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Potato chips frying Equipment

Frying was an early method for preserving food. The most common technique, immersing foods in boiling oils, dehydrates the items and decreases microbial growth. But even with alternative decontamination and preservation methods, frying remains a popular cooking technique. The oils add complexity to the natural flavors and textures of foodstuffs. One of the main challenges of fried products is maintaining oil freshness. Industrial frying equipment processes large volumes of food homogeneously by strictly controlling the temperatures in the frying chamber. However, oil efficiency is also crucial, and temperature control must balance oil levels in the line.

Frying

Manufacturing potato chips is a farm-to-fork process from raw material to the final product. From washing and peeling to processing and frying and more in between. Freshly harvested potatoes are first washed, peeled, and sliced into thin potato slices. After washing them again to remove the starch, potatoes are then blanched, fried, seasoned, packed, and served, ready for your consumer’s enjoyment.

Potato chips

Manufacturers of French fries and potato chips require a lot of energy for heating and cooking. With energy costs rising and emission regulations getting tighter, manufacturers are looking into sustainable and more environmental-friendly solutions for their operations. Producers can reuse energy and reduce emissions by extracting heat energy from the moisture in vapor streams generated in frying systems. This energy can be utilized in other processes, such as cleaning.


<h2>Saving energy costs by reusing heat energy from the frying process</h2>
The Energy Recovery Unit from Kuipers is a heat recovery and odor eliminating system for potato chips and French fries production. The system processes the multi-phase vapor stream containing moisture, oil particles, and odor from the frying system’s exhaust vents or chimneys. First, the oil particles are eliminated. A wire mesh demister separates the droplets from the vapor streams. Further,  the hot vapor streams move upwards the condensate tower. A collection tank at the bottom of the condensate tower collects excess moisture from the vapor in the form of warm water. Now separated from excess moisture and oil fumes, the dryer vapors contain much less odor.

An additional odor treatment system known as Odourtubes removes the remaining odor through the ozone treatment process. With this system, it is important to reuse the energy recovered immediately within the line for other purposes, such as cleaning where warm water is needed.

Energy recovery unit for potato chips production line

Producing high-quality kettle-style potato chips can be challenging due to the need for consistent cooking times and temperatures. Traditional methods for frying often result in chip clusters, uneven cooking, and oil wastage, impacting both the quality and cost-efficiency of production.
<h2>Automatically control frying and stirring processes</h2>
The Batch Fryer by Heat and Control is designed for producing kettle-fried potato chips with consistent quality. It features a fully automated PLC system that controls potato feed, frying, stirring, and unloading of finished chips, ensuring repeatable quality. The fryer includes the optional Chip-Stirr system, which stirs the slices during cooking and prevents slice clusters, thereby maintaining uniform chip quality. The under-pan fired design eliminates the need for heat transfer tubes, allowing cooking with as little as 4 inches of oil, which is continuously managed by an automatic oil level control system. This efficient oil management reduces waste and improves the overall cooking process, making it suitable for producing kettle-style potato chips at production capacities of up to 360 pounds per hour.

Batch frying system for kettle-style potato chips

When producing a diverse range of snack foods like potato chips, cheese puffs, or tortilla chips, a fryer with adjustable settings is needed. This helps control frying conditions for different products, optimizing texture and flavor while maintaining efficiency.
<h2>Adjust frying conditions quickly and efficiently</h2>
The Dynamic Action Fryer® by Heat and Control allows you to respond quickly to market demands by adjusting its versatile functionalities to produce multiple types of snack foods. You can modify the elevation, speed, and motion of the product control paddles to create varied frying conditions. Capable of handling potato chips, plantain chips, malanga chips, taro chips, multi-grain chips, corn and tortilla chips, extruded snacks, pellet snacks, cheese puffs, and corn curls, it is an all-in-one solution for diverse snack production. The compact design saves floor space and is ideal for producers looking to streamline operations without sacrificing product quality. This fryer is particularly suitable for high-mix, low-volume production environments and helps ensure consistent frying results.

