PepsiCo's Lay's potato chips plant recently opened in the city of Azov, Rostov region. In addition, the plant produces Khrusteam crackers. Let's walk sequentially along the entire production line and look at it in detail. It is believed that chips appeared more than 150 years ago in the USA. Legend has it that in one of the elite American restaurants, a client (railroad magnate Vanderbilt) did not like it specialty of the house restaurant "french fries" and he returned it to the kitchen, complaining that the fries were too thick. The restaurant chef decided to play a trick on the client and cut the potatoes into the thinnest 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 menu - chips.
Lay's chips have been produced since 1938. Today, Frito Lay is one of the leading producers 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, Moscow Region.
Unloading, washing and temporary storage of potatoes
2. Nine 20-ton trucks with potatoes are unloaded here every day. The potatoes are transported along a conveyor belt to a washing machine, where recirculated water is used to clean them. There are three such automatic car washes in the world. It is physically impossible to remove the washing process; everything happens in a closed container. After washing, the potatoes are sent for temporary storage in bins - special containers, from where they are supplied to production as needed.
Peeling, sorting and cutting potatoes
3. Before the potato tubers enter a special slicing machine, inspectors visually inspect the tubers moving along the belt and, if necessary, remove visible defects.
4. By the way: Not every potato is suitable for the production of chips. There are so-called chip potato varieties that have a high starch content.
5. All employees undergo periodic medical examinations and have medical records; this is done to ensure that a sick person does not end up at work. In addition, before entering the workshop, everyone must wash their hands.
6. Potatoes are peeled in periodic abrasive drums. Loading happens first required quantity potatoes into the weighing hopper, after which they are unloaded into the drum.
7. Direct 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.
8. After cutting, the potato slices enter the very heart of the chip production line - the frying bath for frying the slices and producing base chips. This equipment, which has no analogues, was created specifically for the PepsiCo plant and cannot be shown.
9. Thinly sliced potato slices are placed in an oil bath, in which they are fried for three minutes at a temperature of 180 degrees Celsius. Quality oil, like high-quality potatoes, is the basis for the taste of chips.
10. The recipe was improved at the plant using a special mixture vegetable oils, including high olinic sunflower oil locally produced, thanks to which the content of saturated fats in the final product is reduced by 25%.
11. Product quality checks are carried out daily at the plant. They check both basic chips just out of the oven and fully packaged bags.
Adding spices
12. At this stage, fried potato chips special aromatic and flavorings, the basis of which is salt.
13. Three flavors can be produced on the line at the same time.
Package
14. By the way: The plant is designed to produce 50 thousand tons finished products in year. Some fantastic figure, in my opinion.
15. Three conveyors transport ready-made chips to packaging. First, distribution and weighing occurs.
16. 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.
17. Weighing machines weigh multiple portions simultaneously and calculate the best weight combination that has the most accurate weight to match the standard and the weight stated on the package.
18. If you consider that the net weight of one pack is 28 grams, you can imagine the accuracy of the equipment settings.
19. The weighed portion is unloaded onto the packaging line.
20. The portion is checked for the presence of foreign impurities (metal detector) and ends up in a bag, which by this time has been prepared by a packaging machine from packaging materials (foil). Before sealing the seam, food grade nitrogen is supplied to the bag, which ensures the required shelf life of the product. Weighing and packaging equipment operates synchronously, at speeds of up to 80 bags per minute.
21. The packaged bag of chips is delivered to operators who manually place the bags into cardboard boxes.
22. Boxes of chips are stacked on pallets and transported to the warehouse.
In parallel there is a line for the production of crackers
24. A mixture of flour and water is fed into the extruder, heated and thoroughly mixed. The crackers come out of the extruder in the form of ropes, which are cut to size by rotating knives.
25. The next step is to dry the crackers in the oven and place them on the seasoning area.
26. The packaging line is identical to the one on which chips are produced.
28. Weighing takes place in a similar weighing machine, which forms several portions and selects the best combination for sealing in a bag.
29. Ready-made crackers.
30. The productivity of one line is 12 tons of finished products per day.
31. Workers are prohibited from wearing watches and jewelry, manicures and false nails are prohibited, and their hair must be covered with a net so that nothing gets onto the conveyor.
32. Except taste qualities and visual compliance of the slices with accepted standards, the quality of the packaging is checked here. The seam should be smooth and the pack should open in one movement exactly along the seam, without tears.
