the meal for smooth running in the extruder.
Extrusions of the meal under high temperature with the help of a screw type high speed extruder to attain non uniform shape of the product. (Non Uniform Shape of the product is market requirement.
Storage of the extruded products into high density polypropylene bags having 75 micron thickness to avoid penetration of moisture.
Online (Continuous) Baking of the products.
Online Flavoring of the product. After flavoring a moisture level of 2~3 % is maintained to protect the product from fungus and to keep its crispness.
Packing in Pillow Shape Packets. Nitrogen gas is filled in the bag to keep the product afresh till its shelf life


The product we are discussing is very soft in texture, have good Crisp & Crunch and dissolves as soon as customer takes it in the mouth.



Sir/Madam! In our Country we have 4 seasons (spring, autumn, summer & winter).



The autumn seasons starts from the first week of July Every year and lasts till the mid of September. During this season, we face high temperature with high humidity level. The temperature goes as high as 38~40 deg C and humidity level rises up to 55~60 %. Since our product is very soft, corn based, and has a inherited characteristics to absorb moisture therefore in hot and humid season, we have a large volume of customer complaints from the market about the sogginess before the end of its shelf life. We have taken many measures to over come this problem for example we try to give minimum stay time to the naked product at packing machines, have improved the sealing of the packet to avoid penetration of the moisture after packing but no improvement as yet has been seen and the volume of customer complaints could not be reduced.



As a matter of fact, the problem starts when the polythene bags are opened in the packing hall where we have to give a stay time of 4~5 minutes to the product in open atmosphere while it is being packed. As our product has very soft texture therefore it has a very week resistance against moisture.



We seek your guidance / help in this regards as to how we can be able to overcome the problem of penetration of moisture in the product. We think that if we can find any food grade chemical etc which can be mixed with its raw material which can increase its strength against moisture without disturbing its basic taste can be helpful.



I hope you will oblige us to take some of your time to guide us. If you need some more information as regards to our process or flavor, I would be pleased to assist you.



With Best Regards,



Aitzaz Naveed Ghauri,

Factory Manager,

Tripple-Em (pvt) Limited,

149-B Industrial Estate Kot Lakhpat,

Lahore-Pakistan.

Tel: 92 42 35150551~3

Direct: 92 42 35121808

Fax: 92 42 35110299		 9/29/2011
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