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I. INTRODUCTION OF FROZEN POTATO FRENCH FRIESIndian fast food sector is growing at 25-30 % annually due to rapid growth of fast

food chain both Indian and international. Out of the total snacks, potato based products

like French fries, wedges, products using potato flakes and other Indian snacks have

about 30 % share in fast food industry, approximately 75 cores in value terms. (Ebeling,

2005)

Frozen potato French fries --often called French fries potatoes-- are among the

highest saleable potato products. This is the most abundant processed potato and can be

found in many varieties such as lattice cut, wedges, curly, batter dipped, seasoned, or

straightcut including French Fries on menu is one of the easiest ways to increase sales

and profits for the companies. (Ebeling, 2005)

Usually, French fries are served hot and generally eaten as an accompaniment with

lunch or dinner, or eaten as a snack, and they are a common fixture of fast food. French

fries are generally salted, and in their simplest and most common form, are served with

ketchup, though in many countries they are topped instead with other things, including

vinegar, mayonnaise, or other local ingredients. (Fishwick, 1998).

French fries can contain a large amount of fat from frying. For example, fat accounts

for 45% of the caloric value of French fries at McDonald's in the United States; since

raw potatoes are virtually fat-free, almost all of it comes from the cooking oil that was

absorbed by potatoes while frying. (Fishwick, 1998).

Potato as Raw Material of Frozen French Fries

Potato (Solanum tuberosum L.) popularly known as The king of vegetables,

because, the dry matter, edible energy and edible protein content of potato makes it

nutritionally superior vegetable as well as staple food throughout the world. Now, it

becomes as an essential part of breakfast, lunch and dinner worldwide.

Potato is a major food crop, grown more than 100 countries in world. The native

South Americans brought Potato under cultivation possibly 2000 years before the

Spanish conquest. In 1537, the Spaniards first came into contact with potato in one of

the villages of Andes. In Europe, it was introduced between 1580 to 1585, in Spain,

Portugal, Italy, France, Belgium and Germany. At present, China, Russia, India, Poland

and U.S.A. contribute a major share of total world production. (profile-potato.pdf)


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It has been revealed that, according to FAO, potato is consumed by more than one

billion people the world over. The protein of potato has high biological value than

proteins of cereals and even better than that of milk. (profile-potato.pdf)

The potato contains vitamins and minerals, as well as an assortment of

phytochemicals, such as carotenoids and natural phenols. Chlorogenic acid constitutes

up to 90% of the potato tuber natural phenols.

A medium-size (150 g) potato with the

skin provides 27 mg of vitamin C, 620 mg of

potassium, 0.2 mg vitamin B6 and trace

amounts of thiamin, riboflavin, folate, niacin,

magnesium, phosphorus, iron, and zinc. The

fiber content of a potato with skin (2 g) is

equivalent to that of many whole grain breads,

pastas, and cereals. (French Fries,

Dialysis......pdf)

The potato is best known for itscarbohydrate content (approximately 26 grams

in a medium potato). The predominant form of

this carbohydrate is starch. A small but

significant portion of this starch is resistant to

digestion by enzymes in the stomach and

small intestine. This resistant starch is

considered to have similar physiologicaleffects and health benefits as fiber: It provides

bulk, offers protection against colon cancer,

improves glucose tolerance and insulin

sensitivity, lowers plasma cholesterol and

triglyceride concentrations, increases satiety, and possibly even reduces fat storage.

(profile-potato.pdf)


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Potatoes are often broadly classified as high on the glycemic index (GI) and so are

often excluded from the diets of individuals trying to follow a low-GI diet. In fact, the

GI of potatoes can vary considerably depending on type, origin (where it was grown),

preparation methods (i.e., cooking method, whether it is eaten hot or cold, whether it is

mashed or cubed or consumed whole, etc.), and with what it is consumed (i.e., the

addition of various high-fat or high-protein toppings) (Global AgriSystem Pvt. Ltd.pdf).


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II. PROCESSES TO MAKE FROZEN POTATO FRENCH FRIES

As potatoes are received, they are sorted,

and pre-graded to correspond with

the type of french fry to be produced.

potatoes then enter the line and pass

through the destoner and washing

process, before being peeled in the

steam peeler. After the skin is loosened

by the steam, the deskinner removes

and collects the peel waste, and is then

washed clean prior to being inspected,

and moving to the cutting process.

The cutting process is performed by


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either a hydrocutting or mechanical

cutting system. These machines cut the

potato into stripscrinkled or straight,

to the desired size, and then pass

through equipment that removes

imperfections, and undersized pieces.

The potato strips then pass through a

blanching system, consisting of two or

more screw blanchers. here the strips

are gelatinized and the sugar levels

reduced, then they go through the

dipping belt, before being pre-dried.