34. Factory staff. By the way, the production line operates around the clock in three shifts.
36. Appearance plant
37. Bon appetit!
More and more people are carefully studying the composition of the product on the packaging in the store. Buyers began to watch what they eat, giving preference natural products. This approach applies not only to main courses, but also to light snacks, which you cannot do without in the modern rhythm of life. Today we would like to tell you about how the chips that many of us love to snack on are made.
The journey of chips begins in the field. We went to one of the farms in the south of our country, in the Rostov region. Potatoes for Lay's chips are grown here.
Few people know, but all over the world only 7 types of potatoes are suitable for making chips, and three of them are grown in Russia - “Lady Rosetta”, “Hermes” and “Saturn”. What is the difference between regular potatoes and chips? As experts say, the latter is much denser in structure and contains practically no sugar. If we talk in simple language— when fried, the potatoes do not fall apart, do not darken, but acquire golden color. Therefore, if you decide to try to make chips at home from ordinary table potatoes, then it is likely that you will succeed simply fried potatoes, not crispy golden slices.
In total, more than 60 potatoes are currently grown in Russia for Lay’s chips. farms- from Rostov to Moscow regions. It all started in 1996, when the manufacturing company launched a special agricultural program to support and develop agriculture in Russia. Thanks to this program, farmers are provided with high-quality planting material, harvesting equipment and the most modern devices that control the quality of the product.
Interesting fact: To ensure that the crop receives as little damage as possible during harvest, a special device is used - electronic potatoes. This “potato spy” goes directly from the ground (where it is previously placed) into the harvester. It is thanks to this device that potato pickers determine whether everything is in order with the crop during cleaning or you need to adjust the machine so that the potatoes do not receive unnecessary “beatings”.
After harvesting, the potatoes are sent to a plant in Azov, which opened in 2010. By the way, this is the second plant in our country where Lay’s chips are produced - the first plant was opened in 2002 in Kashira, near Moscow. Nine 20-ton trucks of potatoes are unloaded at the plant every day! And up to 50 thousand tons of chips are produced here per year (this is approximately the same as 4,000 African elephants).
The scale of the premises and equipment at the plant is amazing. The plant’s employees are very careful to maintain production quality standards at all stages: from washing and cleaning to frying and packaging. The finished chips are transported along conveyors to the packaging shop, and then to the warehouse, where the packs are stored in special sections.
During the trip, we were able to track the path of chips - from the field itself to the finished pack - and learned that a colossal amount of potatoes is grown and processed in Russia. Now you know what and how the world famous Lay’s chips are made from.
Discussion
I never thought about what I eat before. IN Lately I read the ingredients everywhere and on everything! I ate chips, a lot. Now I don't eat! I don't like any brands!
Comment on the article "How chips are made: from field to packaging"
If children at home eat cookies, chips, crackers, why suddenly they won’t eat them in the camp and regarding 1000 rubles a week, where does that come from? I’m ending this incomprehensible dialogue about what parents could do, but don’t. The conversation is about something completely different - why some...
Discussion
I don’t know anything about Stormwind, but I would definitely be bothered not only by the stealing (I can’t exactly call it theft) of food, but also by problems with food in general. If the food in general is such that no one eats it, and you need to catch up with cookies, chips, crackers, and at the rate of about 1000 rubles a week, then this is just a disgrace. And the attitude of the counselors and shift supervisors is also amazing, coupled with the cheating barmaids.
Mine generally doesn’t eat well in school canteen camps, but in the camp he ate everything and praised it. In general, it was forbidden to bring food and store perishable goods, with the possible exception of cookies/snacks. During the entire shift, I brought a couple of packs of fat and three hundred grams of pasta, he brought one pack back, they didn’t finish the whole room. Everyone ate their fill in the dining room; the food was excellent. In general, you could only buy ice cream on site, and only on weekends. And this suits me much more than shared (or not shared, but from a suitcase) cookies/candies/crackers/chips instead of normal food. The absence of retail outlets eliminates any cheating of children by service personnel.
Stealing food from each other is not normal, and creating conditions for such stealing is also not normal.
I would like to send this discussion to Alexander, if anyone is against it, write.
I'm thinking about what to do with them. Chips would be good. So I’m wondering whether I need it or not to spend the money, it’s not that cheap, but I still have to buy additional trays for it. but the marshmallow captivates me, I want to make marshmallows for the winter, I wonder if it looks like Belevskaya or not...
