Dough-to-filling ratios can be changed with the push of a button. This level of control helps snack producers keep the filling in its place — inside the dough jacket. Source: Rheon USA

The last defense
At the end of the day — dough and filling consistency, accurate weights, aside — a proper seal is critical to preventing leaks and blowouts. Without a proper seal, it’s all moot.

“Most people are boiling those pretzels in a caustic bath and then they’ll bake it, and you don’t want that product to open up in the boiling process or the oven because it makes a mess,” Mr. Giacoio said.

Rheon USA features a cutter that keeps pace with the material as it’s extruded, which enables a secure seal that doesn’t damage the product. Mr. Giacoio said if the cutting mechanism is stationary, product will build up as it closes and damage the product.

With leakage being the No. 1 issue, Vemag’s Coex system extrudes around the entire circumference of the product, resulting in no seams. Reiser also features an array of crimping mechanisms to seal both sides of the product.

When it comes to filled pretzels, having the proper processing systems in place not only creates a tasty product but also keeps everyone safe. Moisture content, over-filling and poor seals can all lead to leaks and blowouts that can result in a bakery fire. But this product doesn’t have to be risky with accurate filling scaling, the right pump, consistent dough and filling extrusion, and, of course, a secure seal.