During the drying process (which is

optional for smaller lines), the moisture

content is reduced, and the strips are

now ready for the frying process, where

the fi nal texture and colour is achieved.

for coated fries and other potato

products, a batter and pre-frying step is

added before the normal frying system.

After frying, the golden french fries then

pass through a defatting step before

entering the freezer, on their way to

the packaging system.

With over 35 years in providing

french fry processing solutions,


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ppM Technologies has the knowledge

and experience to provide you with

the complete solution to your potato

processing needs.


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III. PHYSICOSHEMICAL CHANGES DURING PROCESSINGMost vegetables are blanched prior to freezing to inactivate enzymes that cause the

development of off flavors and off-colors during frozen storage. Some exceptions

include onions, leeks, and peppers because they lose flavor and color on blanching.

Blanching removes trapped air (e.g., in broccoli florets) and metabolic gases within

vegetable cells and replaces them with water, forming a semi continuous water phase

that favors a more uniform crystal growth during freezing. Gas removal is the main

benefit of blanching before canning because it allows easier can fill, reduces strain on

can during heating, and reduces can corrosion. Although, in this case, enzyme

inactivation also takes place, it is not relevant because any remaining activity is

destroyed on retorting. Fruits are usually not blanched, or blanched under mild (low

temperature) conditions prior to freezing because blanching produces undesirable

texture changes. Before drying, fruits and vegetables are sometimes blanched.

There are three method of blanching and there are have a positive and negative

impact to the food. First, water blanching, when the method is apply is necessary a

longer time, so it can increase leaking of minerals, vitamins and produce effluents with

large biological oxygen demand (BOD). Second method is steam blanching, the effect

in nutrient value is lower than water blanching because of the food only contact with a

steam. Third is microwave blanching, that only need short time processing and product

have a high value. Fourth is gas blanching that not have impact in a nutrition value, but

it can make a product have a water loss because of the combustion of flue gases.

Flavor

Blanching indirectly and directly affects the flavor of many products because of

inactivation of enzymes responsible for off-flavor development. The most notable is

lipoxygenase (LOX) in several vegetables. Sometimes blanching increases flavor

retention, and sometimes it removes undesirable bitter flavors from the product. Fffect

of blanching for the product depend on temperature and time. When the temperature is

high with longest time, product become off-flavor. So we need the right temperature

and time to do it. Headspace volatiles assayed mostly by gas chromatography have been

correlated to flavor attributes defined in sensory panels.


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Texture

Blanching can result in undesirable softening of vegetable tissues. However,

calcium can be added to reduce the softening. A combination of low-temperatureblanching and calcium addition has also been shown to be effective in firming canned

vegetables.

Texture assessment of the effects of blanching includes sensory characterization of

firmness, crispness, and crunchiness, and instrumental measurements such as cutting

energy and maximum shear force.

During the blanching process, water in potato will leach out and forming cavities in

it. The cavity will be fill with cooking oil when it fry. So the potatoes will form porous

structure that can be causes a crispy French fries. In addition to forming cavities, the

tissue of potato become soft. Its because pectin degradation so the texture become soft

(soften in cell wall).

Blanching with a low temperature will increase the activity of PME (Pectin Methyl

Esterase). The texture of frozen potatoes is influenced by pectic. Hydrolysis PME in

pectin will leave the carboxylic group and then reacted with divalent ions such asmagnesium and calcium which ends on firming products.

Color

Blanching can have both direct and indirect effects on color. The former is

exemplified by the destruction of pigments, such as chlorophyll, by heat. An example of

an indirect effect is in potato processing, in which the reducing sugar content can be

adjusted via water blanching, affecting color development during later, more intensive

heating steps where the maillard reaction takes place.

Nutritional Value

Generally, blanching produces a decrease in the nutritional value of foods. Nutrients

leach out from the product especially during water blanching. In addition, vitamins are

degraded by heat. Vitamin C (ascorbic acid) is, by far, the most commonly assayed

nutrient in blanching probably because its high solubility and heat susceptibility make it


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a conservative indicator of nutrient retention .Vitamins B1 and B2, carotenes, and

dietary fibers have also been assayed.

Quality Indicators

Peroxidase and catalase are the most commonly assayed enzymes for blanching

before freezing because they are more resistant to heat than most enzymes, and there are

simple rapid assays to measure their activity. However, for many vegetables such as

corn, peas, and green beans, LOX, a less heat-resistant enzyme, was found to be the

enzyme responsible for the development of off-flavors Although food processors are

aware of this, it is only recently that some rapid methods to measure LOX activity have

been developed.


