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Potato chips packing Equipment

<span style="font-weight: 400">At last, you reached the final stage of processing your product - welcome to the packing world! Packing preserves and protects a product from damage, spoilage, and contamination while it makes its way from the production line to the consumer or further production. Depending on which industry your products belong to, the type of primary packaging equipment can change drastically. You need to pay careful attention to products with </span><span style="font-weight: 400">chemicals or hazardous substances since they can be potentially dangerous to human health. </span>

Packing

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

If you want to accommodate multiple bag designs and dimensions with fast speed and accuracy, you need a smart automated packaging device.


<h2>High-speed quiet vertical form fill sealing</h2>
The VikingMašek Intermittent Bagmaker series (S250 /300, MS300, S400, S650) are perfect for packaging a large variety of bags. It can accommodate multiple bag designs and dimensions with high speed and accuracy. It can produce from 50-130 bags per minute and handles bag sizes from 40 x 60 mm (S250) up to 650 x 1000 mm (S650).

This vertical bag-maker is perfect for packaging small bags of snacks, candy, coffee, frozen fruit and for large bags of snacks, candy, coffee, pet food, powders, meat and poultry, bulk bags powders, wood chips, soil, grains and much more.

Bagger with servo driven jaw actuation

If you want to pack into gusseted and pillow style bags and packing speed is important for your packaging process, a continuous bagger with twin sealing jaws could be a good investment.


<h2>The world’s fastest vertical form fill sealing machine</h2>
The VikingMašek Continuous motion bag maker velocity is capable of high speed production up to 300 bpm. The unique center mounted filling tube and natural counterbalanced sealing profiles are designed to provide vibration free, extremely smooth operation at all speeds.

The Velocity is also extremely versatile, handling package sizes up to 300 mm wide and multiple package styles. Patented, independently phased, twin sealing jaws separate the velocity from all other high speed machines and virtually eliminate lost cycle time. This is the world´s fastest bagging machine on the market that has no competition.

Continuous bagger with twin sealing jaws

If you want to a complete packaging solution having box erecting, bag placing and box closing technologies, you should consider the smart automated bag in box filler.


<h2>A complete packaging solution for your product</h2>
The CaseBagger combines NIVERPLAST bag inserting and bag closing technologies in one compact machine. Feeding in your product carriers, prefabricated bags and your product, it provides you with your packed product ready to be transported. This can be done with a maximum speed up to 6 boxes per minute. It can handle a wide range of product carriers and dimensions.

The CaseBagger places a bag, fills it with your product, optionally applies a vacuum to protect your product and closes the bag. These four main functions are placed circular in the machine.

Bag-in-box filler

As demand for food production increases, so does that of packaging and sealing the product and making them ready for the end-consumer.<span style="font-weight: 400;"> With the help of an automated endload cartoning system, the level of output can be consistently increased as per the needs of the manufacturing business without compromising on quality or increasing handling costs.</span>


<h2>Customizable endload cartoning system for ice-cream, cereal, and frozen food</h2>
<span style="font-weight: 400;">The CAM systems by Viking Masek are specifically designed for automatic endload cartoning for products ranging from frozen meat to cereal and ice cream to be placed in a pre-folded package and then sealed by the system ready for labelling and distribution.</span>

<span style="font-weight: 400;">Viking Masek’s CAM system is available in two versions; continuous and intermittent. The key difference is that one doesn’t stop and continuously operates, and that the other one can operate in batches or on-demand. Because of this, the continuous CAM system can process up to 240 pieces per minute as compared to just 60 for the intermittent variation. Thus, the intermittent can be more suitable for manufacturers who have lower demand, while the continuous would be more suitable for businesses who are looking to maximize their level of output.</span>

<span style="font-weight: 400;">Viking Masek endload cartoning solutions are created with the goal to be as flexible as possible to match customer´s applications based on speed and size-range requirements. Furthermore, the CAM cartoner system is completely servo driven, highly flexible, and robust.</span>

<span style="font-weight: 400;">The continuous or intermittent motions allow for simple change-overs and a broad range of applications. Featuring easy change-over, various closure systems, and product feeders, the CAM’s customised solutions ensure guaranteed high-quality performance. </span><span style="font-weight: 400;">The systems can handle a range of cartons that vary in size from as little as 225mm x 300mm x 200mm for continuous operations all the way to 400mm x 600mm x 300mm for intermittent processes.</span>

Endload cartoning machine

Automated case packer machines are a good solution to achieve reliability and to increase the production cycle in the last step of the packaging process. These machines insert products, like flexible packaging as pouches, inside of shipping cases, in order to prevent damage and to optimize transport.


<h2>Flexible packaging solution to load pouches in cases</h2>
Senzani CPTL case packers are used for packing different products in a so-called American cases (a regular slotted container) using top-load filling with a production speed up to 25 cases per minute. With CPTL, three steps of the production process (case opener, filling and sealing) are put together, and several products such as cartons, doypacks, pouches, bags, flowpacks and tins can be packed.