Flexible fryer for various snack products

In the production of stackable potato chips, achieving uniform shape, color consistency, and extending shelf life are critical challenges. Producers need reliable fryers that deliver consistent, high-quality results while maintaining precise control over temperature and oil levels.
<h2>Form and fry uniform stackable potato chips</h2>
The Fabricated Chip Fryer by Heat and Control is designed to form and fry consistently uniform stackable potato chips. After the sheeting and cutting stages, chips are conveyed into the fryer where they are shaped using convex stainless steel molds. This process ensures they maintain their shape and cook uniformly. The fryer features precise temperature and oil level control, producing chips with consistent color and extended shelf life. Post-frying, the chips are released from the molds and conveyed to seasoning and packaging equipment, maintaining the quality and appearance required for market sales. The system is optimized for high-volume production, making it ideal for leading producers of stackable chips.

Fabricated chip fryer

In the production of high-quality potato chips, maintaining consistent temperature and oil flow is crucial. Challenges include achieving uniform color, precise moisture content, and removing product particles to ensure long shelf life.
<h2>Control temperature and oil flow precisely</h2>
The Industrial Potato Chip Fryer by Heat and Control is designed to produce some of the world's finest potato chips. This fryer ensures superior oil quality by filtering 100% of the system oil volume every minute to remove product particles. Continuous oil circulation between the fryer, filter, and heat exchanger allows for precise temperature control and rapid adjustment to changes in product load. It can create custom temperature profiles to produce different styles, optimizing your equipment investment. The fryer is ideal for producing traditional, ripple, and wavy potato chips, as well as potato sticks. The result is a reliable and clean operation that delivers consistent product quality.

Industrial potato chip fryer

In snack food production, the ability to customize recipes on-demand and ensure consistent quality can be challenging. Variations in cooking time, temperature, and oil filtration can affect the final product's taste, texture, and shelf life.
<h2>Adjustable frying for versatile snack production</h2>
The Universal Product Cooker by Heat and Control is an advanced fryer system designed to produce a wide variety of snack foods with precise consistency. The system integrates independent fryer modules into one continuous line, allowing for customizable control over time, temperature, and oil flow. This flexibility enables the production of diverse snack types, including traditional and kettle-style potato chips, plantain chips, pellet snacks, and more. The Universal Product Cooker utilizes easy-to-use Programmable Logic Controls (PLC) to store and switch between multiple recipes efficiently. Continuous oil filtration in each frying module ensures superior product quality and extended shelf life. The system operates cost-effectively, making it more economical than separate batch or continuous fryers with similar capacities.

Universal fryer system for snack foods

For small to medium-sized snack producers, creating kettle-style potato chips with a consistent, high-quality finish can be a challenge. Traditional fryers often lead to issues like uneven cooking and chip clusters, impacting the final product's texture and taste.
<h2>Produce uniformly fried kettle chips</h2>
The Mastermatic Batch Fryer by Heat and Control is designed to meet the needs of start-up and market entry lines producing kettle-style potato chips. This fryer features all stainless steel construction, including a heavy-gauge oil kettle, ensuring durability and ease of cleaning. It offers production capacities of 150lbs / 68kg, 200lbs / 91kg, and 350lbs / 159kg of finished products per hour, making it suitable for different levels of production. The Mastermatic Batch Fryer's fully-enclosed combustion system promotes sanitary operation, and large removable panels provide complete access for maintenance. An optional Chip-Stirr system automates the stirring process, eliminating chip clusters by continuously stirring the slices during cooking and directing finished chips to the discharge/drain conveyor. This ensures consistent chip quality batch after batch.

