On-site Planning
Installation & Commissioning
Automated & Energy Efficient
Client Name: **Gruma S.A.B. de C.V.** – Snack Foods Division
Country: United Mexican States
Region: Monterrey, Nuevo León – An industrial hub in northern Mexico and a core region for global corn processing
Core Products: Classic triangular tortilla chips, spicy Mexican roll chips, lime chili flavored corn chips, thick-cut restaurant-style tortilla chips
Equipment Configuration: Hadof custom fully automatic corn sheeting + dual-zone oil bath frying line (1.5 tons/hour capacity, including automatic seasoning drum and nitrogen packaging integration)
Commissioning Date: Q1 2025
Mexico is the birthplace of corn and the world's largest consumer and producer of tortilla chips. **Gruma**, headquartered in Monterrey, is the world's largest producer of corn flour and tortilla chips, with its brands Mission Foods and TortiRicas selling globally. With surging global demand for premium corn snacks, **Gruma** decided to intelligently upgrade its core tortilla chip production line. In industrial frying, they faced challenges that traditional processes could not overcome:
Excessive Oil Absorption: Traditional fried tortilla chips had oil content exceeding 35%, conflicting with the healthy snack trend and feeling greasy. There was urgent demand for lower-oil products in European and American markets.
Inconsistent Curl Affecting Packaging: Tortilla chips naturally curl during frying, but excessive or uneven curl led to high packaging breakage rates and excessive crumbs inside the bag, affecting consumer experience.
Variability Among Corn Varieties: White, yellow, and blue corn differ significantly in starch characteristics and hardness. Fixed processes led to inconsistent color and crispiness.
Seasoning Coating Easily Sheds: Mexican chili, lime, and other seasoning powders did not adhere well to chip surfaces, resulting in significant powder accumulation at the bottom of bags after transport and unstable flavor consistency across batches.
**Gruma**'s global R&D team evaluated equipment manufacturers in the US and Spain before ultimately choosing to partner with Hadof. We stationed engineers at the Monterrey headquarters for nine months of joint R&D, testing eight Mexican native corn varieties to develop this industrial corn frying line, specifically designed for "Mexico's colorful corn + global flavors."
1. NIR Starch Detection + AI Adaptive Sheeting – One-Key Adaptation for White, Yellow, and Blue Corn
To address the challenge of multiple corn varieties, we integrated a near-infrared starch analyzer before the sheeting stage to measure the amylose/amylopectin ratio in real time. The AI algorithm automatically adjusts sheeting roll gap, cooking time, and frying temperature: white corn (high amylopectin) is sheeted slightly thicker with lower temperature; yellow corn (medium) uses standard process; blue corn (high amylose) is sheeted slightly thinner with higher temperature. After frying, chips from different varieties have natural color and consistent crispiness.
2. Dual-Zone Variable Pressure Frying + Centrifugal De-oiling – Oil Content Reduced from 35% to 23%
We designed the frying section with dual-zone variable pressure: Zone 1 operates at atmospheric pressure (190°C) for rapid expansion and setting; Zone 2 uses micro-pressure (0.02MPa) at a lower temperature (165°C) for slow dehydration; after frying, a vacuum centrifugal de-oiling device removes surface oil under -0.05MPa negative pressure. Final oil content is consistently below 23%, 12 percentage points lower than traditional processes, resulting in a light, crispy texture that successfully passes European and American low-fat certifications.
3. Laser Curl Monitoring + Adaptive Cooling – Curl CV Value Reduced from 25% to 8%
To solve the uneven curl problem, we integrated a laser profile scanner at the fryer exit to measure the curl of each chip in real time. The AI algorithm automatically adjusts cooling conveyor belt speed, airflow direction, and temperature to make curl more consistent during setting. The coefficient of variation (CV) for curl dropped from 25% to 8%, packaging breakage was reduced by 60%, and in-bag crumbs decreased by 70%.
4. Vacuum Electrostatic Seasoning + Dual-Layer Adhesion Enhancement – Seasoning Loss Reduced from 20% to 3%
To address the problem of seasoning coating shedding, we incorporated a vacuum electrostatic seasoning system. Under -0.06MPa negative pressure, chili powder, lime powder, and other seasonings carry a negative charge and uniformly adhere to the chip surface, penetrating micropores. A thin edible glue coating is then applied to form a protective layer. After simulated transport tests, seasoning loss dropped from 20% to below 3%, and batch-to-batch flavor consistency improved fivefold.
Capacity and Quality Leap
Daily capacity: Per line output increased from 25 tons to 35 tons per shift (two shifts), with consistent quality for 28 consecutive days. Total production in Q1 2025 exceeded 52,000 tons, with product qualification rate rising from 92% to 97.5%.
Channel Breakthrough
Low oil content + uniform curl + stable seasoning enabled **Gruma**'s "Green Label" low-fat tortilla chip series to quickly enter global markets: Whole Foods in the US, Tesco in the UK, Aeon in Japan, and other premium channels were fully stocked. Exports to Europe grew by 85%, setting a new benchmark for Mexican tortilla chip exports.
Economic Benefits
Return on Investment: **Gruma**'s Global Operations Director noted: "Traditional lines required 14 people per shift; now this line needs only 4. We save over $3 million annually in labor costs alone. Combined with lower oil consumption, reduced seasoning loss, and higher yield, the actual payback period is under 16 months."
Product Premium: The low-fat health label and perfect appearance allow **Gruma**'s low-fat tortilla chips to command a 40% higher selling price than regular chips, making it the company's most profitable snack line.
"Hadof's equipment perfectly combines the millennium-old heritage of Mexican corn with modern healthy snacks. Now every tortilla chip carries the sun of Monterrey and world-class frying technology. This is the secret to **Gruma**'s global leadership."
—— Juan González, **Gruma S.A.B. de C.V.**, Global Vice President of Manufacturing