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IV. THE METHODS TO MAINTAIN QUALITIES AND NUTRITIONSAFTER PROCESSING

French fries is the one of food processing that prefer to the appearance, crispness

and color. Therefore, we need to improve the quality of french fries, especially in terms

of color (Susanto dan Saneto, 1994). Frozen food like french fries that does not go

through the process of blanching will run into a relatively rapid change in the quality,

such as color, flavor, texture and nutritional value due to the continued activity of the

enzyme (Susanto dan Saneto, 1994). So the process of blanching is essential for frozen

french fries.

After the product is ready in frozen condition, we need to maintain the quality of

product. This is also done to extend the shelf life and maintain the product

characteristics. The methods to maintain the quality of french fries are:

1. Freezing after Blanching

Freezing temperatures are appropriately used for frozen french fries is at 10oto 20o

F (-23.3oto 28oC) on a conveyor that is useful to stabilize the product after heating. This

treatment is an important preparatory step prior to packaging and long-term storage. At

that temperature ice crystals remain small so that cells are not ruptured and the product

does not stick to each other (Mosley, 2011).

2. Packaging

Frozen french fries are almost as fragile as eggs, so this product should be handled

accordingly. Damaged packaging (usually plastic) almost certainly indicate a high

percentage of broken fries. To prevent this kind of damage, standard package (plastic)

of frozen french fries should not be stacked more than 6 high either in storage or

shipping containers. Higher stacks tend to crush boxes near the bottom and cause

breakage of fries. Boxes should never be touched directly on the floor or flush against

walls or ceilings for extended periods. They should be carefully stacked on pallets to

promote air circulation beneath. Further, a gap of at least 5 cm should be maintained

between package and walls or ceilings to avoid forming heat from the outside and

promote good air movement (Mosley, 2011).


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3. Transport and Storage

For transport and storage condition, the product should be store at the frozen

condition, minimum at the temperature -18

o

C. The temperature should be maintained atthe appropriate temperature (steadily and no change) because if the temperature change

it will result in a decrease of product quality in terms of texture. In addition, if frozen

french fries will be consumed, frozen french fries should not be left at room temperature

for too long. Because if left too long will cause bad flavor, texture becomes soft after

the products is fried, and changes the color to be darker. This is because the contact

happened between the products and the oksigen that resulting in rapid browning effect

on frozen products. This reaction namely oxidation (Mosley, 2011).

To maintain the quality and nutrition of frozen french fries, another method that can

optimally prevent the enzymatic browning of frozen french fries is combine the

blanching process with the other materials. One of the food additives which can be used

as an inhibitor of browning process is ascorbic acid. Ascorbic acid is a strong reducing

agent that able to act as an oxygen scavenger, so it will prevent enzymatic oxidation of

phenolic compounds contained in potatoes (Winarno, 1997). The use of ascorbic acid as

a food additive for frozen french fries is recommended at 100 mg/kg (Winarno danRahayu, 1994).

In the production of frozen french fries, blanching process which is done by soaking

the ascorbic acid in potatoes will produce a different characteristic color, texture, flavor,

and water levels. When compared with the blanching process without any additions, the

resulting quality of frozen french fries products much better when done soaking in a

solution of ascorbic acid in the blanching process. The resulting color becomes more

yellow and brighter, more crisp texture, and stronger flavor (Winarno, 1997).


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SOURCES:

Ebeling, Charles. (2005). "French fried: From Monticello to the Moon, A Social,

Political and Cultural Appreciation of the French Fry". The Chicago LiteraryClub.

Fishwick, Marshall W. (1998). "The Savant as Gourmet". The Journal of Popular

Culture(Oxford: Blackwell Publishing) 32 (part 1): 5158.

Jurnal French Fries, Dialysis Tubing & Computer Models:Teaching Diffusion &

Osmosis Through Inquiry & Modeling.pdf (Diunduh tanggal 30 Maret 2013)

Jurnal Global AgriSystem Pvt. Ltd.pdf (Diunduh tanggal 30 Maret 2013)

Jurnal profile-potato.pdf (Diunduh tanggal 30 Maret 2013)

Mosley, A.R. (2011). Manufacture, Storage, and Tramsport of Frozen Potato

Processing.xa.yimg.com/kq/.../FrozenpotatoProcessing.pdf. 9 April 2013.

pepitaharyanti.files.wordpress.com/2010/11/skripsi-leni.pdf (Diunduh tanggal 30 Maret

2013)

Susanto, T dan B. Saneto. 1994. Teknologi Pengolahan Hasil Pertanian. Bina Ilmu.

Surabaya.

Winarno FG, Rahayu TS. 1994. Bahan Tambahan untuk Makanan dan Kontaminan.

Jakarta: Pustaka Sinar Harapan

Winarno, F.G . 1997. Kimia Pangan dan Gizi. Jakarta: Gramedia Pustaka Utama.

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