Kettle chip fryer

In the production of snack and prepared foods, achieving consistent frying quality can be challenging, especially for start-ups and entry-level operations. Ensuring uniform frying of products like chips, nuts, and fried chicken requires a reliable and efficient frying system.
<h2>Batch frying for consistent and reliable results</h2>
The Mastermatic Heavy-Duty Batch Fryer from Heat and Control is an economical solution designed for start-up and small-scale productions. It features a heavy-gauge stainless steel pan and a painted steel cabinet, ensuring durability and longevity. The fryer is compact, occupying a small footprint, and is easy to operate with dial controls for precise oil temperature adjustment. Available in sizes supporting up to 600 and 800 pounds per hour (272 and 363 kilograms per hour) of finished product, this fryer is versatile for a range of applications including kettle-style chips, French fries, and various prepared foods. Ideal for meat, poultry, and seafood, the system also accommodates alternative meat products.

Heavy-duty batch fryer for snack and prepared foods

When producing kettle-style potato chips, achieving uniform crispiness and optimal taste can be challenging due to variations in cooking environments and chip clustering. Efficient and consistent frying techniques are essential for maintaining quality across different batches.
<h2>Produce consistent kettle-style chips effortlessly</h2>
The Mastermatic LDKF Batch Fryer from Heat and Control is designed for producing high-quality kettle-style potato chips. The fryer features direct gas-fired longitudinal heat transfer tubes that allow you to customize the cooking conditions for different potato grades. The optional Chip-Stirr system automatically agitates slices during cooking, preventing slice clusters and ensuring uniform chip quality. A stainless steel hood encloses the frying area, enhancing the cooking environment and can be raised using motorized screw jacks for easy operation and maintenance. Capable of producing up to 300 lbs. (136 kg) of chips per hour, the Mastermatic LDKF Batch Fryer is suitable for small to medium-scale production setups.

Batch fryer for kettle-style potato chips

When producing kettle-style potato chips, uniform heating and consistent quality are crucial. Traditional frying systems can struggle with maintaining these standards, leading to issues like chip clusters and uneven frying.
<h2>Ensures uniform frying and reduces chip clusters</h2>
The MasterTherm Kettle Fryer from Heat and Control is designed for batch frying kettle-style potato chips with high accuracy and consistency. This thermal fluid heated kettle frying system features unique thermal fluid heat transfer tubes immersed in the oil, delivering uniform heating with fast heat response and no burning of chips. It reduces thermal stress by allowing the heat exchanger tubes to move independently. The Chip-Stirr system automatically stirs slices during cooking to eliminate clusters, ensuring consistent chip quality. The full-length hood improves safety, energy efficiency, and oil quality by reducing heat loss and purging oxygen.

Kettle fryer for batch potato chips

Fried peanuts are a very popular snack around the world. If you are looking to start a nut processing plant to capitalise on this market, maintenance of product quality and taste is key. When frying nuts, optimal heat distribution and oil quality are the most crucial factors. A state-of-the-art fryer and process are needed to deliver the exact heat load needed to fry your product efficiently while maintaining its taste.


<h2>Save time, frying oil and labour costs</h2>
Kuipers’ production line for nuts and seeds is configured for optimal frying-oil handling and heat treatment resulting in the lowest possible development of Free Fatty Acids as well as lowest frying oil turnover time in the industry.  It is a frying oil heating system with an innovative design that uses circulating thermal oil as a heat carrier. This allows the reduction of the amount of frying oil required to its lowest .

The <a href="https://making.com/peanuts/">peanut processing machine</a> and frying line keeps in mind the importance of oil quality as it not only acts as the heat transfer medium but is also absorbed by your product. It is thus equipped with a unique filtration system where constant removal of the dirt allows the quality of the frying oil to remain adequate much longer than other conventional systems. It is an automatic and continuously operating filtration system.

All Kuipers lines allow the option to heat the frying oil in the fryer with either thermal oil or electrical elements. With a few additions, the plant can also be upgraded to produce coated and <a href="https://making.com/battered-nuts/">battered nuts</a>. It can be applied for the frying of peanuts, <a href="https://making.com/cashews/">cashew nuts</a>, almonds, macadamias and other nuts or seeds.

