In snack food manufacturing, getting the seasoning to stick evenly is far more complex than simply dusting flavour onto product. Every snack producer has faced the frustration of inconsistent coating, where some pieces are overloaded while others are barely seasoned at all. But what actually causes seasoning to fall off?
1. Poor Oil Application
A light coating of oil helps seasoning particles adhere, especially on baked or extruded snacks. If oil is applied unevenly or at the wrong temperature, the seasoning has nothing to bind to. Too much oil can be just as problematic, making seasoning slide off rather than stick.
2. Incorrect Seasoning Particle Size
Seasoning blends that are too coarse tend to bounce or roll off, especially on smooth snack surfaces. Over-fine powders can clump, creating dust rather than coating. The ideal particle size depends on snack geometry and surface roughness.
3. Low Surface Temperature
Snacks that enter the seasoning system too cold do not bond well with oil or dry seasoning. Warm products help activate starch surfaces and improve adhesion. When snacks cool during transfer, coating efficiency drops.
4. Insufficient Tumble Time or Contact
If the seasoning drum is too small, too shallow, or the angle is wrong, snacks will not be exposed to seasoning long enough to achieve a uniform coat. High throughput without matching dwell time is a leading cause of loss.
5. Static Charge & Airflow
Static electricity can interfere with powder flow and adhesion. Likewise, incorrect airflow from ventilation, cooling systems or extraction can pull seasoning away before it settles.
6. Over-Drying or Over-Frying
Snacks with too little surface moisture, particularly baked snacks, can become too dry to hold seasoning. When surface oils are stripped away, adhesion is reduced.
7. Poor Seasoning Delivery System
If the seasoning applicator pulses, drops clumps, or does not meter evenly, the application will never be consistent. Vibratory seasoning conveyors or controlled auger feeders offer better control than manual systems or basic sprinklers.
8. Inconsistent Snack Geometry
Chips, rings, curls, pellets and multigrain shapes all behave differently. Seasoning challenges increase when the line runs multiple products with different surface textures and sizes.
Seasoning fall-off is rarely caused by one issue alone. It is usually a mix of incorrect oiling, poor process control, temperature variation and unsuitable application machinery. Understanding these root causes allows manufacturers to regain control over yield, flavour consistency and product quality. One thing that you can be sure of however, using a KMG Vibratory conveyor will not cause the seasoning to fall off! Have a look at this video for more information: