DKB is always looking for the perfect crunch

A portion of crispy snacks is hard to resist, even if they’re not exactly healthy. Still, there are ongoing innovations in the world of snacks and fries that can help improve their Nutri-Score. DKB Partner in Foodsolutions, known for the brands ECS Paneermeelindustrie and MasterMix, offers every snack and fries manufacturer an innovative solution.

Whether it’s bitterballen (a well-known Dutch snack), chicken nuggets, or fries—snacks have to be crispy. That’s easy to achieve through frying, but with growing focus on health, the industry is actively looking for healthier alternatives. The air fryer has now secured its place in many Dutch kitchens. But its healthy image isn’t entirely justified; snacks and fries are still pre-treated at the factory before they ever reach the air fryer.
“This step is essential to achieve that crispy coating,” says Michiel van der Kaaden, Director of Innovation & Product Development at DKB Partner in Foodsolutions. The company develops, produces, and advises on breadcrumb (mixes), coating solutions (breaders, batters, tempuras, and clearcoats), taste products (spice blends, rubs, and cooking sauces), and functional blends.

Clearcoats

“Fourteen years ago, I travelled to the U.S. to see how they were doing things there. At the time, there was no demand here yet, but we decided to start working on it anyway,” says Michiel. Things really started picking up nine years ago when two cousins approached them with a development challenge. “They were trying to make fries from low-carb potatoes but couldn’t get that crispy coating right,” explains Senior Account Manager Robert Horst. “We took on the challenge and, together with a potato supplier from Friesland, developed low-carb fries for the air fryer.” It proved to be a complex task, as low-carb potatoes—usually used for boiling—contain a high moisture content, making them less than ideal for frying. Michiel: “We developed a special clearcoat that, simply put, helps retain the moisture while also allowing ventilation—a key advantage of using clearcoats.”

Back to the fries example: clearcoats help extend the ‘holding time.’ Regular fries lose their crunch within two to three minutes. Fries with a clearcoat—whether from an air fryer or deep fryer—can sit under a heat lamp for up to ten minutes without losing their crispiness. Robert: “The same goes for snacks coated with a clearcoat. But before the snack and fries industry fully embraces this innovation, there are still some hurdles to overcome.”

Michiel van der Kaaden (left) and Robert Horst

Complex challenges

This case clearly shows that DKB Partner in Foodsolutions knows how to handle complex challenges. Robert: “When potential clients—industrial producers of snacks, meat, poultry, fish, vegetarian, or potato products—come to us, we map out their specific demand and the possible solutions. What machinery is already in place? How do the lines work? What substrate is being used? From there, we find the most optimal product and process: can we apply a spray coating, or would an oven batter be a better fit? That’s how we always arrive at a tailor-made solution.”

Non-fry

The team has been working for years on techniques that deliver that signature crunch in snacks and fries—without the need for pre-frying. Robert: “Manufacturers struggle with how to position a healthier product within their existing range. R&D teams are usually enthusiastic, but marketing departments can be hesitant—they’re the ones who need to convince the end consumer, even when the product changes.” Michiel adds: “We sometimes use the example of Coca-Cola Light and Zero. Internally, there was skepticism too. But now those healthier options might actually be more popular than classic Coca-Cola.”

In development

DKB Partner in Foodsolutions is currently expanding on several fronts. A third coating line is being built, along with a new blending facility and increased capacity for sauces. They’re also developing a dedicated gluten-free production site, where the clearcoat products will be made as well. “We plan to roll out the coating technology developed for fries to a wide range of other products,” says Michiel. “And we’re setting up an R&D demo space where we can inspire both current and potential customers with our innovations.”

www.dkbfoodsolutions.com