Peanut frying line

The key to making a flavorful and crispy bag of potato chips is the frying temperature within the frying machine. Uniform cooking conditions ensure a consistent taste, bite, and color when it comes to potato chips processing. But maintaining steady temperatures across the entire processing line can be challenging, particularly when frying potato chips at high capacities.


<h2>Distribute the frying temperature evenly with multiple oil injection points</h2>
The semi automatic Potato chips production line frying plant from Kuipers uses multiple fully automatic oil injection points to deliver even temperature distribution within the potato chips machine. Manufacturers can manage heat across the width and length of the system to maintain optimum frying conditions throughout the whole process. Distinct oil injection zones facilitate temperature control which needs to be optimal for quality, tasty products.

A full turnkey system for producing potato chips is included in this production line. The machine includes washing, peeling machine, cutting potato slices, blanching, packing machine and most importantly, fries potato chips. For a small scale or full scale potato chips plant, this stainless steel production line does it all so you can successfully make potato chips from start to finish including packaging.

The chip fryer is designed for processing all styles of potato-based fried snacks, including chips, sticks, and hard-bite-style crisps. As well as sweet potato chips, banana chips and french fry style crisps. Capacities are offered from 250 kilograms per hour output to 1000 kilograms per hour output depending on oil volume. The best oil will produce the best final product.

Potato chips production line

<span style="font-weight: 400;">From cassava to sweet potatoes, various types of vegetables are processed to make one mixed bag of vegetable chips. Mainly consisting root vegetables like taro and parsnip, vegetable chips are often introduced as a healthy alternative to potato chips. To make these chips, you first need to slice the vegetables and cook them depending on your product; you can simply bake them or fry them, deep fry them, or dry them. After this process, flavorings are added to the chips. </span>

Vegetable chips

Pellet snacks, or snack pellets, are intermediate products which you can further process and develop into snack products for consumption. Pellet snacks production involves mixing, extrusion, frying, and packing. Since these are intermediate products, final product customization on the production line will depend on your customer’s desired product and flavor profile.

Pellet snacks

Peanuts, also known as groundnuts are one of the most popular edible seeds in the world. You can eat them as-is or process them further into on-the-shelf products like peanut butter, oil, snacks, and soups. Depending on what you want to make, some peanut manufacturing processes include roasting, frying, boiling, grinding, pressing, and coating the peanuts.

Peanuts

Kuipers Food Processing Machinery specializes in the technology for the frying and processing of snacks, savouries, nuts, seeds and potato products.

Fast plant startups require well-defined roadmaps for scope, time, cost, and quality, to facilitate decision-making when purchasing and installing industrial technology. We spoke to Valeria Lucinschi, General Operations at Kuipers Food Processing Machinery, to learn how they ensure an efficient buying and installation cycle and align their fryers with producers’ goals.


<h2>The buying cycle from product testing to FAT</h2>
Valeria explains that when you contact Kuipers to choose a frying technology for your snack, the food engineering team will observe the product's behavior, document it, collect data, and perform computer simulations considering oil efficiency and turnover times. Product testing will help to determine the ideal fryer, size, oil amount, processing time, and other product-specific parameters. “Many new products need further testing to ensure the target outcome can be achieved,” Valeria states.

The buying cycle described by Valeria begins once the parameters are agreed upon. “The engineering department creates the drawings and sends a work order to manufacturing. When the fryer is built and assembled, Kuipers’ service team takes over with electrical pre-wiring and automation. Then the plant is fully pre-tested to ensure that all the main parts are functional. You are invited to attend the factory acceptance test (FAT) and may request alterations at this stage if needed,” Valeria indicates.

