How potato chips are made. Cooking crispy hard cheese strips in the oven

Potato chips are a favorite delicacy of many, which is in great demand among both children and adults. However, due to the large number various additives included in their composition, chips are considered junk food and are not recommended for daily use. To protect your body from the effects of taste and odor enhancers, starch and genetically modified products, as well as various stabilizers, you can refuse to consume purchased chips and replace them with homemade ones, which are not at all difficult to cook on your own.

One of the most popular ways to make homemade chips is to bake them in the oven. To do this, select a few even large potatoes and rinse them thoroughly in warm water. Peel the skin and use a vegetable cutter or sharp knife cut potatoes into thin slices, the thickness of which should not exceed 3-4 millimeters. After that, put the chopped slices in a deep plate, season with sunflower oil, salt well and mix thoroughly. To enhance the taste, you can add a little paprika or pepper. After that, spread the potatoes on a baking sheet in one layer and place in the oven, preheated to 190-210 degrees, for 10-15 minutes. The main advantage of this method is a large number of finished product received at one time. Next method- cooking chips in a pan. Before starting the cooking process, the pan must be properly heated. Therefore, it is recommended to put it on the stove at the very beginning and only after that start washing the potatoes. Cut the peeled potatoes into slices, the thickness of which is chosen at your discretion. However, you should not make them too thick, as you will not be able to fry them well, and you will forget about crispy chips. After that, pour sunflower oil into the pan with a layer of 3-5 centimeters. When it is hot, carefully dip the potato slices into it and fry them until golden color. After 5-6 minutes, remove the chips from the oil and spread them on paper towel, in order to get rid of excess fat. In order for the potatoes to be well fried and not burnt, follow only one rule - fry thin slices at maximum heat for a short time, thick slices at medium heat, turning them from side to side. Cooking chips in microwave oven is the simplest and fast way. Cut the washed and peeled potatoes into thin slices, then transfer them to a colander and rinse under running water. cold water, in order to get rid of excess starch. Let the water drain and place the sliced potatoes on a glass plate lined with parchment paper. If desired, potatoes can be greased with vegetable oil or sprinkled with paprika. Then place the plate in the oven for 3-4 minutes, turning it on at maximum power. Since different ovens have different wattages, try not to move away from it while cooking to prevent the potatoes from burning, and remove them at the exact moment when they turn into golden crispy chips.

Potato chips you make at home are much tastier and safer than store-bought ones. And as you can see, they can be made quickly and easily, and most importantly, they will be absolutely harmless and will not harm the health of your children.

Photos

Yasia Vogelhardt

There are about 40 different brands in the catalog of PepsiCo corporation: drinks ("I", Lipton ice tea, "Aqua Minerale", Pepsi, J7, Mirinda), dairy products (" Happy Milkman”,“ Miracle ”,“ Imunele ”), baby food("Zdrivery", "Agusha") and not only. At the Frito Lay plant in Kashira near Moscow, the international giant produces snacks - Lay's and Cheetos chips, Khrusteam crackers (another snack plant is located in Azov). A year ago The Village I visited the PepsiCo production near Moscow and saw . This time we went to the Frito Lay factory to find out how chips are made.

Chips production

Chip base - good potatoes. According to the company's calculations, four kilograms of potatoes make a kilogram of chips. The plant buys potatoes mainly from Russian suppliers from the Moscow and Tula regions. Employees say that not every variety of potato is suitable for making chips. The fruit must be firm in texture and contain minimal amount sugar, there are only seven such varieties.

Potatoes are transported to production in trucks that can carry up to 20 tons of product at a time. Arriving at the factory, the machine pours the potatoes into a receiving container. An employee inspects potatoes - checks if they are suitable for chips. If there is a lot of greenery or black spots on the tubers, such a batch can be sent back to the supplier.

Frito Lay Factory

Snack manufacturer

LOCATION:
Kashira, Moscow region

OPENING DATE: 2002

EMPLOYEES: 1,000 people

PLANT AREA: 25 ha

lays.ru

Potatoes on the conveyor system enter the bunkers, where the first stage of sorting takes place - cleaning from sprouts and earth. The potato tuber should be between four and nine centimeters in diameter, so very small tubers are rejected and the machine discards them in a separate bag. There are only eight such bins at the plant, each of them can hold 40 tons of potatoes, which are completely processed in four hours.

