Potato and corn snacks: slice, fry, season and bag under nitrogen.
Every bag on weight, every seal tight, every flavour cleared.
totalMOS runs a chip and snack plant from the fryer to the bagger: the seasoning weighed out against the formula, the line cleared between flavours, bag weight, residual oxygen and seals checked on time at the bagger, and every bad reading taken to closure.
Where a snack line loses product
Giveaway hides in the average
A bagger set a few grams heavy to stay safe gives product away all shift, and one set light puts the whole order at risk. A clipboard of single weights never says which one you have until the shift is over.
One flavour bleeds into the next
Cheese & Onion after Sea Salt is an allergen changeover, not a film swap. When the clearance lives on paper, nobody can prove the seasoning drum was emptied before the next flavour started.
Seals and gas flush fail quietly
A leaking seal or a weak nitrogen flush looks like a perfect bag at the end of the line and a stale one on the shelf. When the check is late, the pallets are already wrapped.
How totalMOS runs a snack line
Every check on its own clock at the bagger
Bag weight and residual oxygen every hour, the metal detector every thirty minutes, moisture and colour grade every two hours. Each counts down on the iPad at the bagger and is judged against that SKU’s limits the moment it is typed.
Seasoning weighed out against the formula
A batch order turns the product’s formula into the kilograms of potato, oil, seasoning blend and salt. Two people sign the sheet, and it keeps the formula it was struck from.
A failed seal puts the pallets on hold
An out-of-spec reading opens a non-conformity before the check can close. The supervisor counts the hold in bags, cases, pallets or kilograms, records the AQL disposition, and the mechanic records the fix on the same record.
Giveaway and defects, by machine
Every production order’s weight curve shows its bag weights against the target weight, and the Pareto shows which bagger and which defect type are behind the out-of-spec readings.
The checks on the line
The demo snack plant ships with the checks a bagging line runs, from bag weight to broken chips per bag. Your own tests, limits and frequencies replace them.
- 50 products, each with its own limits
- Holds counted in cases, pallets, bags, or kilograms
| Check | Default spec | Sample | Frequency |
|---|---|---|---|
| Bag weightWeight curve10 samples · Every hour | 147-156 g · average ≥ 150 g | 10 samples | Every hour |
| Residual oxygen10 samples · Every hour | 0-3 % | 10 samples | Every hour |
| Seal integrity10 samples · Every hour | Pass | 10 samples | Every hour |
| Moisture3 samples · Every 2 h | 1-2 % | 3 samples | Every 2 h |
| Oil content3 samples · Every 4 h | 30-36 % | 3 samples | Every 4 h |
| Salt content3 samples · Every 4 h | 1.2-1.8 % | 3 samples | Every 4 h |
| Metal detector check1 sample · Every 30 min | Pass | 1 sample | Every 30 min |
| Colour grade5 samples · Every 2 h | Light, Golden, Amber | 5 samples | Every 2 h |
| Broken chips per bag5 samples · Every 2 h | ≤ 6 pieces | 5 samples | Every 2 h |
| Date code1 sample · Every 2 h | Best-before, counted from the shelf life | 1 sample | Every 2 h |
Frequently asked questions
Can every flavour and pack size have its own spec?
Yes. Every product carries its own limits for every check: a 40 g bag and a 200 g bag have their own weight band, and a lightly salted tortilla has its own salt range. The demo plant ships with fifty SKUs built that way.
How does it handle allergen changeovers?
A changeover checklist runs whenever the bagger last ran a different product. Critical items, such as emptying the seasoning system to the changeover matrix, must pass before the run starts, and the completed checklist stays on the run’s record.
Does it show giveaway on bag weight?
Yes. Each product has a target weight, and the weight curve of every production order plots its bag weights against it, so giveaway and underweight risk are visible order by order instead of in a month-end reconciliation.
How is the metal detector check recorded?
As a pass-or-fail check with its own countdown, every thirty minutes in the demo plant. A failure opens a non-conformity with defect types such as detector sensitivity drift or reject gate fault, and the pre-start checklist confirms the test pieces before the first bag.
Other industries
See it with your own SKUs.
Thirty minutes, with your flavours, pack sizes and specs set up before the call.
Book a demo