“After your agreement, the fryer is packed in Lego-like blocks and shipped. In the best-case scenario, a small standard fryer can be ready within 36 weeks. However, delivery times may be longer depending on the waiting list,” Valeria concludes.
<h2>Site preparation and modular design: the key to quick startup</h2>
Site preparation is crucial for a quick startup. Ensure your facility has the required electrical connection, automation cables, and piping in place beforehand. Kuipers’s modular design makes installation nearly plug-and-play. “The plant can be assembled like Lego blocks and plugged into the utilities,” Valeria says. Kuipers will run an acceptance test on your site and train your operators before finalizing the handover.

According to Valeria, “Kuipers' modular design allows small standard frying plants to be operational within one week of delivery, compared to most equipment suppliers, which take about a month to install and start up a plant. This can save you a significant amount of time and money, considering that an average engineer day costs more than 1000 euros.”

When choosing industrial technology, consider the operation and maintenance requirements as well. Valeria highlights that “With Kuipers' frying systems you can operate for many days without having to change your oil’’. These efficient systems allow you to produce continuously while not compromising your product quality.

Modular plant designs are a way to go if you want to start and run your production, saving time, and hence, money.

Modular design for a fast fryer plant startup

Food

Our food chain starts in the soil, growing crops and livestock. But between the fields and the stores, there is a line of industrial food processing equipment. Processes may be as minimalistic as cleaning fruit and as complex as homogenizing milk alternatives made from pressed legumes. In each case, processing technology is an important link in the food production chain.

A fresh salad with a walnut oil dressing or a peanut butter sandwich? A bag of roasted cashews or a pack of almond cookies? The common thread among these tasty treats is nut processing equipment. Not all nut ingredients are indeed nuts, botanically speaking. But the machinery that transforms shelled fruits, legumes, and drupes into fried snacks or a paste is similar. As for the food products, there is a nut recipe for every mood and occasion.

Nuts

A snack is a small portion of food ready to eat and simple and fast to prepare. People usually consume snacks during the day between traditional meals such as breakfast, lunch, or dinner. Snack foods include simple products such as nuts, dried fruits, peanuts as well as packaged and processed foods. Puffed corn products made by extrusion or flavored potato chips are examples of processed foods.

Snacks

Water is one of our most precious assets, and we are not making good use of it. It has been estimated that by 2030, half the population will face water scarcity problems due to climate change, water pollution and a growing population. The manufacturing industry consumes between 20-40% of all available freshwater, so the question arises: what are manufacturers doing to reduce water consumption in the industry?

We broached the subject with Valeria Lucinschi, from <a href="https://kuipers.nu/">Kuipers Food Processing Machinery</a> to learn how this works in potato chip production.


<h2>Potato chip producers use on average eight cubic meters of water per hour. Wait, what?</h2>
Yes, you heard it right. On an industrial scale, producers consume 8 m<sup>3</sup> of water per hour when making potato chips. Water is used in almost all preparation steps and is essential when preparing potato slices before frying. And not just for cleaning purposes as you may be thinking. After being washed for the first time and peeled, the potatoes are sliced and rewashed to remove some of the starch. If this step is not done well, it can greatly affect the quality of the end product as well as the frying process. Starch can block the evaporation of moisture from the potato when frying by leading to a browning reaction. If this happens, forget your crispy and golden-colored chips.

It is recommended to have a good slice washing system to wash the potatoes very carefully, mainly when the blanching is not applied. Although producers may skip this step, especially when potatoes are fresh, it is generally advised to blanch to ensure a smoother deep frying process. If blanching is applied, slices must pass a final washing and drying to remove any adherent particles and water before frying.
<h2>Reduce water consumption in your potato chip production line by 60%</h2>
Back to our question now. What are producers doing to reduce these eight cubic meters of water?

Valeria explained that Kuipers has reduced water consumption in the potato chip production line by recycling water from one stage to another. This can be done thanks to a water treatment system that only uses fresh water at one stage of production - to be clear when potatoes are on the spreading belt that blows water to wash them just before frying. From here, the system recycles the water that goes back to the previous stages. The water is filtered through a cyclone system that cleans it and removes the starch so it can be reused again. The Kuipers water system technology uses up to 60% less water than conventional systems, meaning they use 4 m<sup>3 </sup>per hour on average.