From the bins, the potatoes go to the next section, where the potatoes are washed and separated from foreign contaminants, stones and chips. Cleaning takes place in a large tank - a drum is installed inside it, on which clean water enters with the help of nozzles. Then they get rid of the peel using a round-shaped installation: getting into it, the tubers rotate around the rough walls, and the peel is erased. This happens in just 90 seconds.

After that, the potatoes are washed again in special baths to avoid getting the smallest particles of the peel after peeling. Then there is a sorting by size, and especially large tubers are waiting for a grader - in it the potatoes are cut into several pieces using round knives. especially large potatoes then cut in half again. The sorted tubers get to the inspection table - employees monitor the quality of the product, manually cut the pieces missed by the machine or throw out the unsuitable ones.

After sorting, the potatoes go through the conveyor system to the next section - a slicer, which cuts the tubers into thin slices: the allowable thickness of one slice is no more than 1.3 millimeters. The slicer has five "heads" inside which there are drums with knives - slicers. For the preparation of corrugated chips, the knives are changed to wavy ones. Then the slices are moved by a stream of water to the stage of a quick wash, where they are washed again - this procedure is necessary in order to get rid of excess starch. Starched water goes to a special plant, where the liquid is evaporated, getting dry starch. His company collects and sells.

Finally, the slices enter the frying stage, which takes place in a closed container at a temperature of 180 degrees. The chips are in the fryer for only three minutes - during this time, each slice is immersed in a hot mixture vegetable oils until ready. At the exit of the machine there are moisture meters that check whether the potatoes are fried enough. If suddenly the potatoes turn out to be raw and poorly fried, the system will give a signal to the operator, and he will be forced to dispose of the batch. The next stage of verification is optical sorting, during which chips with defects are “shot” with the help of nozzles. Only then is the product sent to the spice application area.

The chips enter a large spinning drum, inside of which seasonings are sprayed. Due to the fact that the slices are oily, the seasoning fits well on each slice and sticks to it. Herbs are used as spices in production ( dried parsley, onion or dill), spices, flavorings and salt. All these ingredients are mainly purchased in Russia, they are delivered to the conveyor already in a mixed form. The company says that for some flavors - such as garlic, tomato and paprika - a powder is applied to the chips, which consists of chopped vegetables. Monosodium glutamate and flavorings are also used to enhance the flavor. The company clarifies that all flavors are food grade and identical. natural products. “All this is indicated in the composition on the pack,” employees add.

Eight can be made at the same time in production. different tastes chips. Some flavors are produced only for Russia - for example, "Porcini mushrooms with sour cream", " Pickled cucumbers and Crab. For several years now, the most popular taste among Russians is “Young green onion”.

On applying seasonings, the process of making chips ends. The slices first enter the weigher, and then the mass is fed into the opened bag, which looks like a sleeve. The former fills the bag with nitrogen and seals it: this way the product can be stored for a long time and not deteriorate. Cooking time for one batch of chips is a little less than an hour. After packaging, the packages are put into boxes and sent to a warehouse, from where they go to stores in Russia and the CIS countries.

How chips are made aslan wrote on March 25th, 2016

Chips are believed to have originated over 150 years ago in the United States. Legend has it that in one of the elite American restaurants, the client (railroad tycoon Vanderbilt) did not like specialty of the house French fries restaurant and he returned it to the kitchen, complaining that the fries were too fat. The chef of the restaurant decided to play a trick on the client and cut the potatoes into thin slices and fried them in oil and served them to the table. Surprisingly, the client especially liked the dish, and since then a new dish has appeared on the restaurant's menu - chips.

Today in we will learn how chips are made.

Lay's chips have been produced since 1938. Today Frito Lay is one of the leading manufacturers of salty snacks both in the world and in Russia. Deliveries of Lay's chips to Russia began in the mid-90s, and in 2002 it was the first Frito Lay plant was opened in Kashira near Moscow.

The basis of chips is a good potato. According to the company's calculations, four kilograms of potatoes make a kilogram of chips. The plant buys potatoes mainly from Russian suppliers from the Moscow and Tula regions.

Employees say that not every variety of potato is suitable for making chips. The fruits should be dense in structure and contain a minimum amount of sugar, there are only seven such varieties.