All equipment movements are simultaneous and synchronised, to guarantee high speed and a good case form. The cases are kept in shape in the transfer phases towards the filling area thanks to the transport chains and catenaries.

It’s easy to change the shape and size of the packaging, there is no need for any additional tools. The size changeover set includes instructions on the operator’s manual to avoid mistakes. Photocells detect any irregularities in the case sealing, self-adhesive tape or hot-melt glue. This automatic control system ensures very good reliability.

Case packer machine for pouches

When packaging products such as seeds, cereal, snacks, candies, nuts, tea, dried fruits and many other bulk or small products, a pillow bag is one of the most popular packaging choices. It saves on space, is light, easy to open, and most importantly – cost effective. For gaining the best profit, it is also important that a pillow bag machine is fast and flexible. A packaging machine that works at a good speed and uses pillow bags as a packaging form, is a great cost-effective fit.


<h2>Top loading the product in the bag and sealing it shut</h2>
The Basis17, designed by Basis, is a fast model for packing bulk production a so called pillow bag, gusset bag or stabilo bag.  The machine reaches a speed of up to 120 packs per minute. A pillow bag is formed from a continuous roll of packaging film and guided over a forming tube. Seal bars bond the film on the two long sides of the bag after which the shorter bottom side is sealed by a separate seal bar. The product is then loaded into the bag through a forming tube and once the bag is filled, the top of the bag is sealed as well. The long film that forms several bags is now separated by a knife to form individual bags. After this stage, the end product is discharged from the machine.

The Basis17 gives the opportunity to pack the product in a wide range of packages, including pillow, gusset and stabilo bag. It can be integrated with weighters such as a volumetric rotary, a volumetric auger, a weight vibration (linear) or a combination (multi-head) of types. It is possible to pack products in the weight range from 25 gram to 1000 gram.

Pillow bag vertical packing machine

Mass production lines need faster and more efficient package processing to meet increasing supply chain demands. A case packer for large scale production of confectionary items, like cookies, can help you make your packaging more retail oriented and speed up your packaging process.

<h2>Fast and automated packing for cookies and other confectionary products</h2>
The Gantry 300 Swing Case Packer by BluePrint Automation can pack bags both vertically and horizontally on the same machine. The case packer is designed with an automated system that consists of two axes, which helps pick and pack bags effectively and with higher speeds.
With dedicated handling parts, the case packer can easily match your customized applications. Moreover, the Gantry 300 also includes BluePrint Automation’s SmartTrak system that provides rapid pre-collation of confectionary bags - bags are arranged before they are loaded onto the boxes. The tracking system helps simplify changeovers, making the case packer easy and flexible to adapt to consistently changing requirements in the future.

The confectionary bag packer has an ergonomic design, providing seamless accessibility and full-time process overview.

Apart from the confectionery products, the machine is suitable for applications from snacks, personal &amp; home care, bakery, pet food, dairy, frozen food and fresh produce industries.

Confectionery bags case packer for large scale

In small to medium scale production units, packing items manually can consume a lot of time. Moreover, manual packing can also lead to underutilized box space. One way to speed up the entire process and make maximum use of the box space is to invest in semi-automatic assembly products that can provide seamless and more optimized solutions.
<h2>Maximize production speeds with rapid, continuous, and flexible packing</h2>
The Collator 200, by BluePrint Automation, helps significantly increase your manual packaging speeds. It <a href="https://making.com/potato-chips/">processes potato chips</a> and other snack bags that come from a primary packaging machine and have different sizes and dimensions, without requiring any changing parts. The semi-automatic case packer is designed to flexibly and rapidly accept bags from a primary bagging machine or a thermoform machine and quickly forms vertical stacks on the accumulation conveyor belt.

The Collator 200 is suitable for packing all different types of bags - with snacks, confectionery products, fresh vegetables, shredded cheese, coffee, spices, sugar, crisps, salads, or nuts.

Semi-automatic case packer for chip bags

If you want to pack your food cartons, doy packs and pouches into regular cases, a smart food-grade system with quick toolless changeovers will enable you to run smaller batches efficiently at higher speeds.


<h2>Automatic packing of food-grade products into regular slotted cases</h2>
The SOLANO, from Mpac, is a top load case packing system for regular slotted cases (RSC) with broad experience with different food types. The system has compact dimensions and a production output of up to 15 cases per minute. A flexible infeed system can be adapted easily for chip bags, baby food, and coffee pouches, drink cartons, or bag-in-box cereals. The line has an open design for easy access and maintenance and there is an Intelligent Machine Interface in place to check machine status and make sure to meet all food processing standards. The case packer is driven by a servo motor coupled directly to the components for minimum wear and improved operating life. Quick automatic toolless changeovers take less than 10 minutes and the system is designed to run continuously without trouble, resulting in 98% efficiency. The unit comes with an adjustable case magazine that can accommodate up to 300 cases.

Top load Case Packer For Food Products

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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