How Potato Chips Are Made - Chips Production Line | Potato Chips Factory

Summary

This video takes viewers inside Russia's largest potato chip factory, showcasing the entire production process. From unloading 20-ton potato trucks to careful selection, washing, peeling, and cutting, each step ensures the highest quality chips. The factory uses only specific potato varieties with high starch content for the perfect crunch. After frying, chips are seasoned with a range of flavors, from classic to gourmet. The process concludes with a professional tasting, focusing on the texture and crunch that make chips irresistible. The video highlights the precision and attention to detail that goes into creating these popular snacks.

Takeaways

• 😀 The largest chip factory in Russia processes potatoes from all over the country.
• 😀 Potatoes are unloaded from trucks using a special platform that tilts at a 30-degree angle, ensuring a smooth and gradual release.
• 😀 Only potatoes with a diameter greater than 1.4 inches are selected during the first stage of sorting.
• 😀 The factory uses specific potato varieties with high starch content to achieve the perfect crunch for chips.
• 😀 After unloading, the potatoes are washed in a rotating drum to remove dirt and excess starch, which floats as gray foam.
• 😀 The peeling process is done in large centrifuges, capable of peeling 66 pounds of potatoes per minute.
• 😀 A second manual sorting is performed, where workers remove green potatoes, which are discarded.
• 😀 Potatoes are sliced into thin pieces in a cutting machine, with the thickness of the slices affecting the final taste and texture of the chips.
• 😀 The potato slices are rinsed again before being fried in a large fryer at 356°F for three minutes to achieve a crispy texture.
• 😀 Chips come in a wide variety of flavors, ranging from basic options like sour cream and onion to more refined ones like veal on the grill and parmesan.
• 😀 In the tasting room, chips are tested by smelling, biting, and listening for the ideal crunch sound, which indicates the perfect texture.

Q & A

What is the primary ingredient used in the production of chips at the factory?

The primary ingredient used in chip production at the factory is potatoes, which are sourced from all over Russia.

How are the potatoes unloaded from the trucks?

The potatoes are unloaded from the trucks by raising the truck to a 30-degree angle, allowing the potatoes to roll out gradually. This process takes about 30 minutes for a 20-ton truck.

How many tons of potatoes can the factory process per shift?

The factory processes up to 800 tons of potatoes per shift, using three potato lines.

What is the first step in the potato selection process at the factory?

The first step in the potato selection process is size grading, where potatoes with a diameter smaller than 1.4 inches are rejected.

Why are only certain potato varieties used for chip production?

Only certain potato varieties are used because they have a higher starch content, which is necessary to achieve the perfect crunch in the chips.

What happens after the potatoes are washed?

After the potatoes are washed, they are peeled in high-speed centrifuges, which can peel 66 pounds of potatoes per minute.

What is the role of human intervention during the sorting process?

Human workers are involved in sorting the potatoes, specifically removing any green ones, which are not suitable for chip production.

How are the potatoes cut into thin slices?

Potatoes are cut into thin slices using a cutting machine that employs angular acceleration, moving the potatoes in a circle through special trays to achieve uniform thickness.

Why is the thickness of the potato slices a closely guarded secret?

The thickness of the potato slices is kept secret because it directly affects the texture and taste of the final product, which is crucial to the quality of the chips.

What types of flavors does the factory produce for their chips?

The factory produces a variety of flavors, including basic ones like sour cream and onion, as well as more sophisticated flavors like veal on the grill and parmesan cheese.

What is the process for professional chip tasting at the factory?

During professional chip tasting, the chips are first smelled for aroma, then tasted, focusing on the crunch and texture. A key criterion is the crisp, satisfying sound heard when biting into the chip, which indicates the proper texture.