Potatoes are transported to production in trucks that can carry up to 20 tons of product at a time. Arriving at the factory, the machine pours the potatoes into a receiving container. The employee inspects the potatoes - checks if they are suitable for chips. If there is a lot of greenery or black spots on the tubers, such a batch can be sent back to the supplier.

The potatoes are conveyed through the conveyor system to the bunkers, where the first stage of sorting takes place - cleaning from sprouts and earth. The potato tuber should be between four and nine centimeters in diameter, so very small tubers are rejected and the machine discards them in a separate bag. There are only eight such bins at the plant, each of them can hold 40 tons of potatoes, which are completely processed in four hours.

After that, the potatoes are washed again in special baths to avoid getting the smallest particles of the peel after peeling. Then there is sorting by size, and especially large tubers are waiting for a grader - in it the potatoes are cut into several pieces using round knives.

Especially large potatoes are then cut in half again. Sorted tubers get to the inspection table - employees monitor the quality of the product, manually cut the pieces missed by the machine or throw out the unsuitable ones.

After sorting, the potatoes go through a conveyor system to the next section - a slicer, which cuts the tubers into thin slices: the allowable thickness of one slice is no more than 1.3 millimeters. The slicer has five "heads", inside of which there are drums with knives - slicers. For the preparation of corrugated chips, the knives are changed to wavy ones.

Then the slices are moved by a stream of water to the stage of a quick wash, where they are washed again - this procedure is necessary in order to get rid of excess starch. Starched water goes to a special plant, where the liquid is evaporated, getting dry starch. His company collects and sells.

Finally, the slices enter the frying stage, which takes place in a closed container at a temperature of 180 degrees. The chips are in the fryer for only three minutes - during which time each slice is immersed in a hot mixture of vegetable oils until cooked. At the exit of the machine there are moisture meters that check whether the potatoes are fried enough. If suddenly the potatoes turn out to be raw and poorly fried, the system will give a signal to the operator, and he will be forced to dispose of the batch. The next stage of verification is optical sorting, during which chips with defects are “shot” with the help of nozzles. Only then is the product sent to the spice application area.

The chips enter a large spinning drum, inside of which seasonings are sprayed. Due to the fact that the slices are oily, the seasoning fits well on each slice and sticks to it. Herbs (dried parsley, onion or dill), spices, flavorings and salt are used as seasonings in production. All these ingredients are mainly purchased in Russia, they are delivered to the conveyor already in a mixed form.

The company says that for some flavors - for example, garlic, tomato and paprika - a powder is applied to the chips, which consists of chopped vegetables. Monosodium glutamate and flavorings are also used to enhance the flavor. The company clarifies that all flavors are edible and are identical to natural products. “All this is indicated in the composition on the pack,” employees add.

At the same time, eight different flavors of chips can be made at the production facility. Some flavors are produced only for Russia - for example, "Porcini mushrooms with sour cream", "Salted cucumbers" and "Crab". For several years now, the most popular taste among Russians has been Young Green Onions.

After packaging, the packages are put into boxes and sent to a warehouse, from where they go to stores in Russia and the CIS countries.

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Chips - loved by millions, a high-quality product made from fresh potatoes in the form of the thinnest slices, plates or straws.

Chips are deep fried and ready to eat. They are used as a dry breakfast, garnish for fish and meat dishes or appetizers various drinks. Goes great with chips thick sauce- dip.

The creator of modern chips is considered to be George Crum, a chef from the United States, who, according to legend, came up with a recipe for french fries back in August 1853. Since then, chips have changed significantly, acquired new shapes and tastes, but the only true process of their preparation has remained unchanged for many years.

What are chips made from?

Chips are prepared only from fresh potatoes, otherwise unappetizing dark spots form on the slices. At the same time, the ratio of potatoes before cooking and at the exit is four kg to 1 kg. Less commonly, other root vegetables fried in oil are used as the basis for chips. For the preparation of chips, only high-quality potatoes of a certain variety are selected. Such potatoes are firm in structure and contain a minimum of sugar. In the production of chips, about seven varieties of potatoes are used with high content starch, including: "Lady Rosetta", "Hermes" and "Saturn".

As for the product prepared from a thin layer of dried mashed potatoes- it should rather be called potato waffles.

Stages of chips production

The technological process for the production of chips consists of the following stages of production:

unloading and preparation of raw materials;
washing and temporary storage of potatoes;
cleaning, sorting and cutting potatoes;
roasting;
adding spices;
package.

