There are literally hundreds of bits, morsels, and inclusions to choose among. Therefore, the first step in determining how each should be handled is testing. Whether the final product is a cracker with specks included to enhance flavor, or a breakfast bar that includes caramel bits, careful consideration about how to best handle each ingredient is crucial for success. Most need gentle handling; indeed, some inclusions should not be automated to ensure consumers see what they are paying for!
Bits, Morsels, Inclusions Attributes
Toxicity
Low
High
Abrasiveness
soft
hard
Friable
Solid
delicate
Combustible
Low
High
Flowability
free-flowing
poor
Hygroscopic
not
high
Bulk Density (lb/CF)
light
heavy
particle Size
Coarse
fine
Bits, Morsels, and Inclusions Handling: Overview
Bits, morsels, and inclusions are the large, identifiable ingredients often used in manufacturing food such as snacks, candy confectionary, and mixes and blends. Inclusions are often explicitly advertised on product packaging, so their presence is both expected and verified by consumers. Frequently sticky, prone to clumping, or easily crumbled or broken (friable), bulk ingredient handling of bits, morsels, and inclusions requires a high degree of expertise. Careful consideration of each ingredient’s unique characteristics ensures the bulk handling system delivers consistent, reliable flow that addresses the challenges of bits, morsels, and inclusions.
Bits, Morsels, and Inclusions Handling: Common Challenges
Bits, morsels, and inclusions have a broad range of diverse characteristics.
Bits, morsels, and inclusions have a broad range of diverse characteristics.
Automated handling must overcome stickiness in dried fruits.
Automated handling must overcome stickiness in dried fruits.
Many popular breakfast bars contain fruit-based bits that could range from blueberries to cranberries, strawberries to apples, and beyond. Whatever the fruit, it’s likely very sticky and difficult to handle. Thorough product testing is recommended before finalizing any material handling plans. If a recipe calls for dried fruit inclusions, their unique handling requirements are a potential risk that should be understood completely before making any capital equipment investment.
Some bits, morsels, and inclusions require cool, dry environments.
Some bits, morsels, and inclusions require cool, dry environments.
Another factor to consider when handling bits, morsels, and inclusions is the hygroscopic nature that some of them possess. Certain dehydrated or powdered fruits, for example, will readily absorb moisture. This can result in clumps that resist flow, as well as undesirable color changes, such as browning or premature spoiling. It is important that the automated handling system incorporate the proper environmental controls to optimize safe, reliable flow and preserve product integrity.
Automated handling must safeguard the integrity of delicate ingredients.
Automated handling must safeguard the integrity of delicate ingredients.
Certain bits, morsels, or inclusions are ingredients that require special attention. Some bits are more delicate than others — such as dried herbs that are prone to crumbling — and require gentle handling. Inclusions, like granola clusters, are comprised of several ingredients pressed together that can easily break apart or even turn to dust. To preserve the integrity of any of these ingredients, it is important to convey them as slowly and gently as possible.
Accurate dosing of bits, morsels, or inclusions for consistent portioning.
Accurate dosing of bits, morsels, or inclusions for consistent portioning.
Customers like to see the bits, morsels, or inclusions in their favorite products. Some even want a specific number of morsels included in each individual piece of product. Precise portions can only be accomplished through high-quality micro and minor ingredient handling systems. While it is impractical to assign a specific number to each bit, morsel, or inclusion in a product, customers like to see what they are paying for. Only with an accurate, reliable dosing system specifically designed for bits, morsels, or inclusions can consistent portioning be achieved.
Food manufacturers that use bits, morsels, or inclusions as ingredients must meet hygiene and food safety requirements.
Food manufacturers that use bits, morsels, or inclusions as ingredients must meet hygiene and food safety requirements.
Product safety is a critical concern for food manufacturers when handling bits, morsels, or inclusions as ingredients. Contamination can not only affect quality, but also pose risks to consumers. Storing, dosing, weighing, or conveying these hard to handle ingredients is only the first step. Producers must also employ proper hygienic handling practices from the mixer to the packaging lines. Regular sanitation, such as wipe-downs, are required to eliminate cross-contamination risks, verify cleanliness, and prevent allergen cross-contact.