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Thursday, June 29, 2017

MUST WATCH: Take A Peek At How Pringles, Frito Lays Make Your Favorite Bag of POTATO CHIPS – THIS WILL MAKE YOU CRAVE!

Ever wonder how potato chips are made? A bag of potato chips, arguably, is one of the most favorite guilt-food cravings. People consume it when they are traveling, watching a movie, partying with friends or just when they feel like eating one. But, did it ever occur to you how potato chips came into existence and how they are made?

According to a popular legend, the potato chip was invented in 1853 by a chef named George Crum at a restaurant called Moon's Lake House in Saratoga Spring, New York. Angered when a customer, some sources say it was none other than Cornelius Vanderbilt, returned his French fried potatoes to the kitchen for being too thick, Crum sarcastically shaved them paper thin and sent the plate back out. The customer, whoever he was, and others around him, loved the thin potatoes. Crum soon opened his own restaurant across the lake and his policy of not taking reservations did not keep the customers from standing in line to taste his potato chips.

via The New York Times
Since then, several families started preparing their own recipes of homemade potato chips and sold it to the market. However, shelf life was quick. Later, innovations in food productions paved the way for mass production of potato chips. Today, we have big brands like Pringles and Frito Lays.

Here’s a fascinating video that shows you how potato chips are made.

The Manufacturing Process

According to, here is the step-by-step process of how large manufacturers make potato chips:

When the potatoes arrive at the plant, they are examined and tasted for quality. A half dozen or so buckets are randomly filled. Some are punched with holes in their cores so that they can be tracked through the cooking process. The potatoes are examined for green edges and blemishes. The pile of defective potatoes is weighed; if the weight exceeds a company's preset allowance, the entire truckload can be rejected.

The potatoes move along a conveyer belt to the various stages of manufacturing. The conveyor belts are powered by gentle vibrations to keep breakage to a minimum.

Destoning and peeling

The potatoes are loaded into a vertical helical screw conveyor which allows stones to fall to the bottom and pushes the potatoes up to a conveyer belt to the automatic peeling machine. After they have been peeled, the potatoes are washed with cold water.


The potatoes pass through a revolving impaler/presser that cuts them into paper-thin slices, between 0.066-0.072 in (1.7-1.85 mm) in thickness. Straight blades produce regular chips while rippled blades produce ridged potato chips.
The slices fall into a second cold-water wash that removes the starch released when the potatoes are cut. Some manufacturers, who market their chips as natural, do not wash the starch off the potatoes.

Color treatment

If the potatoes need to be chemically treated to enhance their color, it is done at this stage. The potato slices are immersed in a solution that has been adjusted for pH, hardness, and mineral content.

Frying and salting

The slices pass under air jets that remove excess water as they flow into 40-75 ft (12.2-23 m) troughs filled with oil. The oil temperature is kept at 350-375°F (176.6-190.5°C). Paddles gently push the slices along. As the slices tumble, salt is sprinkled from receptacles positioned above the trough at the rate of about 1.75 lb (0.79 kg) of salt to each 100 lb (45.4 kg) of chips.

Potato chips that are to be flavored pass through a drum filled with the desired powdered seasonings.

Cooling and sorting

At the end of the trough, a wire mesh belt pulls out the hot chips. As the chips move along the mesh conveyor belt, excess oil is drained off and the chips begin to cool. They then move under an optical sorter that picks out any burnt slices and removes them with puffs of air.


The chips are conveyed to a packaging machine with a scale. As the pre-set weight of chips is measured, a metal detector checks the chips once more for any foreign matter such as metal pieces that could have come with the potatoes or been picked up in the frying process.

The bags flow down from a roll. A central processing unit (CPU) code on the bag tells the machine how many chips should be released into the bag. As the bag forms, (heat seals the top of the filled bag and seals the bottom of the next bag simultaneously) gates open and allow the proper amount of chips to fall into the bag.
via Ben E. Keith
via The Fairfield Mirror
The filling process must be accomplished without letting an overabundance of air into the bag, while also preventing the chips from breaking. Many manufacturers use nitrogen to fill the space in the bags. The sealed bags are conveyed to a collator and hand-packed into cartons.

Some companies pack potato chips in cans of various sizes. The chips flow down a chute into the cans. Workers weigh each can, make any necessary adjustments, and attach a top to the can.

H/T: Made How

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