Episode 6: Nutella B-Ready

In this episode of the Biscuit People podcast, we explore challenges, testing methodologies, and potential innovations for optimizing the shelf life of Nutella B-Ready. From analyzing moisture sensitivity to evaluating packaging seals, this discussion offers valuable insights for biscuit manufacturers and packaging specialists alike

Product Overview: Nutella B-Ready Characteristics

Nutella B-Ready, a popular snack with a crispy wafer shell and creamy Nutella filling, serves as our case study. The product's unique structure presents both opportunities and challenges:

• Wafer’s Strength and Sensitivity: Its dry, stable nature makes it appealing, but it’s highly susceptible to moisture, which can lead to sogginess and loss of crunch.
• Filling Analysis: The Nutella filling, rich and creamy, contributes to the product's appeal but adds complexity in sealing and preserving freshness.
• Key Risks Identified: Moisture ingress remains the primary threat, while oxidation is less significant.

Testing Packaging Performance

We conducted thorough tests to evaluate the performance of individual and large packaging formats. The findings highlight the importance of precision and innovation in maintaining product quality:

• Leak Rate and Burst Tests: Using air pressure techniques, we identified leak sizes, with individual packs performing better than larger ones.
• Results at a Glance:
  • Individual pack: 50-micron leak size, 213 millibar burst pressure.
  • Large pack: 500-micron leak size, 162 millibar burst pressure.

The data underscores the need for robust seals to prevent moisture and air penetration, which can vary significantly under different climates.

Packaging Materials and Layers

Nutella B-Ready utilizes a dual-layer system for its packaging:

1. Primary Layer: A 40-micron pearlized polypropylene film offering moderate barrier properties.
2. Secondary Layer: A metallized film with enhanced barrier capabilities.

Despite these strong materials, micro-leaks in seals remain the weak point. Improving sealing techniques could significantly enhance overall protection.

Climate and Transportation Considerations

Shelf life challenges amplify under tropical conditions, where high humidity accelerates moisture uptake. For example:

• A 50-micron leak in tropical conditions results in three times the moisture ingress compared to European climates.
• Optimizing seal integrity and reducing leak sizes from 50 to 25 microns could dramatically improve product longevity, particularly for international markets.

Recommendations for Improvement

To address the issues uncovered, our experts suggest:

• Seal Optimization: Focus on fin seal design, temperature control, and pressure consistency during sealing to minimize micro-leaks.
• Process Testing: Conduct detailed experimentation with sensitive leak detection techniques to identify and rectify weak points.
• Material Efficiency: While existing materials are cost-effective, better seal alignment and production consistency could extend shelf life without major expenses.