Analysis: five trends reshaping snack production

The global savoury snacks market is undergoing a rapid evolution, moving from a category dominated by indulgence to one defined by functional benefits, complex flavours, and intense sustainability demands.

According to a new analysis by Twan van den Berg, group solution specialist manager – processing at TNA Solutions, snack manufacturers must shift from incremental upgrades to a holistic, integrated approach to line design to capitalise on five key trends driving the future of snacking.

​The analysis, titled “Feeding the future of snacking from end to end,” identifies the need for production lines that are more flexible, precise, and resource-efficient than ever before.

​1. The dual health imperative: function and plant-powered

Snacking is rapidly replacing traditional meals, with consumers seeking products that offer explicit health benefits. The report notes that better-for-you (BFY) segments, driven by claims like high protein, fibre, or immune support, are growing at double the rate of indulgent categories.

This trend, coupled with the exponential rise in plant-based snacking (a market valued at $16 billion in 2024), is forcing manufacturers to handle increasingly delicate and complex raw materials, including pulses, seeds, and protein isolates.

• ​Operational impact: processing equipment, including slicing, frying, and conveying systems, must now possess unprecedented flexibility to switch parameters — such as oil absorption, moisture retention, and temperature control — between starch-heavy, high-moisture, or unusually shaped inputs while maintaining consistency and high throughput.

2. Mitigating risk: control of carcinogens and trans fats

Regulatory scrutiny over food safety and quality continues to intensify, particularly concerning acrylamide (a naturally occurring substance in starchy foods cooked at high temperatures) and trans fats.

To minimise acrylamide formation without compromising product texture or flavour, manufacturers are increasingly relying on advanced technologies:

• Advanced frying: technologies like low-temperature finish frying (LTFF) and continuous vacuum frying allow precise control over temperature and pressure.
• PEF integration: pulsed electric field (PEF) pre-treatment is becoming essential, gently puncturing cell membranes to remove moisture and sugar before cooking, thereby enhancing sugar extraction and reducing acrylamide formation.

​3. Sustainability and traceability become operational requirements

The focus on sustainability is moving from a brand promise to a non-negotiable operational standard. Aggressive carbon and packaging reduction goals set by major retailers mean manufacturers must design for efficiency and data collection.

• Processing efficiency: solutions must incorporate energy recovery systems, smaller oil volumes to improve turnover time, and water reclaim systems to recycle wash water.
• Packaging mandate: equipment must enable the use of thinner, recyclable films and seamlessly integrate digital, pack-level traceability to comply with legislative mandates, as the reusable packaging market continues its rapid growth.

​4. Flavour innovation demands precision
​Finally, while health and sustainability drive the base product, bold and hybrid flavours — such as smoky lime and “newstalgia” interpretations — are essential for consumer appeal.

Delivering these layered flavour profiles consistently requires high-precision application systems. The analysis highlights that gravimetric on-machine seasoning (OMS) systems are vital for applying exact amounts of dry and liquid flavours, significantly reducing waste and flavor variance. Furthermore, manufacturers must invest in gentle horizontal motion conveyors to ensure fragile, heavily seasoned products reach the packaging line intact.

Van den Berg concludes that to successfully navigate these five intersecting trends, a holistic, integrated production line — from raw product reception to final packaging — is necessary to ensure the flexibility, precision, and digital oversight required to feed the future of snacking.

The fifth and final major trend identified by Twan van den Berg of TNA Solutions is Bold Tastes.

This trend focuses less on health and more on delight, with consumers actively seeking complex and exciting flavor experiences.

Key details of the trend include:

• Flavour profiles: consumers are gravitating toward bold, globally inspired, and hybrid flavors. Examples cited include hot honey, smoky lime, and “newstalgia” flavours — modern interpretations of enduring comfort foods.
• Operational challenge: creating layered flavour and consistent crisp textures requires precise control over seasoning and product handling. Delicate or heavily flavored products must be protected from breakage and flavor variance as they move down the line.

To meet this demand for bold, consistent flavour, manufacturers must utilise:

• Gravimetric seasoning systems: tna intelli-flav OMS (on-machine seasoning) systems are necessary to apply exact amounts of dry and liquid flavours per recipe. This precision is critical for reducing costly ingredient waste and ensuring every bag delivers the same intense, layered flavour profile.
• Gentle handling: horizontal motion conveyors are required to transport fragile or heavily seasoned products, ensuring they arrive at the packaging line intact without losing seasoning or experiencing breakage.