Manufacturing
The wet side and the dry side,
sealed in one pass.
Every interesting problem in this category is the same problem: keeping something crunchy crunchy while it sits next to a sauce at room temperature for six months. This is how we solve it.
- Halal certified
- MAP sealed
- Inline checkweighing
- 6–9 months ambient
The line
Six stations, one continuous pass.
Nothing is assembled by hand and nothing is filled twice. The tray is formed, dosed, sealed, coded and cased in a single flow.
- Station 01
Snack base intake
Tortilla chips, crackers, toast bites, biscuit sticks and marshmallow arrive to spec and are held at controlled humidity. Moisture at intake is the single biggest driver of whether the crunch survives six months next to a wet dip.
- Station 02
Sauce kitchen
Dips are batch-cooked, pH-adjusted and viscosity-checked against a reference sample every batch. Every recipe has a target Brix, pH and flow band, and a batch outside the band does not leave the kitchen.
- Station 03
Tray forming
The signature triangle is formed with two isolated compartments — a deep well for the dip and a shallower bay for the snack — so neither migrates into the other.
- Station 04
Dual dosing
Sauce is hot-filled volumetrically into the well while the snack side is weight-dosed, both on the same pass. Fill weights are checkweighed inline and out-of-tolerance trays are rejected automatically.
- Station 05
MAP sealing
A single peel-back film is heat-sealed across both compartments under modified atmosphere. Seal integrity is destructively tested each hour and logged against the batch.
- Station 06
Code, sleeve, pack
Batch and best-before are laser-coded, sleeves and labels applied, then cases built, palletised, shrink-wrapped and released against the batch QA record.
Tray formats
One shape, four sizes.
The triangle is the brand’s signature and the reason the pack gets picked up. The same fill technology runs into slimmer single-serves, retail multipacks and bulk foodservice cases.
Signature Triangle Tray
Dual-compartment, film-sealed
The shape the brand is known for. One deep well for the dip, one bay for the snack, one peel-back film across both.
65–105 g total
Slim Triangle
Single-serve, checkout-facing
A shallower tray at a lower price point, sized for impulse racks and vending planograms.
55–70 g total
Multipack Sleeve
4, 6 or 8 trays
Printed board sleeve or shrink with a header card, for grocery take-home and club-store formats.
320–800 g total
Foodservice Case
24 or 36 trays
Plain or lightly branded trays in a shipper, for airlines, catering, hotels and QSR side-sales.
Bulk
Quality & compliance
What your food-safety team will want to see.
Ask for any of these and we send the document, not a promise that it exists.
- Halal certification
- Full halal production, with a certificate issued per shipment.
- Allergen control
- Documented allergen matrix per SKU with segregated handling for dairy, gluten and soy lines.
- Shelf-life validation
- Accelerated plus real-time studies on every new formulation before it is released for sale.
- Traceability
- Batch-level traceability from raw-material lot to pallet, retained samples held for the full shelf life.
- Inline checkweighing
- Every tray weight-verified; rejects diverted automatically rather than sampled after the fact.
- Documentation pack
- Spec sheets, nutritionals, ingredient declarations, certificates of origin and analysis on request.
Customisation
Six levers you can actually pull.
Anything on this list can change without new tooling. Anything that needs new tooling we will tell you about up front, with the cost.
Recipe
Heat, sweetness, acidity, salt and viscosity all adjustable. Full bespoke formulation available.
Fill weights
Snack and dip weights can be shifted within the tray’s volume to hit a price point.
Tray colour
Base tray in black, white or clear; the film carries the flavour colour.
Film print
Bespoke printed film from the Growth tier; printed sleeve on stock film below it.
Language
English, Arabic or dual-language, plus French, Turkish or Russian on request.
Case format
Case count, shipper print, SSCC labels and pallet build to your retailer’s inbound spec.
Bring us a spec.
We’ll tell you if it runs.
Send a target flavour, a fill weight and a price point. You get an honest feasibility answer, not a maybe.