Regulatory scrutiny over acrylamide and trans fats is intensifying. Acrylamide, a naturally occurring substance that forms when starchy foods are cooked at high temperatures, has caused health concerns among consumers. In response, technologies such as low-temperature finish frying (LTFF), vacuum frying and pulsed electric field (PEF) treatment are becoming essential for snack producers.
Multi-zone fryers like the tna conti-pro PC3, the tna thermo-wash HW3 (blancher), and continuous vacuum fryers like the tna vac-pro® 3 allow precise control of temperature and pressure to minimise acrylamide formation and reduce oil content without compromising texture or flavour. For example, PEF technology gently pre-treats the raw material by using pulses of electricity to puncture cell membranes, allowing fluid to exit. As a result, sugar and moisture are removed. This enhanced sugar extraction results in reduced acrylamide formation during cooking, while also allowing the use of all potato varieties, including those with high sugar levels / late-season potatoes. Integration with in-line oil filtration and defatting ensures optimum oil quality and reduces waste.
4. Planet-friendly treats
Sustainability is no longer just a brand value; it’s an operational requirement. Leading retailers have set aggressive carbon and packaging reduction goals, and snack manufacturers are expected to meet them with both design and data.
This means incorporating energy recovery systems, smaller oil volumes to improve turnover time, reclaim systems to recycle wash water, and low-footprint frying solutions. According to Towards Packaging, the reusable packaging market will grow from $114 billion USD in 2022 to nearly $200 billion USD by 2032, driven by legislative mandates. Equipment must now enable thinner, recyclable films and seamless integration of digital pack-level traceability.
5. Bold tastes
The final trend is less about health and more about delight. Consumers are gravitating toward bold, globally inspired and hybrid flavour experiences. Hot honey, smoky lime, and “newstalgia” flavours — offering modern interpretations of enduring products such as cinnamon toast — are entering the mainstream.
But creating products that deliver layered flavour and crisp textures consistently requires precise control over seasoning and product handling. Gravimetric on-machine seasoning (OMS) systems such as tna intelli-flav® OMS 5.1 apply exact amounts of dry and liquid flavours per recipe, reducing waste and flavour variance. Meanwhile, horizontal motion conveyors ensure fragile or heavily seasoned products reach the packaging line intact.
Staying a cut above
These five trends demand not just better equipment, but better integration. It is no longer viable to address each new requirement in isolation. What’s needed is a holistic approach to production line design and execution.
TNA Solutions offers complete line solutions for snack manufacturers, from raw product reception to primary and secondary packaging. Our systems are engineered not only to meet current standards, but to provide the flexibility, precision and digital oversight needed for what comes next.
One company already benefiting from this integrated approach is Benestar Brands, a leading US-based producer of pork rinds and cracklings. Facing rising energy costs, evolving quality expectations and retailer-led sustainability targets, Benestar turned to TNA to help overhaul its processing and packaging lines.
Together, the two teams developed a fully integrated system covering everything from frying and seasoning to primary and secondary packaging. At the heart of the solution was the tna batch-pro12, a high-performance batch fryer that helped reduce oil use and bring product rejects below 3 percent. Featuring a serpentine heat exchanger tube configuration, the batch fryer system utilises a remotely installed gas-fired heating system for enhanced energy efficiency and lower operating costs. Thanks to its high-speed, three-stage oil filtration system, the tna batch-pro 12 extends oil life and maintains product consistency, too.
To complement this, the tna intelli-flav® OMS 5.1 seasoning system enabled precise flavour application across both pork rinds and cracklings, cutting down on costly ingredient waste and ensuring flavour consistency at speed. Finally, the tna robag® 3e vertical form-fill-seal system brought high-speed versatility to the packaging line, allowing Benestar to pack multiple product types and bag sizes on a single line without compromising throughput.
The results were significant: improved product quality, reduced environmental impact, and a faster return on investment. TNA’s remote support and training also ensured Benestar’s team were fully equipped to operate and optimise the new line with confidence.
In a market that rewards flexibility, quality and sustainability, Benestar’s success is a compelling example of how the right systems — and the right partner — can help snack manufacturers stay ahead of the curve.
As the snack aisle continues its shift from guilty pleasure to purposeful choice, manufacturers will face even greater expectations in 2026. Portion control will rise further as consumers manage calorie intake. Retailers will increase demands for transparent, clean-label products and recyclable packaging, reinforced by tightening regulations. At the same time, the snacking-as-meal trend will deepen, making efficiency, flexibility and sustainability non-negotiable. In a market that rewards resilience and agility, TNA’s complete line solutions help producers stay ahead of these shifts, ensuring that snacks not only taste good, but do good.
