Innovation Helps Manufacturers Tackle Challenges

Automation helps snack manufacturers grapple with several challenges, including the need for sustainability and energy efficiency, streamlined production processes and increasing labor shortages. Image courtesy of TNA Solutions.

Labor shortages and shifting consumer preferences challenge snack makers.

By Mukul Shukla, Vice President of TNA North America

According to Statista, the U.S. snack food market is projected to generate $51.63 billion in revenue in 2024, with an annual growth rate of 3.25% through 2029.[1] On average, Americans are expected to consume 20.8 kilograms of snacks per person in 2024. As consumers demand healthier, convenient, and affordable snack options, manufacturers face growing pressure to adapt to these evolving trends.

Consumer Trends Shaping the Industry

GlobalData’s 2024 Industry Insights identify key trends driving the snack industry:

The “health and wellness” megatrend continues influencing consumer choices, pushing brands to offer healthier snacks without sacrificing taste. This trend, known as “restrained hedonism,” has encouraged the development of better-for-you options and smaller portion sizes to help consumers meet daily calorie goals.

Meanwhile, the trend “easy and affordable” is growing as consumers, affected by the cost-of-living crisis, become more cautious of “greedflation” and “shrinkflation.” This has led to the rise of “value skepticism,” where consumers expect a balance between high-quality products and affordability, placing greater emphasis on transparency and value for money.

At the same time, the demand for “comfort and authenticity” has intensified as consumers seek snacks that not only provide taste satisfaction but also help alleviate stress. Termed “snacks to relax,” this trend focuses on products offering a sensory escape and a brief moment of calm.

To meet these diverse demands, snack manufacturers are turning to production solutions that are efficient, scalable and capable of delivering a wide variety of high-quality products.

The tna ropac® 5 case packing system, handles up to 200 bags per minute with precision. Image courtesy of TNA Solutions.

Key Manufacturing Challenges

The U.S. food manufacturing sector is grappling with several challenges, including the need for sustainability and energy efficiency, streamlined production processes and increasing labor shortages.

Sustainability and energy efficiency: As consumers demand more sustainable supply chains, manufacturers prioritize energy-efficient production methods that reduce greenhouse gas emissions. These initiatives not only address climate change but also offer long-term economic benefits by lowering operational costs.

Efficient and fast production: Affordability is key in the competitive snack industry. Manufacturers must adopt rapid, streamlined production processes to meet high demand while staying competitive. The trend of restrained hedonism has led to smaller portion sizes, such as launching a 1 oz snack bag or even smaller, requiring manufacturers to produce these bags efficiently and with minimal waste.

Labor shortages: Labor shortages remain a significant challenge. According to Deloitte, 1.9 million U.S. manufacturing jobs are projected to remain unfilled by 2033, highlighting the need for increased automation. The future of food manufacturing lies in embracing technological advancements to balance affordability with flexibility and sustainable practices. Automation, particularly in areas like secondary packaging, will be crucial.

Packaging Equipment Considerations

When selecting packaging equipment, manufacturers need systems that can handle a variety of product sizes and materials, particularly as consumer demand for smaller portions grows. Equipment must be capable of high-speed performance with precision packaging to maximize production efficiency. Automated solutions with tool-less changeovers are important, allowing quick adjustments between product runs, reducing downtime, and ensuring that snack producers can operate continuously.

The tna robag® 3e and tna auto-splice 3 are the perfect pair, delivering up to a 5% increase in production uptime. Image courtesy of TNA Solutions.

Secondary Packaging is a Critical Factor

Secondary packaging is often a bottleneck in snack production. This stage involves securing snacks packaged in pillow bags, for example, into larger containers for transportation and retail. Misalignment between primary and secondary packaging can lead to inefficiencies and excess waste, hindering overall production efficiency.

Innovations such as automated case packers with semi-rotary bag stacking technology can handle up to 200 bags per minute, speeding up the process without compromising product integrity. By utilizing systems that achieve at least 95%

efficiency, manufacturers can optimize production lines, avoiding bottlenecks and improving throughput. This can be achieved with rotary shelves, which gently catch the bags in rows before collectively loading them into the case. The system avoids high accelerations, a critical factor to its success.

Such systems offer tool-less changeovers, allowing manufacturers to quickly switch between different product sizes and configurations, further increasing production line flexibility. Snack producers could opt for a twin-packer configuration to ensure it fits seamlessly into various production environments with minimal floor space requirements—as little as 48 inches per system, which includes a bag conditioner, case packer, case erector and checkweigher.

Packaging Innovations to Enhance Efficiency

The use of automatic film splicing systems in packaging equipment is another element that can help snack producers improve efficiency. Traditional methods required production to be halted when film rolls needed replacing, leading to unnecessary downtime. The latest innovations in automatic splicing systems, featuring a dual-spindle film system and rotary reel-swapping mechanisms, ensure that a new pre-prepared film is always ready to take over from the current roll without interrupting the packaging line.

When combined with the latest vertical form, fill, and seal (VFFS) technology, a significant increase in production uptime can be achieved. For a typical seven hour shift with three shifts per day, bagging at 150 bags per minute, the system can generate an additional 3.5 million bags annually, reducing machine downtime by 385 hours and delivering a 5.1% boost in overall equipment efficiency. Additionally, automatic splicing reduces waste levels to as low as 0.1% while also lowering the risk of human error and improving product consistency.

To further support efficiency gains and reduce waste, snack manufacturers can consider using single-serration jaws on VFFS machines. This can reduce the amount of film used per bag, yielding significant material savings. In a factory producing 150 bags per minute, these savings translate to 2.26 million bags per month. With 10 packaging lines operating 12 hours a day, this results in nearly 240 miles of film saved monthly.

Partnering with a complete line solutions provider can further enable savings for snack brands and reduce the total cost of ownership. Enhanced connectivity between packaging systems and auxiliary equipment, which is easily achieved in this case, allows operators to utilize production lines more efficiently, further improving ROI.

Future Trends in Snack Packaging

Looking ahead, the snack industry will continue to focus on advancements that improve efficiency, reduce waste and enhance sustainability. Automation and connectivity will play critical roles as smart packaging systems increasingly integrate with digital platforms, enabling real-time monitoring and optimization. By embracing packaging innovations, prioritizing sustainability, and addressing labor shortages through automation, snack producers can remain competitive and meet the growing demands of a health-conscious, value-driven market.

About the Author

Mukul Shukla is Vice President of TNA North America with over 25 years of global experience in food processing and packaging. TNA Solutions is a global leader in food processing and packaging solutions, committed to helping people succeed responsibly in a changing world. With over 40 years of experience, TNA’s global team of experts have installed more than 14,000 systems in over 120 countries. Visit www.tnasolutions.com or contact tnateam@tnasolutions.com to learn more.