What Is The Process of Making Lay's Potato Chips?

Lay's potato chips have won the favor of consumers around the world for their crispy texture and diverse flavors. But what is the process of making lay’s potato chips? From a potato to the final packaging into a bag, the entire process is completed automatically by potato chip production equipment, reducing human contact.

1. Selection and harvesting of fresh potatoes

Lay's is very strict in the selection of raw materials. The taste of potato chips depends largely on the quality of potatoes, so they only use high-quality potatoes of specific varieties, which usually have moderate starch content, appropriate moisture, smooth skin, and full shape. The harvested potatoes need to be transported to the processing plant in a short time to maintain their freshness.

2. Washing and peeling

The first step after entering the factory is to wash the potatoes. The surface of potatoes is often covered with dirt, and the washing system uses strong water flow and brushes to clean it thoroughly. The next step is peeling. Large factories will use steam peeling to quickly remove the potato skin and retain the white and tender potato flesh. The peeled potatoes will also pass through an automatic inspection system to remove potatoes that are green, spotted, or have traces of pests and diseases to ensure the consistency and safety of the product.

3. Slicing and cleaning starch

The potatoes are precisely cut into thin slices of uniform thickness by a slicer. The thickness of the slices is usually around 1.2 mm, which is determined after repeated experiments to ensure crispness after frying without being too greasy. The cut potato slices will be sent to the cleaning pool, rinsed with cold water to remove excess starch, and briefly blanched to prevent oxidation and discoloration.

4. Frying

After washing and drying the potato chips, they will then enter the high-temperature frying stage. This process is usually carried out in edible vegetable oil at 170 to 190 degrees Celsius and the time is controlled within a few minutes. During the frying process, the potato chips are quickly dehydrated and tiny bubbles are formed inside, thus obtaining a crispy texture. Lay's uses a closed frying system, continuously monitors the oil temperature and frying time, and regularly changes the oil to ensure hygiene and taste.

5. Seasoning

The fried potato chips need to be cooled quickly before entering the seasoning stage. The seasoning powder is evenly distributed on the surface of the potato chips through a special spraying device to ensure that every chip can enjoy a rich flavor.

6. Packaging

After seasoning, the potato chips will enter the automatic packaging stage. Lay's uses multi-layer composite packaging materials, which can not only effectively prevent moisture and oxidation, but also block sunlight to keep the potato chips crispy. Nitrogen is usually injected into the packaging bag to replace oxygen in the air. This "nitrogen-filled packaging" can effectively extend the shelf life and prevent oil oxidation.