How to reduce your water footprint when making potato chips

If you are starting your own production for potato chips or expanding your brand to include fried potato snacks, you need a complete and cost-efficient production line. A solution that ensures minimal loss of raw material and efficient use of water and energy while maintaining excellence in taste, colour and texture of your fried potato snacks.


<h2>A complete and sustainable solution for frying potato products</h2>
<a href="https://making.com/equipment/potato-chips-production-line/">Kuipers’ complete processing and frying lines for various potato products</a> provide a turnkey solution of turning raw potato input into delicious deep-fried snacks until packaging. It offers a customized approach to process potato  products which consequently ensures efficiency throughout the line.

The frying line for potato chips uses gentle heat transfer to heat up the frying oil and ensure that your product is evenly fried. The production plant is a continuous and fully automatic operation. It starts with receiving the raw potatoes and includes the necessary potato washing and de-stoning equipment to clean and prevent damage to the peeling and slicing or dicing units. In the peeling stage, it applies batch type, abrasive peeling. It is also equipped with a blancher to reduce the sugar content from the potato slices and prevent quick dark colouring The plant also includes a smart water treatment system which allows the lowest possible water usage in the industry, reducing it by three hundred per cent.

Kuipers’ systems provide you with an option for frying oil heating via a thermal oil heater or electrical elements. Apart from potato chips, Kuipers also designs and manufactures small French fries factories for either frozen or chilled end products. The chips line can also be used to produce potato sticks.

Frying line for potato chips (redirected)

Do you have a guilty pleasure? Do you pause while walking down the supermarket's chips and fried snacks aisle? If the answer to those questions is yes, do you ever wonder about the journey of a raw potato from a farm up to the crispy, crunchy, and salty goodness that goes into your mouth? It involves many steps, from the raw potato input to peeling, slicing, and <a href="https://making.com/equipment/potato-blanching-machine">blanching the potato</a> until it is fried and coated with your favorite <a href="https://making.com/products/spices">flavors and spices</a>. With growing competition in the fried snack industry, these steps must be carried out carefully and consistently to produce the highest quality chips.


<h2>From farm to the fryer</h2>
The availability of raw inputs combined with a high local and global demand provides <a href="https://making.com/products/food">food processing</a> companies and local farmers with many growth opportunities. A regular <a href="https://making.com/potato-chips/">potato chip plant</a> makes thousands of chips every hour. The potatoes are washed and de-stoned to ensure they are clean and prevent damage to the peeling, slicing, or dicing units. In the peeling stage, batch type, abrasive peeling takes place. The potatoes then move along a belt to a slicing machine that slices them quickly using a razor-sharp blade. Ripple potato chips are cut by a serrated knife. It is then transported into a blancher to reduce the sugar content from the potato slices to prevent quick dark coloring and maintain product quality. These potato slices are then put into a vat of boiling vegetable oil with special <a href="https://making.com/deep-frying-equipment">deep fryer equipment</a>. As the potato chips cook, the water inside them turns to steam. After this, they are collected, drained, salted, and then ready to be packaged.
<h2>Producing the perfect bite</h2>
The fried snack market around the world is constantly growing. The main factors facilitating this growth include lifestyle changes, increased urbanization levels, and simply because the population has access to many more snacks than in previous years. This makes optimal production and quality control of utmost importance. The transportation of your product through the fryer must be perfectly done. Every piece must have the same frying time and no possibility of staying behind and burning. The <a href="https://making.com/technologies/frying">industrial fryers</a> for making potato chips are a continuous and fully automated production plant that ensures gentle heat transfer to heat the frying oil so that your chips/crisps are evenly fried. It also prevents the degradation of the oil quality, allowing you the lowest possible oil turnover needed!

[embed]https://www.youtube.com/watch?v=1wPYqa2OqMg[/embed]

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