Discussion
I bought a dryer in the fall "Sukhovey". I dry berries for fruit teas (strawberries, raspberries), various greens, and make marshmallows. Read more about dryers on the website "Bread Maker.ru" (dryers forum). The pastila turns out amazing.
if anything, Tillotama is on vacation until September...
I barely managed to grab this device myself... it’s like nothing, we’re mastering it.
Guacomole goes well not only with chips :), take rye crisps for example or Borodino bread. I bought an avocado.. what to do next? It seems to me that avocado is a little heavy for a child’s stomach 05/02/2006 16:11:05, Ambra. where to put the avocado?
Discussion
Avocado, St. cucumber, shrimp, dezzh. yogurt, salt, pepper. I love it very much. :)
I have a signature salad - you layer it: tomatoes in half rings, avocado in half rings, mozzarella, corn lettuce (preferably just like that). I fill it with a couple of sprays olive oil and balsamic with raspberries (no sugar). You can lose weight by eating avocados in moderation (I’m in the process myself :))), just take these fats into account daily diet. Now I’ll try to provide a link to a photo of the salad
Your daughter may be doing this selflessly, but it RUINS other children. Don't give her too much money. (And I didn’t, they were from In your case, I would focus not on safety, but on the fact that this is other people’s money. Yes, and I would periodically buy cola chips.
Discussion
We had such a case, but exactly the opposite. In the second grade, when I came to pick up my child for after school, the teacher called me back and said - your daughter is too kind, she gives her money to the children when we go to the buffet after school. chocolates, juices and more. This, he says, is bad. Your daughter may be doing this selflessly, but it RUINS other children. Don't give her too much money. (And I didn’t give them, they were from my grandparents’ gifts for BD and NG). In general, I listened to the teacher’s opinion and began to control this moment. Although why my daughter did this, I understand - she didn’t know the value of money at all then , she didn’t feel sorry for it, the grandfather would still give it to his beloved granddaughter...
I would talk to S.’s mother, but only in the spirit that you do not condemn her son for his generosity, but this may negatively affect your son’s worldview, and therefore let her keep an eye on this... We can only hope that S.’s mother will turn out to be an adequate woman...
It is useless to tell strangers how and what to spend money on if you cannot convey to your own people who you can take money from and who you can’t. And what should they be spent on and what should they not be spent on.
In your case, I would focus not on security, but on the fact that this is other people's money.
Yes, and I would buy cola chips from time to time.
sea of apples I wanted to make chips. just so that they are crispy, or close to it. I couldn’t find it on the Internet. I really didn’t Google it. with what apple chips Are they different from just dried apples? Apples, I guess White filling?
Chips recipes: how to make chips at home in the oven and dehydrator; healthy chips from vegetables and fruits. But who said it has to be super-calorie potato chips from a bag? Crispy chips can be made at home...
Can you make crackers at home? Teach you how to cook! Cooking. Cooking recipes, help and tips on cooking, holiday Can crackers be made at home? It’s interesting... otherwise I eat them in unimaginable quantities... I mean the small ones, “Kaleidoscope”...
Discussion
I once wrote down cracker recipes, but haven’t made them myself yet.
cracker
3 cups (300 g) flour
100 g butter
3/4 cup water
2 tbsp. l. curdled milk
1 tbsp. l. salt
2 tbsp. l. sesame or cumin seeds
Sift the flour into a bowl. Cut the butter into small pieces and rub with flour. Pour in slowly cold water while simultaneously stirring the flour with the right
hand so that the water is distributed evenly. Then knead the dough well.
Sprinkle the table with flour and roll out the dough thinly, like noodles, to form a round layer with a diameter of about 60 cm. Brush the surface of the layer with curdled milk, using a brush, and sprinkle evenly with salt and sesame or cumin seeds. Then use a knife or a special grooved wheel to cut into small diamonds.
Place the diamonds on a baking sheet and place in the preheated oven. Bake over medium heat for 10 - 15 minutes, until golden brown.
Spicy crackers.
200 gr. Flour, 1 tsp. curry, 2 tbsp. drain butter, 1 raw egg yolk, 1 half glass of grated cheese, 2 teaspoons poppy seeds.
Mix flour with curry + drain. rub the butter with your hands to make a butter coating, add grated cheese, poppy seeds, beat in the yolk. Knead the stiff dough. Put it in a bag and refrigerate. Leave for 30 minutes. Roll out into a thin layer. Cut out cookies with a cookie cutter and place on a greased sheet. Place the baking sheet with cookies in the cold for 15 minutes, then place in a preheated room at 200 degrees. Oven, bake until golden brown.
