Client
SPF Food Manufacturing Company
Industry
Snack & Ready-to-Eat Food Manufacturing
Challenge
Inconsistent drying of snack products led to variable crunch levels, longer processing times, and high energy costs.
Background
A leading manufacturer of baked snacks and ready-to-eat items was facing persistent issues in their drying stage. Their conventional dryers produced uneven moisture removal, which caused some batches to be under-dried (leading to softer texture) and others to be over-dried (causing breakage and wastage). The inconsistent texture lowered product quality and shelf life, while inefficient drying increased both time and energy consumption.
To address these problems, they partnered with Nexgen Machines and implemented the Tray Dryer, designed to deliver uniform hot-air drying with precise control and hygienic construction, ensuring consistent crispness and efficient throughput for their snack manufacturing line.
Challenges
Uneven Drying
Variable airflow and temperature zones led to inconsistent moisture levels across trays.
High Rejection Rate
Over-dried snack pieces were brittle; under-dried pieces lacked crispness – both affected quality
Energy & Time Inefficiency
Older dryer technology consumed more power and required longer cycles to meet quality specs.
Manual Supervision
Operators needed to continuously monitor and adjust the process, reducing operational efficiency.
Solution: Nexgen Tray Dryer
Nexgen Hygiene Systems supplied their Tray Dryer, tailored for snack production demands: uniform drying, controlled heat, and hygienic design.
Key Features:
Uniform Air Distribution
Ensures even hot-air flow across every tray to avoid dry spots or wet spots.
Digital Temperature Control
Maintains set drying conditions to deliver consistent texture.
Hygienic Construction
Food-grade stainless steel, easy to clean, meets snack manufacturing sanitation standards.
Energy-Efficient Design
Optimized insulation and air recirculation reduce power usage.
Flexible Tray Loading
Compatible with different snack SKUs – chips, puffs, seasoned items – allowing scale and variation.
Implementation
- Phase 1 – Process Audit:
Nexgen’s team assessed current drying bottlenecks, measured airflow inconsistencies and load variation across trays. - Phase 2 – Installation & Calibration:
The Tray Dryer was installed in line with SnackPlus’s production belt; settings were calibrated for each snack type to achieve the target moisture level and crispness. - Phase 3 – Training & Validation:
Operators were trained on tray loading, temperature adjustment, and maintenance routines. Post-installation runs validated performance and consistency.
Results
Consistent Crisp Texture
All batches achieved the desired level of crunch and uniform appearance.
40% Reduction in Drying Time
Optimized drying cycle accelerated throughput and freed line capacity.
25% Energy Savings
Less power required thanks to efficient heating and air recirculation.
Zero Batch Rejection from Drying
No snack batch rejected due to drying inconsistency.
Improved Shelf Life & Quality
Residual moisture lowered → better product stability and customer satisfaction.
Product Aroma and Colour Maintained
Client-highlighted outcome — the most important parameter in the dehydration process, confirming controlled heat transfer and uniform airflow.
Client Testimonial
“The Nexgen Tray Dryer has completely transformed our snack drying stage. Every load now comes out evenly crisp with no weak spots. We’ve also shortened our cycle and cut down energy cost — a great step forward for quality and efficiency.”
– Production Manager, Manufacturer of Baked Goods
Conclusion
With the installation of Nexgen’s Tray Dryer, SnackPlus Foods solved its long-standing drying issues. The solution delivered faster, consistent, energy-efficient drying and elevated product quality – enabling the brand to meet consumer expectations while optimizing production output.
Want to enhance your drying process for snacks? Reach out to Nexgen Machines to explore how our Tray Dryer can bring texture consistency and efficiency to your line.
Note:
For confidentiality reasons, the actual name of our client has not been disclosed. In this case study, SPF Food Manufacturing Company has been used as a representative name. The results, challenges, and process improvements described are based on a real implementation of Nexgen Hygiene Systems’ Tray Dryer Technology. This allows us to respect client confidentiality while sharing the measurable success achieved, including 40% faster drying time, improved texture consistency, and significant energy savings in snack and ready-to-eat food manufacturing operations.