Let's consider each of these stages in more detail.

Unloading and preparation of raw materials

Potatoes are delivered to production by trucks, up to 20 tons each. The raw materials unloaded in the receiving container are carefully examined by the employees of the enterprise, checking it for suitability for making chips. When green or dark spots on root crops, the goods are sent back to the supplier.

The inspected potatoes are fed by a conveyor belt into so-called bins, which can hold approximately 40 tons of potatoes. Here its primary sorting, cleaning from greenery and sprouts takes place. The criterion for sorting potato tubers is a diameter of four to nine centimeters. Small root crops are laid separately as marriage. Processing potatoes in bins lasts an average of about 4 hours.

Washing and temporary storage of potatoes

At the next stage, the potatoes are separated from foreign debris (chips, stones), and also washed. Potato tubers can be washed in large capacity with a drum inside. pressure supply clean water adjusted through injectors.

Cleaning, sorting and cutting potatoes

Peeling potatoes is also an automated process: the peel of root crops is actually erased against the abrasive walls of a special device in about 90 seconds. Such a potato peeler is able to peel about 5 tons of potatoes in just 1 hour.

To avoid residues potato peel after cleaning, the potatoes are washed again. Next, it is sorted by size, as a result of which the largest tubers will be cut into pieces by a grader (a device with built-in large knives). The quality of the sorted product is monitored by employees at the inspection table. Here, the potatoes correct the omissions of automatic cutting and remove parts unsuitable for making chips.

The slicer cuts the potatoes selected by specialists into the thinnest slices in the next step. The allowable thickness of the slice does not exceed 1.3 mm. The design of the slicer includes "heads" with drums and knives (slicers) inside. No less popular today are "wavy" (corrugated) chips. To prepare them, the knives in the slicer change. Under the influence of centrifugal force and spicy potatoes turns into slices. The root vegetable must be cut into approximately 36 pieces to make regular chips.
The finished slices are again transferred by the water flow to the water tank for the washing stage. This step is necessary to remove excess starch from potatoes. The same starch is then, after passing through a special installation, evaporated and sold.

Roasting

Potato slices are dried under a stream of hot air and sent to the frying stage. Ovens and oil are heated to 190 degrees Celsius, so it takes only three minutes to fry potatoes. When the chips leave the oven on the conveyor, excess oil flows into a special reservoir. If the potatoes are poorly fried, the moisture meter system sends a signal to the operator, who, in turn, sends the entire batch for disposal.

The fried slices are tested again, this time optically. Quality product with the help of nozzles it is sorted out from chips with defects and only after that they go to the area for adding spices.

Adding spices

Chips are placed in a large drum filled with appetizing seasonings. Seasoning perfectly wraps each oiled potato slice. To prepare high-quality chips, manufacturers use only natural spices: onion, dill, parsley, etc. To create such unique tastes like tomato or garlic, a powder made from dried vegetables is applied to the surface of the slices. All flavorings used in the production of chips are natural.
Seasoning precedes the last step in the production of chips - their packaging.

Package

Slices of fried potatoes are first weighed and dosed, and then they are poured into a special bag-sleeve. Before sealing the bag, nitrogen is poured into it, which allows the chips not to deteriorate and retain their taste qualities much longer. Thus, a pack of chips under production conditions goes through all stages of preparation in about an hour. Packages with chips in boxes are placed in a warehouse, from where they are further delivered to stores.

It should be noted that the production line is maximally automated with the help of modern equipment. This minimizes human contact with the finished product.

Thus, we have traced the production line of chips from the delivery of raw materials to the placement of finished chips on store shelves, and now you know how chips are made.

The topic of today's report is the plant PepsiCo for the production of Lay's potato chips, recently opened in the city of Azov, Rostov Region. In addition, the plant produces Khrusteam croutons. Let's walk sequentially along the entire production line and consider it in detail.

Chips are believed to have originated over 150 years ago in the United States. Legend has it that at one of America's finest restaurants, a customer (railroad tycoon Vanderbilt) didn't like the restaurant's signature dish, french fries, and returned it to the kitchen, complaining that the fries were too fat. The chef of the restaurant decided to play a trick on the client and cut the potatoes into thin slices and fried them in oil and served them to the table. Surprisingly, the client especially liked the dish, and since then a new dish has appeared on the restaurant's menu - chips.

