Frito-Lay snack patent: It’s baked, but tastes fried

Frito-Lay is now looking to patent a corn-based baked product made using its method

Frito-Lay has been granted a US patent for its manufacturing process to bake snacks that maintain the taste and texture of a fried product using a hydration step.

The snack giant filed patents for the same process in Europe, Canada and China but they remain pending. Since the US patent grant, Frito-Lay has filed a request to patent a corn-based snack made following its method.

“Recently, as the consumer becomes more health conscious, baked snack foods have been developed as a healthier alternative to fried snack foods. However, many baked snack foods have been unable to mimic the texture and taste associated with traditional fried products,” it wrote.

Therefore, Frito-Lay said there was a need to manufacture a low-fat baked product that resembled a traditional fried snack food.

Hydration is the secret

A hydration step, introduced after mixing and extrusion, was the vital step, the snack firm said.

“…The hydrating step has a surprising effect on the texture of the baked product,” Frito-Lay wrote. “Applicants discovered that as the moisture content of the collet before baking increased, the crunchiness of the baked product likewise increased.”

Hydration fluids could be a mix of water, oil, additives and surfactants and added immediately after extrusion or days, even weeks, after.

However, findings showed there was an optimal level of hydration - 30 g of water per 100 g of product. Once over this, the product significantly reduced in size.

This increase in hydration changed the surface cellular structure from porous to a closed cell structure and promoted more heat transfer in the baking stage, Frito-Lay said. Used at the hydration step, the oil also improved taste.

Benefits? Better seasoning with a healthy twist

Frito-Lay said the increased moisture content led to stickier collets, which had benefits when flavoring the product.

“One such benefit is the ability to better adhere ingredients such as spices or seasonings to the surface of the collet. This increased adherence also provides for the addition of starches, seeds, or other ingredients that can enhance the taste or nutritional qualities of the snack food,” it wrote.

In addition, the hydration fluid could be used to lower oil use – enabling manufacturers to better control the fat content – and incorporate flavors and even nutritional ingredients like protein fractions.

“The hydrating step provides for a way to control texture and size of an extruded starch product without adversely affecting the nutritional value of the product. Put differently, the hydrating step allows the textural attributes of the baked snack food to better resemble the textural attributes of the fried snack food,” Frito-Lay wrote.

Related News

'At Frito-Lay, we believe the productivity opportunity is significant. Our productivity agenda pursues cost reduction and capability building initiatives to deliver results,' says company president

Frito-Lay president: 'We’re laser-focused on productivity’

'Moisture in the mouth provides the catalyst to initiate popping and provide the desired carbonated soda feel'

Crunchy, chewy, and fizzy? PepsiCo seeks to patent chewy granola snacks with carbonated candy

Frito-Lay has drawn inspiration from pizzas, caprese salads and tostadas to make chunky, 3D snacks

Is that a pizza or a pretzel? Frito-Lay files patent for chunky 3D snacks

Frito-Lay harnesses Twitter’s video streaming platform for Doritos Roulette launch

Frito-Lay gambles on US market with Doritos Roulette

Frito-Lay has filed a patent for crisp bread snacks that use traditional dough recipes

Frito-Lay files patent to ‘snackify’ bread

Frito-Lay claims its method is more efficient than previous processes for industrial pita chip production. Photo Credit: Simply So Good

Frito-Lay files patent for ‘improved’ pita chip production

Frito-Lay said the oil reduction is 'surprising' with reduced pressure production

Frito-Lay granted US patent for reduced oil potato chip process

Lay's was the third most-chosen global food brand in 2013

Snacks stretch PepsiCo’s global reach 3%: Kantar Worldpanel

Frito-Lay has filed an international and US patent on process method and design relating to its deep-ridged potato chips; the first launch was Ruffles in 2012

Frito-Lay to drive deep-ridged success wider in 2014/15

Comments (2)

Kacey Culliney - 23 Jul 2014 | 05:23

Patent number

Hi A Smith - the patent number for the US one that was granted is: US8703226

23-Jul-2014 at 17:23 GMT

A Smith - 23 Jul 2014 | 05:04

Patent link?

I would like more information on this patent, do you have a link?

23-Jul-2014 at 17:04 GMT

Submit a comment

Your comment has been saved

Post a comment

Please note that any information that you supply is protected by our Privacy and Cookie Policy. Access to all documents and request for further information are available to all users at no costs, In order to provide you with this free service, William Reed Business Media SAS does share your information with companies that have content on this site. When you access a document or request further information from this site, your information maybe shared with the owners of that document or information.