How are potato chips made step by step?

How Are Potato Chips Made Step by Step in a Factory?

Potato chips are one of the world’s most popular snacks — crispy, salty, and delicious. But have you ever wondered how they're made in large factories? Let’s take a behind-the-scenes look at the industrial process of turning raw potatoes into perfectly crispy chips.

1. Sourcing and Delivering Potatoes

The process begins with sourcing high-quality potatoes from local or contracted farms. Factories prefer specific varieties that are ideal for frying and have low sugar content to avoid browning during cooking. Once harvested, the potatoes are delivered to the factory in bulk.

2. Cleaning and Sorting

As soon as the potatoes arrive:

Washing machines clean off dirt, rocks, and debris using high-powered water jets and brushes.

Then, the potatoes are sorted by size and quality. Damaged or green (toxic) potatoes are removed, often with the help of automated vision systems.

3. Peeling

The cleaned potatoes are sent through mechanical peelers. These machines use:

Abrasive rollers or

Steam pressure followed by brushes

to quickly and efficiently remove the skins.

4. Slicing

The peeled potatoes are moved into slicing machines that cut them into thin, uniform slices — usually between 1.2 to 2.0 mm thick. The thickness affects the final texture and crunch.

Some factories use crinkle-cut blades to produce wavy or ridged chips.

5. Rinsing and Starch Removal

After slicing, the potato slices are rinsed in cold water to remove excess surface starch. This step helps prevent sticking and ensures even frying. Some processes may include a blanching step (brief boiling) to improve texture and color.

6. Drying

The slices go through a drying tunnel or are spun in centrifuges to remove excess moisture. This step is important to prevent oil splatter and ensure crispiness during frying.

7. Frying

Now comes the magic! The slices are fried in large vats or conveyor-belt fryers filled with hot oil (typically at 170–190°C / 340–375°F) for 3–5 minutes. The oil type varies (sunflower, canola, or palm oil), but it must be clean and consistently maintained.

The slices puff up and turn golden and crisp.

8. Seasoning

Right after frying, while the chips are still warm and slightly oily (to help seasoning stick), they are transferred to a rotating drum where they’re sprinkled with:

Salt

Cheese, barbecue, sour cream & onion, or other flavor powders

Sometimes even spices, herbs, or vinegar solutions

9. Cooling

To avoid condensation in the packaging, chips are cooled using ambient or filtered air. This also helps stabilize their texture.

10. Packaging

Once cooled, the chips are transported via conveyor belts to automated packaging machines. They're:

Weighed for consistent portion size

Sealed in nitrogen-flushed bags (to prevent oxidation and keep them fresh)

Labeled and boxed for shipment

Final Quality Checks

Throughout the process, quality control teams test:

Taste and texture

Oil content and moisture levels

Packaging seal integrity

Only the best batches make it to store shelves.

From Farm to Bag

What starts as a humble potato becomes a crunchy snack through a series of highly automated and carefully controlled steps. Thanks to modern potato chips machine, we get uniform, tasty chips — every time we open a bag!