Puffed Snacks 1: Wherefore the Puff?

posted by Dave Arnold

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I love puffed snacks. Everyone loves puffed snacks. I thought it was time we posted on them.

Why do things puff?

Most puffed snacks are created using an extruder to process starch. Inside a lengthy barrel, a screw mixes, compresses, and cooks the starch mixture through friction (sometimes with added heat). By the time the mixture reaches the die at the end of the barrel, it is extremely hot (well over 100°C) and under substantial pressure. The pressure release at the die causes the water to boil off rapidly, both puffing and drying the product in the process. Though we don't have an extruder at school, we still manage to produce puffed treats.

Foods meant to be puffed snacks have a glass transition temperature higher than water's boiling point. When you heat the glassy pre-snack above 100°C, the trapped water begins to boil, causing the material to become rubbery and allowing for rapid expansion. Once the water evaporates, the product sets into a crunchy texture.

Points to remember if you want to do your own puffing:

• The product you start with must be amorphous. Crystals won’t puff. This is crucial to remember.
• The water content must be correct. Too little water results in burning and less puffing because the temperature will rise too high before reaching the glass transition, there is inadequate water for sufficient puffing, and without enough water, the snack won't be flexible enough to expand.
• Other substances like salt and maltodextrin can also act as plasticizers.
• Heat quickly and evenly. Methods like frying, air popping, using heat guns, or microwaves are all effective.
• Avoid adding ingredients like sugar that will burn before the snack is fully puffed or compete with the water and prevent proper puffing.

Two main categories of things that puff: connective tissue and starches.

Connective tissue, rich in collagen, puffs when the collagen turns into gelatin and subsequently becomes a glassy substance upon dehydration. Examples include pork rinds and even experiments with beef tendon and cod swim bladders.

Starches contain amylopectin and amylose, with amylopectin contributing to structure and amylose aiding in fluidity and expansion. Proper cooking is essential to disrupt the crystalline nature of native starches, turning them into an amorphous state suitable for puffing.

Almost anything primarily composed of starch can be puffed: rice, corn, pasta, tapioca starch, wheat starch, etc.

How do you make a puffed snack?

Making puffs involves over-cooking, dehydrating, and frying. First, over-cook the item to fully gelatinize the starch or break down the connective tissue. Then, dehydrate the product until its moisture content is between 10-15%. Finally, fry the dehydrated item in hot oil to achieve the puffed texture.

For example, over-cook pasta in heavily salted water for about 45 minutes. Dehydrate the pasta until it becomes flexible yet plastic-like. Then, fry it to create delicious puffed pasta.

Similarly, for pork rinds, boil pork skin in salty water for 60-75 minutes, refrigerate and scrape off the fat, dehydrate until plastic-like, and fry in very hot oil.

Puffed and extruded snacks never go out of style. Top brands like Cheetos and Fritos remain staples in many American homes.

However, companies continue to explore new and better-for-you ingredients, benefiting product developers aiming to meet the needs of the mindful snacking consumers. According to IRI data for the 52 weeks ending on September 6, 2020, the “other salted snacks (no nuts)” segment hit $5.2 billion in sales, an 8.2% increase. Leading this category was Frito-Lay, with $3.5 billion in sales and a 10.4% growth.

The cheese snacks segment within salty snacks grew by 10.7%, reaching $3.0 billion in sales. Frito-Lay leads again with $2.4 billion in sales. The corn snacks segment brought in $1.3 billion, with Frito-Lay dominating at $1.1 billion.

The pork rinds segment saw $600.7 million in sales, growing by 3.3%. Mac’s Snacks is gaining on the segment leader, Frito-Lay, with an 18.2% increase in sales.

Ingredient inspirations

Despite pandemic-induced challenges, product innovation continues. Many brands focus on core products, working to keep their existing fan base happy. Additionally, brands are addressing label concerns, embracing options like sunflower oil and pea protein to replace traditional ingredients.

Brands also reassess their starch choices, with some replacing modified starches with functional, label-friendly options like Cargill’s SimPure line. Innovation in incorporating new textures and flavors is ongoing, as brands move towards more label-friendly formulations.

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Mel Festejo, COO, American Key Food Products, notes the focus on millennial consumers, who drive growth for better-for-you snacks by preferring health and wellness foods. This trend brings non-traditional ingredients into extruded snacks, increasing protein and fiber while reducing sugars and carbs.

Cheeses, nuts, root vegetables, and exotic ingredients like seaweed are now used in extruded snacks, providing diverse options for health-conscious consumers. Some ingredients are blended with others to ensure proper extrusion. Non-GMO and gluten-free flours are also gaining popularity as extrusion aids.

Better technology

Nutritious snack inclusions like legume-based proteins are drawing attention. Processing methods like impingement processing create new puffed products from ingredients like black-eyed peas and quinoa. Twin-screw extrusion is expected to grow rapidly due to its flexibility in processing various ingredients and differing final product configurations.

The twin-screw extruder enables manufacturers to incorporate dry vegetables and seeds into snacks, adding both visual appeal and nutritional value. Co-extrusion technology enhances snacks with crispy outer shells and soft fillings, catering to clean, all-natural appeal or savory and dessert-style flavor combinations.

Product innovations

In 2020, Ancient Ingrained Snack Co. launched 100% Ancient Grain Sorghum Puffs in flavors like Vegan Cheddar and Sriracha. These puffs are top sellers online, with consumers seeking flavors they crave while maintaining a healthy profile.

Comfort foods are trending, driving demand for flavors like Cheddar Chips and Cinnamon Churro Puffs. Brands focusing on emotional and value-based benefits are outpacing those targeting traditional health claims. Consumers are increasingly supporting brands addressing climate change and transparency.

Outstanding Foods launched vegan PigOut Pigless Pork Rind in February 2020. This plant-based product mimics the taste and texture of traditional pork rinds while offering 7 grams of protein per ounce. It has attracted a diverse consumer base, including former pork rind eaters and those looking for high-protein snacks.

The primary trend in puffed snacks is great taste coupled with nutritional functionality. The first wave of healthier puffs removed artificial ingredients, while the second wave added nutrition. The current trend significantly boosts the nutritional profile of puffed snacks.

The demand for high-protein and high-fiber snacks is rising, with healthy ingredients appearing in simpler formulations. Puffed snacks are now utilizing plant-based proteins, non-GMO flours, and bold flavors for differentiation.

Extruded snacks are gaining popularity due to their nutritional status, with expanding interest in non-GMO, organic, low-carb, and Paleo options. Research and development efforts continue to enhance shelf life, texture, flavor, and nutritional value.

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