A Deep Look into the Lays Chips Factory | How Fresh Potato Chips are made

Summary

This video takes viewers on a detailed tour of the Lays (Frito Lay) potato chip factory, explaining each step of the manufacturing process. From receiving and quality checking the potatoes, to washing, peeling, slicing, and frying them, every stage is carefully automated to ensure perfect chips. The chips are then seasoned and packaged, with final checks for quality control, including metal detection. The video concludes with a nod to the growing demand for low-fat chips, highlighting how manufacturers are evolving with consumer preferences.

Takeaways

• 😀 Potatoes are sourced directly from the fields and undergo rigorous quality checks for defects and blemishes.
• 😀 The potatoes are moved through a conveyor system with gentle vibrations to minimize breakage during transport.
• 😀 Stones are separated from the potatoes using a helical screw conveyor before they reach the peeling machine.
• 😀 After washing, the potatoes are peeled using an automated electric machine that ensures quick and efficient peeling.
• 😀 The potato slices are cut into thin pieces, with the option to make regular or ridged chips depending on the blade used.
• 😀 Some manufacturers chemically treat the potato slices to enhance color and reduce sugar levels, using substances like citric acid and phosphoric acid.
• 😀 The sliced potatoes are then fried using automated systems, ensuring consistency in the cooking process.
• 😀 After frying, spices are added to the chips on a conveyor system before they are sent to the packaging stage.
• 😀 Chips are weighed and metal detectors check for any foreign matter, ensuring quality and safety during packaging.
• 😀 Bags are filled with chips, sealed, and sometimes filled with nitrogen to prevent breakage and maintain freshness.
• 😀 With growing consumer demand for healthier options, manufacturers are increasingly exploring low-fat and reduced-calorie chip alternatives.

Q & A

What is the main focus of the video?

The video focuses on explaining the process of how potato chips are made in the Lays Factory, from raw potatoes to packaged chips.

What is the significance of the name 'Frito Lay' in the context of the factory?

The factory is referred to as 'Frito' because both Lays and Fritos are brands under the Frito Lay company, which owns the chip factory.

How are the potatoes tested when they first arrive at the factory?

Upon arrival, the potatoes are examined and tested for quality. A random selection of potatoes is checked for blemishes, green edges, and other defects.

What happens if the weight of defective potatoes exceeds the allowed limit?

If the weight of defective potatoes exceeds the company's preset allowance, the entire truckload may be rejected.

Why are stones removed from the potatoes during the manufacturing process?

Stones are removed from the potatoes to avoid any damage to the machines and ensure that only clean potatoes are processed.

What process is used to peel the potatoes?

The potatoes are peeled using an automated electric potato peeler, which quickly and efficiently removes the skin.

How are the potato slices treated after they are cut?

After the potatoes are cut into slices, they go through a cold water wash to remove excess starch, which helps prevent the chips from browning during frying.

Why are some potato chips chemically treated during production?

Some potato chips are chemically treated with acids like phosphoric acid, citric acid, or calcium chloride to reduce sugar levels and enhance their color.

How are the potato chips packaged after they are fried?

Once fried and seasoned, the chips are weighed, checked for foreign matter with a metal detector, and then filled into bags. The bags are sealed and prepared for further distribution.

What role does nitrogen play in the packaging of chips?

Nitrogen is sometimes used to fill the space in the bags to prevent the chips from breaking and to maintain their freshness.