Potato Chips Production Line — Detailed Description

Below is a practical, engineering-grade overview of a continuous potato-chips line, from raw tubers to nitrogen-flushed retail packs. It covers unit operations, key parameters, quality targets, utilities, and typical performance.

1) Raw Material & Receiving

Potato spec.

Variety: frying types with dry matter 20–24%, reducing sugars <0.2% (as glucose + fructose), low defects.

Size: 45–85 mm dia. for uniform slicing.

Storage: 8–12 °C, 90–95% RH; reconditioning (15–18 °C for 2–3 weeks) if sugars are high.

Receiving & grading

Infeed hopper → roller/coil grader to remove stones/clods and to split overs/unders.

Inspection conveyor for manual removal of green, sprouted, or damaged tubers.

2) Washing & Peeling

Abrasive drum/brush washer-peeler (SS304).

Removes soil and skins; adjustable dwell (30–120 s).

Water recirculation with sediment trap; optional high-pressure spray bars.

Peel loss target: 8–12% (variety dependent).
Alternative: Steam peeler for minimal loss at high capacities.

3) Trimming & Slicing

Trimming table (optional) → Slicer (flat or ripple/krinkle cut).

Slice thickness: 1.2–1.6 mm (standard chips), 1.8–2.2 mm (kettle style).

Knife pack: hardened SS; speed-matched feed for uniformity.

Online thickness gauge recommended for SPC.

4) Slice Rinsing / De-starching

Flume or rotary washer immediately after slicing.

Purpose: wash off surface starch to prevent clumping and reduce dark color.

Water temp 15–25 °C; TDS control with bleed-and-make-up; overflow to starch recovery (optional).

5) Blanching (if required)

Used when raw sugars are borderline or for very light color targets.

65–75 °C for 3–6 min (continuous belt blancher).

Counter-current water; optional 0.1–0.3% sodium acid pyrophosphate (SAPP) dip to limit after-cooking darkening.

Post-blanch rinse to remove carryover.

6) Dewatering

Vibratory dewaterer + air knives / centrifugal de-watering drum.

Reduces surface moisture before frying → better texture and lower oil pick-up.

Target exiting moisture on surface: “dry-to-the-touch” (<2% free water).

7) Frying (Core Process)

Continuous fryer (gas, thermal oil, or electric; SS304/316).

Oil: high-oleic sunflower, palm olein, or blends; antioxidants as per regulation.

Setpoint: 175–190 °C (kettle style: 160–175 °C longer dwell).

Dwell time: 120–180 s depending on thickness and texture.

Oil levels and belt speed controlled by PLC (PID).

Oil management: fines removal, in-tank filtration, external leaf/bag filters; turnover time 6–8 h typical.

Steam hood & ventilation with fire suppression; auto-top-up and continuous free-fatty-acid monitoring (optional).

Targets leaving fryer

Final moisture: 1.5–2.2%.

Oil pick-up: 30–38% of final weight (thickness-dependent).

Color score within customer spec; acrylamide managed by raw selection + blanching + fryer control.

8) De-oiling / Cooling

Continuous centrifugal de-oiler or vibratory cooling conveyor with ambient/tempered air.

Reduces surface oil, stabilizes texture, and improves seasoning adhesion.

Chips cooled to <45 °C before packaging to avoid bag condensation.

9) Seasoning

Tumbling drum with loss-in-weight powder feeder and oil spray (for slurry or kettle style).

Recipe-based dosing; typical addition 3–8 g/100 g finished chips.

Dust extraction for hygiene; allergen segregation if applicable.

10) Packaging

Multihead weigher + VFFS (vertical form-fill-seal) or HFFS for premium packs.

MAP/Nitrogen flush to residual O₂ <2% for shelf-life.

Bag materials: metallized BOPP/CPP or high-barrier laminates; easy-open notch; euro-hole optional.

In-line checkweigher and metal detector; print/apply date and lot code.

11) Oil & Water Systems (Skids)

Oil filtration loop: pump, heater, filter housing(s), instrumentation (ΔP, temp).

