Potato chips processingPotato chips processing

Group members Nguyễn Gia Hưng - BTFTIU13032 Nguyễn Nam Phương - BTFTIU13089 Nguyễn Thị Mỹ Duyên - BTFTIU13137 Lê Trần Quốc Thắng - BTFTIU13128

Outline

1/ Material for processing.2/ Potato chips manufacturing 3/ Machinery

Overview

A potato chip or crisp is a thin slice of potato that has been deep fried, baked, kettle cooked, or popped until crunchy.

Potato chips are commonly served as a snack, side dish, or appetizer

The snack food has been around since 1853. when The Potato Chip Company (the oldest potato chip company in the world) began manufacturing in 1910, potato chip became massed-produced for home consumption the number one bestselling snack in the world.

Some famous potato chips products

1/ Material for processing- Raw material: fresh potatoes. (20 – 25 % dry matter

content and low reducing sugar levels about 0.25 – 0.5 %)

- Frying medium: edible oil, vegetable oil ( refined cottonseed oil, refined groundnut oil, refined soybean oil, palm oil,…)

- Seasoning: salt, seaweed, cheese, flavor enhancer, sugar, natural flavor…

Packing material: metalized polypropylene, board packaging, cellulose film, high-density polyethylene

2/ Potato chips manufacturing

- After harvesting from the fields, potatoes will be examined the quality. If the quality of potatoes is not as the company expected, they can be rejected.

- The selected potatoes move along a conveyor belt to the various stages of manufacturing. The process of producing potato chips undergoes these main steps

PackagingSeasoning

Sorting

De-oiling Frying Dewatering Blanching

Slicing

Picking

PeelingWashing

Washing The best qualified potatoes

will be poured into water pipe with the high flow rate and velocity to clean the soil and residue on potatoes.

Figure 1

Peeling and sorting- Subsequently, they are applied to the peeling machine

to separate the rough bark from fresh potatoes.- Because of the shape and size of potatoes is different

so it is necessary to classify them in order to facilitate the process later. Only full-size potato will be allowed to continue processing, which ensures the product's design.

Frying and salting The slices are passed under air jets in order to remove

excess water. Then, they are flow into 40-75 ft troughs filled with oil. The oil temperature is kept at 176-190°C.

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.

Slicing and color treatment

- The potatoes pass through a revolving impaler/presser that cuts them into paper-thin slices, about 1.7 mm in thickness. The slices fall into a second cold-water to wash away all starch released.

- 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.

Figure 2

Cooling and sorting Potato chips quickly transported to chain of excessive

frying oil separation system. Chips will move along conveyor belt, excessive oil will be drained off and chips begin to cool down the temperature.

During frying, there may appear burned potatoes. The conveyor belt fitted with a color identification sensor to remove pieces of unqualified potato chips.

Packaging

- The chips then move to the packing machine. In this stage, the air is sucked out of the bags filled with chips. Many manufacturers use nitrogen to fill the space in the bags. The sealed bags are conveyed to a collator and hand-packed into cartons.

3/ Machinery- In potato chips producing, variety of machines to be

used simultaneously and interconnected by the conveyor.

- There are two kind of potato chips machine:+ Semi-automatic potato chips machine.+ Full automatic line potato chips machine.

Machines (2 types)

Elevator

- Have the structure and operating principle similar to escalator.

- Transmitting large quantity of potatoes to the next stage.

Washing & Peeling machine- Washing machine have the structure of a cleft. Water

is pumped inside with high flow rate.- The structure of peeling machine have a spindle

transmitting potatoes in spiral direction. The roller are mounted around inside the machine rotating continuously, colliding each other and creating friction to remove the crust. The machine productivity is more than 5 tons of potatoes per hour.

Picking line- The picking line ensure the quality of potatoes go to

the next process by classifying.- Classifying potatoes is done by a refinery. The

machine works based on the principle that small potatoes will tend to fall down and refine many times. For the too large potatoes, they will be halved to ensure sizes.

Potato cutting machine & washing line- The cutting machine have a rotating cutter blade and

can be adjusted corresponding to the thickness of the cut pieces. In average, one potato can be cut into 36 slices.

-Then potato slices are washed with chilled water to wash away starch on the surface of potatoes slices to prevent potatoes from sticking together.

Blanching machine- There are three different blanching techniques

common in the potato industry:+ Immersion potato blanchers: Total water immersion used to inactivate

enzymes, leach sugars and  partially cook the potato or potato products.

+ Deluge potato blanchers: showering potatoes with hot water to inactivate enzymes and partially cook the vegetables.

+ Steam potato blanchers: a process in which the potato products both blanch and restore surface moisture. The steam blancher minimises water contact, thereby leaving the natural sugars and flavours in the potatoes.

Air-cooled dewatering machine & frying machine

- At this stage, chips are transported on the conveyor and the remaining water will be dried by electric fans. Shorten time frying, improve the product tastereduce production cost.- Due to different proportion of water and oil, water in the

bottom, heat the oil in the upper to frying potato chips, residues generated direct precipitation in the water, the oil is not smoke, greatly extending the life cycle of oil, so that the cost has dropped significantly. Oil temperature control precision, thus ensuring the quality and taste of potato chips. Paddles gently push the slices along

De-oiling machine - Apply centrifugal principle technology to de-oiling

Machining swarf put into the slot is deoiled inside the rotary bucket.It moves along the wall surface, then is ejected from the bucket and drops from the ejecting slot. Removed oil is recovered separately from the drain.

Continuous automatic machining swarf deoiling separator

De-oiling machine Centrifugal blower type HSZ350

is a vertical drum centrifuge for continuous deoiling of short chips.

Short chips can be fed to the centrifuge intake via a slat-band belt conveyor for example.

The chips slide to the bottom of the drum and are subjected to high centrifugal forces by the rotary movement and pressed through the drum sieve in the direction of the chip outlet.

The liquid flows through this sieve and is discharged via the coolant outlet. Centrifugal blower type HSZ350

Seasoning Machine - The chips seasoning machine is made of stainless steel,

sanitary and easy to clean. The diameter and length of roller seasoning machine can be customized according to your need.

- There are three types of potato chips seasoning machine: + Disc type chips seasoning machine: Equipped with low-speed

motor, avoiding damage to the fried food.+ Octagonal type fried food seasoning machine: Octagonal

design can process the food material with the required spices and mix full uniformity in a short time. Convenient to disinfect and no dead ends. 

+ Roller type seasoning machine: this seasoning machine is a full automatic equipment. The seasoning barrel length and diameter can be customized according to customer needs

ROLLER TYPE SEASONING MACHINE

Picking line & Automatic chips packing machine- Potato chips are then picked up by picking line. Moving along

conveyor to the packing machine. - 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.

- Then, 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, gates open and allow the proper amount of chips to fall into the bag.

- The filling process must be accomplished without letting an overabudance of air into the bag, while also preventing the chips from breaking.

Reference Trager, James. The Food Chronology. Henry Holt, 1995. "Potato Chips," Jays Foods, Chicago, IL 60628. 773/731-

8400.— Mary F. McNulty http://www.bakeryandsnacks.com/Processing-

Packaging/Sustainable-snack-pack-materials-What-s-out-there

https://www.youtube.com/watch?v=REqhl-s97LE https://www.youtube.com/watch?v=SeycnVLYfMI