I only found this recipe:
Bernese potato crackers
To prepare the dish you will need:
potatoes - 4-5 pcs.;
potato starch - 3 tbsp;
salt, ground black pepper - to taste.
Potato starch is added to mashed potatoes, the mass is released from a conical nozzle or cut into slices and dried, before serving, fried in fat and served as a side dish
Sprinkles for cheese chips. . Cooking. Culinary recipes, help and advice on cooking, holiday menu and reception Topping for cheese chips. Adore. Some tasty powder is poured into the chips; I especially like the cheese and sour cream-cheese ones.
How are Lace chips produced in Russian factories made? Let's find out below. Let's start with the fact that their production is designed in such a way that it fully complies with the technologies accepted as the norm in the West. Such snacks have been produced since 1938, and they began to be supplied to Russia in the 90s.
The history of their creation lies in the pride of one of the chefs. In one of the elite American restaurants, a visitor did not like the French fries, he said that they were cut into very thick slices and the offended chef prepared him another dish. I specially cut the potatoes into very thin slices and fried them until crisp. The client happily ate this dish and it was added to the restaurant menu. The whole truth about the production of today's advertised chips.
How Lay's chips are made
On designated plantations, a special variety of potatoes for chips is grown, which is why they cannot be prepared at home from ordinary potato tubers.
Cooking steps include:
- Unloading and washing potatoes. The plant uses a closed container from which washed vegetables are delivered to bins - special storage tanks.
- Cleaning, sorting and cutting potatoes. First, the inspector checks the tape and eliminates visible defects in the raw material.
- Potatoes are peeled in special abrasive drums with millstones.
- Special blades are installed in the bottoms of the drums; they rotate and cut the tubers to the desired thickness.
- Frying Lay's chips. Potato blanks end up in a frying bath, the design of which was created specifically for the preparation of chips of this brand.
- Adding spices. Aromatic and flavoring additives are sprinkled onto the fried chips.
- Product packaging according to the specified grams.
Three types of Lace chips can be made simultaneously on one plant line.
What are Lay's chips made of?
Many cheap brands have long been replacing potatoes with starch. They cook the chips like baked goods. From the technology above, it became clear what Lays chips are made from. Most of their crispy rings are obtained from potatoes, but special substances are added to them in the form of monosodium glutamate, which increases the shelf life of the chips. Additives are also used for flavor.
The heroine of Nadezhda Rumyantseva - Tosya from the legendary film "Girls" could immediately list 15 potato dishes: fried, boiled, mashed potatoes, French fries, pie, pies and pancakes, roll, casserole, stewed with prunes, stewed with bay leaf and pepper, young boiled with dill and so on. We want to talk about one more product, perhaps the most popular in our time - potato chips.
Bigpiccha had the opportunity to see with my own eyes absolutely the ENTIRE production process of Lay’s chips - from harvesting to shipment to retail chains. And now we can say with confidence that we know everything about chips! Well, almost everything :)
(Total 20 photos)
But first, a little history. Lay's chips, the production process of which we actually studied, have been produced since 1938. Today, the PepsiCo company (they own the Lay’s brand since 1965) is one of the leading producers of salty snacks both in the world and in Russia. Deliveries of Lay’s chips to Russia began in the mid-90s, in 2002 the first plant was opened in Kashira near Moscow, and in 2010 the company’s second plant was opened in the city of Azov (Rostov region).
1. Bigpiccha arrived with an inspection to one of the agricultural enterprises in the Rostov region.
2. The first and, perhaps, the most important problem that the PepsiCo company faced when opening the production of chips in Russia was the lack of raw materials. Just 10-15 years ago, potato chips were not grown in Russia at all. Farmers supplied only traditional varieties, which were suitable only for cooking, frying, starch production, etc.
3. Few people know this, but all over the world only 7 types of potatoes are suitable for making chips, and only three of them are grown in Russia - “Lady Rosetta”, “Hermes” and “Saturn”. What is the difference between regular potatoes and chips? The latter is much denser in structure, and there is practically no sugar in it. To make it completely clear, when fried, such potatoes do not fall apart, do not darken, but acquire a pleasant golden color. Therefore, if you decide to try to make chips at home from ordinary table potatoes, then it is likely that you will end up with just fried potatoes, and not crispy golden slices :)
By the way, did you know that one kilogram of potatoes produces 300 grams of chips? That is, in a regular pack of Lays there are approximately three potato tubers.