Oil storage/conditioning tank with nitrogen blanketing; periodic polishing filtration.

Water:

Slice washer/blancher circuits with counter-current design.

Starch recovery (settling/centrifuge) and wastewater pre-treatment (DAF or screens).

12) Automation & Controls

Central PLC + HMI/SCADA; recipe management for slice thickness, fryer temp, belt speeds, seasoning dose.

Instrumentation: temperature, level, flow, ΔP across filters, O₂ analyzer at packaging.

Alarms & interlocks: over-temp, low oil level, exhaust fan failure, fire system, belt jam, metal detector reject.

Data logging: OEE, yield, energy; batch/lot traceability.

13) Hygiene, CIP & Safety

Zoning: “dirty” (receiving/peeling) → “clean” (post-fryer to packing) with personnel/airflow control.

CIP for slicer, flumes, blancher, seasoning lines; fryer cleaned with controlled cool-down and hot caustic cycle.

Flooring: resin with 1–2% falls to SS channels; hose-down points.

Safety: guarding, E-stops, LOTO, fryer fire suppression & exhaust ventilation; hot-oil PPE procedures.

14) Quality & HACCP Check-points

Raw acceptance: reducing sugar, defects, size.

In-process: slicer thickness SPC; blancher temperature/time; fryer temperature profile; oil quality (FFA, PV, TPM).

Finished product: moisture (oven), oil content (Soxhlet/NMR), color chart, texture (crispness), acrylamide monitoring, salt content, O₂ in pack, leak test.

Traceability: lot tracking from raw trucks to pallet IDs.

15) Throughput, Yields & Manpower (typical)

Capacity bands (finished product): 100, 300, 600, 1 000 kg/h.

Yield from raw tubers: after peeling/trim/fines → ~60–70% slices; after frying with oil uptake → ~30–38% finished chips per 100% raw (variety & peel method dependent).

Staffing (per shift, 300 kg/h line): 6–8 operators (receiving 1, trim 1, fryer 1, seasoning/packing 2–3, QA 1, forklift 1).

16) Utilities (indicative for a 300 kg/h line)

Electrical installed: 120–180 kW (washers, slicer, pumps, conveyors, de-oiler, seasoning, packaging).

Thermal for fryer: 350–600 kW heat duty (gas/thermal-oil).

Compressed air: 6–8 bar, 1–2 Nm³/min for actuators, weigher, VFFS.

Water: 1–3 m³/h make-up (with recycling); additional for sanitation.

Ventilation/extraction: sized to fryer hood and seasoning dust capture.

17) Standard Equipment List (typical, SS304/316 contact)

Infeed hopper & elevator

Stone/soil remover & rotary washer

Abrasive/brush peeler (or steam peeler)

Inspection conveyor

Slicer (flat & ripple heads) with feed pump or chute

Slice washer/flume & options for blancher

Dewatering shaker + air knives or centrifugal de-waterer

Continuous fryer with oil filtration & heat system

De-oiling drum / cooling conveyor

Seasoning tumbler with powder feeder & oil spray

Bucket elevator to multihead weigher

VFFS machine with nitrogen and date coder, metal detector & checkweigher

Oil storage/conditioning & polishing filter skid

Water treatment/starch recovery (optional)

Platforms, guards, electrical panels, SCADA

18) Layout & Footprint (guide)

Linear flow: receiving → wet area → fryer room → seasoning → packing.

Footprint (300 kg/h): ~25–35 m × 8–12 m production hall plus raw/finished warehousing.

Separate technical rooms for gas burners/thermal oil, compressors, and electrical MCC.

19) Options & Upgrades

Ripple/kettle-style switchable slicing and frying programs.

Low-oil system (enhanced de-oiling) for 26–30% fat targets.

Acrylamide mitigation package (advanced blanch control + analytics).

Allergen-segregated seasoning with quick-change drums.

Energy recovery from fryer exhaust; oil polishing centrifuge; inline O₂ control.

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