Lay's chips have been in production since 1938. Today, Frito Lay is one of the leading manufacturers of salty snacks both in the world and in Russia. Deliveries of Lay's chips to Russia began in the mid-90s, and in 2002 the first Frito Lay plant was opened in Kashira near Moscow.

Unloading, washing and temporary storage of potatoes

Every day, nine 20-ton trucks with potatoes are unloaded here. The potatoes are conveyed through a conveyor belt into a washing machine, where recirculated water is used to clean them. In total, there are three such automatic car washes in the world. It is physically impossible to remove the washing process, everything takes place in a closed container. After washing, the potatoes go for temporary storage in bins - special containers, from where they are fed to production as needed.

Cleaning, sorting and cutting potatoes

Before the potato tubers enter the special cutting machine, the inspectors visually inspect the tubers moving along the belt and, if necessary, remove visible defects.

By the way: Not every potato is suitable for the production of chips. There are so-called potato chips, which are characterized by a high content of starch.

All employees periodically undergo a medical examination and have medical books, this is done so that a sick person does not get to work. In addition, before entering the workshop, everyone must wash their hands.

Potato peeling takes place in abrasive drums of periodic action. Loading first required amount potatoes into the weight hopper, after which it is unloaded into the drum.

Directly cutting occurs mechanically due to the rotation of the cone-shaped bottom of the drum. Inside the cutting machine are eight pairs of extremely sharp blades that cut the tuber into thin slices. The thickness of each slice is less than two millimeters.

Roasting

After slicing potato slices go to the heart of the chip production line - the frying pan for frying the slices and getting the base chips. This equipment, which has no analogues, was created specifically for the PepsiCo plant and cannot be shown.

Thinly sliced potato slices go into an oil bath where they are fried for three minutes at 180 degrees Celsius. quality oil, as well as high-quality potatoes - the basis of the taste of chips.

The recipe was improved at the plant, using a special mixture of vegetable oils, including high-olin sunflower oil locally produced, thanks to which the content of saturated fats in the final product is reduced by 25%.

The quality of products is checked daily at the factory. They check both basic chips, just out of the oven, and fully packed packages.

Adding spices

At this stage, in fried potato chips special aromatic and flavor additives which are based on salt.

Three flavors can be produced simultaneously on the line.

Package

By the way: The plant is designed to produce 50 thousand tons finished products in year. Some fantastic figure, in my opinion.

On three conveyors, ready-made chips go to packaging. First comes distribution and weighing.

By the way: Please note that there are very few workers along the entire length of the line. It uses modern equipment that operates in a fully automated mode. In addition, it is important that as few people as possible come into contact with the finished product.

Weighing machines weigh several portions at the same time and calculate the best weight combination, which has the most accurate weight in order to meet the standard and the weight indicated on the package.

Considering that the net weight of one pack is 28 grams, you can imagine the accuracy of the equipment setting.

The weighed portion is unloaded onto the packaging line.

The portion passes control for the presence of foreign impurities (metal detector) and enters the package, which by this time has been prepared by the packaging machine from packaging materials(foils). Before sealing the seam, food nitrogen is supplied to the bag, which allows to ensure the necessary shelf life of the product. Weighing and packaging equipment works synchronously, at a speed of up to 80 bags per minute.

The packaged bag of chips arrives at the operators, who manually stack the bags into cartons.

Boxes of chips are stacked on pallets and transported to the warehouse.

In parallel, there is a line for the production of crackers

A mixture of flour and water is fed into the extruder, heated and thoroughly mixed. From the extruder, crackers come out in the form of bundles, which are cut to size by rotating knives.

At the next stage, the crackers are dried in the oven and get to the seasoning area.

The packaging line is identical to the one on which chips are produced.

Weighing takes place in a similar weighing machine, which forms several portions and selects the best combination for sealing in a bag.

Ready crackers.

The productivity of one line is 12 tons of finished products per day.

Employees are forbidden to wear watches and jewelry, manicures and false nails are prohibited, hair must be covered with a net so that nothing gets on the conveyor.

Except palatability and visual compliance of the slices with accepted standards, the quality of the packaging is checked here. The seam should be even and the pack should open with one movement exactly along the seam, without gaps.