ESG-Italy: Your Partner in Snack Manufacturing.
At ESG-Italy, we specialize in designing and supplying snack production lines, assisting manufacturers in establishing efficient, high-quality, and sustainable snack facilities.
With headquarters in Italy and a regional office in Dubai under ESG-Middle East, we bring decades of expertise in manufacturing equipment for tortilla chips, potato chips, popcorn, pretzels, extruded snacks, and more.
Tortilla Chips: A Growing Global Market with Smart Production Advantages
Once a staple of Mexican cuisine, tortilla chips have evolved into a global snack phenomenon, loved for their crunch, versatility, and shareability. Valued at $27.3 billion in 2023, the global tortilla chip market is expected to reach $48.7 billion by 2030, with a compound annual growth rate of 8.8% (Tortilla Chips Market Size, Share and Growth Report, 2030, 2024). This surge is driven by the growing demand for healthier, plant-based, and gluten-free snacks, making tortilla chips a smart investment for manufacturers looking to tap into a booming industry.
In the Middle East, where the food industry is expanding rapidly, tortilla chips present a lucrative opportunity. Several leading snack manufacturers in the region are actively exploring this segment to diversify their portfolios. This growing interest stems from the fact that tortilla chips have historically been dominated by a single global producer, leaving enormous potential for local and regional manufacturers to establish themselves in the market.
Unlike other snack products that require hard-to-source ingredients, tortilla chips can be produced with widely available raw materials. Additionally, while their energy consumption is comparable to potato chips, their water usage varies significantly: when using corn flour, water consumption is around 0.5 liters per kg, whereas cooking whole corn increases the usage up to 8 liters per kg. This difference makes them a highly strategic product in regions where water conservation is a priority.
Moreover, one of the biggest advantages of tortilla chips is their efficiency in production. Unlike potato chips, which yield only 250g of chips per kilogram of raw potatoes, tortilla chips offer a 1:1 production ratio—meaning 1 kg of raw material produces 1 kg of tortilla chips. This reduces food waste and improves profitability.
How Are Tortilla Chips Made? Choosing the Right Production Method
Tortilla chips are made using a straightforward yet highly efficient production process that involves masa preparation, sheeting, cutting, baking, frying, seasoning, and packaging. While most of these steps remain the same, the key difference lies in how the dough is prepared. Manufacturers can choose from three distinct methods, each with its own advantages:
Corn Cook Method: Traditional & Cost-Effective
This classic method starts with dry corn, which is cooked, simmered, and soaked before being ground into fresh masa. While it requires additional cooking equipment, it provides complete control over the process and can be highly cost-effective in regions where whole corn is significantly cheaper than corn flour.
Masa Flour Method: Fast & Simple
For a quicker and more streamlined process, manufacturers can use pre-ground corn flour instead of whole corn. This method eliminates the cooking phase, reducing processing time and equipment costs, making it an ideal choice for manufacturers looking for a fast, efficient setup.
Continuous Masa Production Unit: The Future of Masa Production
The Continuous Masa Production Unit is a cutting-edge solution that produces fresh Masa in minutes rather than hours. By eliminating the traditional soaking and cooking phases, this method dramatically boosts efficiency, reduces water consumption, and lowers production costs.
When choosing between these methods, manufacturers should consider local raw material costs. While the corn cook method requires a longer production cycle, it can be the most cost-effective in regions where raw corn is cheaper than corn flour. On the other hand, the Masa flour and Continuous Masa Production Unit methods streamline production, making them attractive options for facilities prioritizing speed and operational efficiency.
Middle East: A Fast-Growing Market for Tortilla Chips
The snack food industry in the Middle East is experiencing rapid growth, driven by an increasing young population, rising disposable income, and a shift toward Western-style eating habits. The demand for premium, healthy, and convenient snacks is fueling interest in tortilla chips, making them a strategic product for manufacturers looking to expand in the region.
Countries like Saudi Arabia, the UAE, and Iraq are investing in food processing, making this the perfect time for manufacturers to expand into tortilla chip production. With growing demand and the right setup, the market is full of opportunity—ESG-Italy is ready to help you seize it.
