Donkey Brands partners with FOODesign to increase production of its tortilla chips

By Jenny Eagle contact

- Last updated on GMT

Donkey Brands increases tortilla chips production

Related tags: Tortilla chips, Manufacturing, Tortilla

Donkey Brands has partnered with FOODesign from tna, to install an immerso-cook frying machine and quik-coat system for its tortilla chips.

Immerso-cook ​keeps oil clean by removing any particulates and its infeed system stops oil from overheating, preventing harmful fatty acids and free radicals from forming, which can contaminate the oil and compromise product quality. 

An out-of-date manual process

Robert Tisljar, partner, Donkey Brands, said the machine complements its existing FOODesign cutting, conveying and quik-coat seasoning systems and replaces an out-of-date manual process with an automated system. 

Our previous line was predominantly manual and included a smaller fryer, as well as more conventional conveying systems. We were looking for the best way to step into the world of automation to increase production output and improve overall quality of our products​,” he added. 

Immerso-cook has a customizable belt feed system which can reduce the risk of product breakage while optimising throughput speeds.

Any unpreventable waste that can result from delicate snack applications like tortilla chips is continuously discharged from the fryer by the system’s based mounted mesh conveyor.  

Since installing the machine in Carol Stream, Illinois, US, the company claims to have doubled production volumes and optimized its tortilla chip colour, texture and flavour. 

Donkey Brands can produce more tortilla chips with significantly less downtime from changing oil​,” said Tisljar.  

All its tortilla chips have a consistent appearance & taste

According to Tim Reardon, group solutions manager – processing for the Americas, FOODesign, seasoning is vital to a product’s overall taste, texture and appeal. 

He said Donkey Brands installed FOODesign’s quik-coat seasoning drum to ensure uniform coating on every single tortilla chip produced. 

The quik-coat system seasons uneven surfaces and gently tumbles the product, dispersing the right amount of seasoning so all the tortilla chips have a consistent appearance and taste. 

As part of the quik-coat installation, casters were adjoined to the machine so that it can be pulled away from the production line for easy cleaning. 

Now that the new system is up and running, we are experiencing double the production volumes, consistent seasoning application, reduced product breakage and virtually no downtime​,” said Tilsljar. 

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