Production of corn masa traditionally requires lots of time, water, and floor space and has always been a challenging area to achieve efficiency gains. Heat and Control developed a method to overcome these barriers and created a unique process of making fresh masa that eliminates corn simmering, soaking, and washing. Masa Maker™ will change the way the industry thinks about the masa making process.
Since the inception of industrial food production, Heat and Control has helped corn snack and tortilla product manufacturers meet every challenge to achieve higher capacities, lower production costs, and superior product quality. Heat and Control’s Guadalajara, Mexico manufacturing facility, one of eight global manufacturing operations, is in the heart of the tortilla and corn products industry. Close relationships with manufacturers over the last 30 years has resulted in continued advancements in corn processing technology.
The Masa Maker footprint is significantly smaller than the traditional corn simmer/soak system required to make masa.
Fresh masa is made in a matter of minutes with the Masa Maker compared to traditional corn simmer/soak systems.
Fiesta Charras, popular brand of tostada products in Mexico and USA, recognized the benefits of Masa Maker, and adopted the system for masa production at its Tostadas Charras plant.
Founded in 1982, Fiesta Charras Group is a leading producer of tostadas and other foods. Distributed throughout the United States, Canada, Mexico, and Central America, Charras brand foods include 16 varieties of fried and baked tostadas, plus tortilla chips, salsas, and extruded snacks. Fiesta Charras recognized the benefits of Masa Maker, and adopted the system for masa production at its Tostadas Charras plant.
“We are always looking for products that surprise our customers in both innovation and quality, and this system has helped us to lower production costs and become more productive in our processes without neglecting quality,” explains general director, Raul Leal. “We are always looking for ways to improve and exceed the expectations of our customers,” he adds. “Masa Maker has helped us succeed in both areas.”
The patent-pending Masa Maker system produces fresh masa from dry corn in minutes compared to hours required by the traditional simmer/soak process. Masa Maker needs no steam generator, simmer kettles, soak tanks, or washers and eliminates water discharge and sewage fees. It allows tortilla and snack manufacturers to produce customized masa almost on demand, eliminating the long lead times for dry corn preparation. And compared to using pre-milled corn flour, Masa Maker produces masa at a significantly lower cost.
“This is revolutionary technology which has eluded the industry for decades,” says Andy Caridis, Chairman of Heat and Control. “The flexibility of the Masa Maker process allows you to develop unique flavors and textures for your end product,” he explains. “To truly understand the versatility of this new process, we invite processors to visit our technical center in Guadalajara, to see how Masa Maker can produce customized masa formulations for many different types of corn products.”
From masa production to forming, toasting, conditioning, frying, seasoning and packaging, Heat and Control provides all the equipment and services required to make the highest quality corn and tortilla chips, taco shells, tostadas and tortillas.