At ESG-Italy, we design and supply high-performance snack production lines, helping manufacturers build efficient, high-quality, and sustainable facilities.
With headquarters in Italy and a regional office in Dubai (ESG-Middle East), ESG-Italy brings decades of expertise in manufacturing equipment for tortilla chips, potato chips, popcorn, pretzels, extruded snacks, and more. As tortilla chips continue to gain popularity, we provide custom solutions to help manufacturers set up or optimize production lines, ensuring efficiency, profitability, and sustainability. Many leading snack producers in the Middle East are already investing in this fast-growing market.
Why Invest in Tortilla Chips?
Originally a staple of Mexican cuisine, tortilla chips have become a global snack phenomenon, loved for their crunch, versatility, and shareability. The global tortilla chip market, valued at $27.3 billion in 2023, is projected to reach $48.7 billion by 2030, growing at a CAGR of 8.8% (Tortilla Chips Market Size, Share and Growth Report, 2024). This surge is driven by increasing demand for healthier, plant-based, and gluten-free snacks. In the Middle East, where the snack industry is booming, tortilla chips present a significant opportunity for local manufacturers.
Traditionally dominated by a single global brand, the market is now ripe for expansion. Unlike other snacks, tortilla chips rely on widely available raw materials, simplifying production. A key factor for manufacturers is water consumption, which varies significantly. Using corn flour requires just 0.5 liters per kg, while whole corn cooking can use up to 8 liters per kg. This makes tortilla chips an ideal product for regions prioritizing water conservation.
Additionally, tortilla chips offer one of the highest production efficiencies in the snack industry. Unlike potato chips, which yield only 250g per kg of raw potatoes, tortilla chips maintain a 1:1 production ratio—1 kg of raw material produces 1 kg of chips. This eliminates food waste and increases profitability, while lower water consumption makes them a more sustainable option, particularly in water-scarce regions.
Choosing the Right Production Method
The tortilla chip production process includes masa preparation, sheeting, cutting, baking, frying, seasoning, and packaging, with the key difference in dough preparation. The Corn Cook Method starts with whole dry corn, which is cooked, soaked, and ground into fresh masa. While it requires more processing, it can be cost-effective where raw corn is cheaper than corn flour.
The Masa Flour Method uses pre-ground corn flour, eliminating cooking for faster processing and lower equipment costs. The Continuous Masa Production Unit is a cutting-edge system that produces fresh masa in minutes, reducing water consumption and production costs. The best method depends on local raw material costs and production priorities.
Tortilla Chips vs. Potato Chips: The Competitive Edge
Tortilla chips are increasingly popular, especially among younger consumers and families, thanks to their crunchier texture and lower oil absorption, making them lighter than potato chips. They are also ideal for dipping and sharing, pairing perfectly with salsas, guacamole, and cheese dips. Additionally, they are perceived as a healthier option, with many consumers favoring whole grain, baked, and gluten-free varieties.
Middle East: A Fast-Growing Market
The Middle East’s snack industry is expanding rapidly, driven by a young and growing population, an higher disposable income and a shift toward premium, healthy, and convenient snacks. Countries like Saudi Arabia, the UAE, and Iraq are heavily investing in food processing, making this the perfect time for manufacturers to enter the tortilla chip market.
With the right production setup, this is a golden opportunity—and ESG-Italy is here to help you seize it!
For more information https://esg-italy.com