4. How are these potato chips grown? Being the largest industrial potato processor in our country, the company initially set a course for maximum localization of production and, since 2002, began implementing its own agricultural program aimed at supporting Russian agricultural producers. And the fact that our agriculture needs to be supported is probably beyond any doubt among any of you.
5. What is the support? In fact, this is a whole range of measures: firstly, farmers are provided with financial assistance (through interest-free loans for the purchase seed material, necessary equipment for growing and storing potatoes).
6. Secondly, assistance is provided with the purchase of high-quality imported potato seeds (as you understand, a very important aspect on which a lot depends). There is a whole team of agricultural specialists who advise farmers in the fields: how to plant, grow, how to properly harvest and preserve the crop, that is, they cover the entire spectrum necessary work. As a result average yield PepsiCo's potato suppliers are 25 tons per hectare, which is almost twice as high as the national average - 13 tons per hectare. Surprised? We are not very good 🙂
7. To ensure that the crop receives as little damage as possible during harvesting, a special device is used - electronic potatoes. This “potato spy” goes straight from the ground (where caring farmers first place it) into the harvester. It is thanks to this device that potato pickers determine whether everything is in order with the crop during harvesting or whether the machine needs to be adjusted so that the potatoes “do not get unnecessary bruises.”
8. Today, more than 85% of potatoes supplied to the company’s factories are grown in Russia. Every year the company purchases more than 250 thousand tons!
9. And, of course, it’s worth mentioning about people. After all, as you know, no matter how much money you invest, if there are no qualified personnel on the ground, then all your efforts will be in vain. That is why PepsiCo developed a program to support agricultural higher education, which started back in 2008. As part of this program, students are encouraged to study agricultural specialties, and the best of them are given grants.
10. Then the harvested potatoes are brought to the factory, where they are unloaded in such a cunning way. Nine 20-ton trucks of potatoes are unloaded here every day! And up to 50 thousand tons of chips are produced here per year (that’s about 4,000 African elephants).
11. It then travels along a conveyor belt to a washing machine, where recycled water (water that is reused many times) is used to clean it. technological cycle). And after washing, it goes for temporary storage in bins - special containers, from where it is supplied to production as needed.
12. The 3 main stages are clearly shown: cleaning, cutting and frying. As you can see, everything is as simple as possible and nothing superfluous. Absolutely natural product.
13. Immediately after cutting, the potato slices are frying to form basic chips.
14. After cooking the chips, purchase one of unique tastes Lay's. By the way, the brand’s portfolio includes international bestsellers that are sold all over the world (salt, cheese, bacon, green onions), as well as flavors that can only be bought in Russia (crab, lightly salted cucumber, porcini mushrooms with sour cream).
A large assortment of chips is presented on the shelves grocery stores and supermarkets. Children and adults love crunchy snacks, and therefore many will be interested in learning how chips are made and what raw materials are used to prepare them in factories. A available recipes will allow you to make your own homemade chips from a variety of products.
How different brands of chips are made at the factory
Chip manufacturers use special varieties of potatoes to prepare their products, which have a denser structure and minimum quantity Sahara.
Thanks to this composition, the root vegetable retains its golden color and does not fall apart during cooking.
Surely, when putting another portion of a crispy snack into your mouth, you have at least once thought about how chips are made at the factory. Meanwhile, this is a rather labor-intensive process. Potatoes there go through several stages until they turn into familiar snacks in bright packaging.
- Raw materials delivered from the fields are unloaded, washed and placed in special storage boxes.
- Vegetables undergo visual inspection for defects and their removal.
- Potatoes are peeled in special drums.
- The blades at the bottom of the drum cut slices up to 2 mm thick.
- Then the slices fall into a frying bath filled with oil heated to 180 degrees, where they are fried for 3 minutes.
- The chips are sprinkled with salt and special flavoring and aromatic additives.
- After weighing, the finished snacks are packaged.
Some manufacturers use a simpler method of preparing chips. They take corn or wheat flour and mix it with starch. Chips are formed from this dough and fried in boiling oil. It is difficult to call such a product potato chips, but with the help of special ingredients it turns into snacks.
Homemade recipes
Supporters healthy eating they don’t trust the quality of store-bought chips with an unclear composition and big amount food additives. Therefore, many cooks prepare them themselves in their home kitchen.
What are chips made from? In addition to traditional potato ones, you can prepare carrot, apple and banana chips, as well as delicious snacks made from pita bread, onions and cheese. Simple and quick recipes available to everyone.
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