How and from what they make the chips leis. Potato chips

How and from what they make the chips leis. Potato chips


The topic of today's report is a PepsiCo plant for the production of potato chips Lay "S, recently opened in the city of Azov, Rostov region. In addition, the plant produces crackers KharTeam. We will pass consistently along the entire production line and consider it in detail.


It is believed that chips appeared more than 150 years ago in the United States. The legend says that in one of the elite American restaurants, the client (railway magnate Vanderbilt) did not like the branded dish of the restaurant "Potato Friend" and he returned it to the kitchen, with a claim that potatoes are too thick. The chef of the restaurant decided to make fun over the client and cut potatoes on the finest slices and roasting in the oil filed to the table. Surprisingly, the client did the dish especially liked, and since the restaurant's menu has appeared a new dish - chips.

Lay chips are produced since 1938. Today, Frito Lay is one of the leading manufacturers of salt snacks both in the world and in Russia. The supply of Lay chips "S to Russia began in the mid-90s, and in 2002 it was The first Frito Lay plant in Kashira near Moscow is open.

Unloading, washing and temporary storage of potatoes

2. Nine 20 ton trucks with potatoes are unloaded here. Potatoes on the ribbon conveyor enters the washing machine, where recycling water is used for cleaning it. In total, there are three such automatic sinks in the world. The process of washing is physically impossible to remove, everything happens in a closed container. After washing, the potatoes go to temporary storage in Bins - special containers, from where it is necessary to produce.

Cleaning, sorting and cutting potatoes

3. Before the potato tubers fall into a special car for cutting, the inspector visually inspect the tuber-running tape and, if you need to remove visible defects.

4. By the way: no potato is suitable for chips production. There are so-called chipseed varieties of potatoes, which are distinguished by increased starch content.

5. All workers periodically pass a medical examination and have medical records, this is done so that the sick person does not get into production. In addition, before entering the workshop, everything is necessarily washed.

6. Potato cleaning occurs in abrasive drums of periodic action. First, the required amount of potatoes in the weight bunker is loaded, then unloading to the drum occurs.

7. Directly cutting occurs mechanically by rotating the cone-shaped bottom of the drum. Inside the cutting machine, eight pairs of acute blades that cut the tuber on thin slices. The thickness of each slice is less than two millimeters.

Roast

8. After cutting, potato slices come to the very "heart" of the chips production lines - a frying bath for roasting slices and obtain basic chips. This equipment that has no analogues was created specifically for the Pepsico plant and it is impossible to show it.

9. Thin chopped potato slices come into the bath with oil, in which they are roasted for three minutes at a temperature of 180 degrees Celsius. High-quality oil, as well as high-quality potatoes - the basis of the taste of chips.

10. The plant has improved the formulation, using a special mixture of vegetable oils, including highly fat sunflower oil oil, due to which a 25% reduced the content of saturated fats in the final product.

11. Daily at the factory is checked product quality. Check as basic chips, only out of the furnace, and completely packaged packages.

Adding spices

12. At this stage, special aromatic and flavor supplements are added to fried potato chips, the basis of which is salt.

13. At the same time, the production of three flavors can go on line.

Packaging

14. By the way: the plant is designed to produce 50 thousand tons of finished products per year. Some kind of fantastic figure, in my opinion.

15. For three conveyors, ready-made chips come on packaging. First, the distribution and weighing occurs.

16. By the way: Please note that there are very few workers on the entire length of the line. It uses modern equipment that works in fully automated mode. In addition, it is important that as few people can come into contact with the finished product.

17. Weighing machines are weighing at the same time several servings and calculate the best weight combination, which has the most accurate weight in order to match the standard and specified on the packaging weight.

18. If we consider that the net weight of one pack is 28 grams, you can present the accuracy of the equipment setting.

19. Weighted portion is unloaded on the packaging line.

20. The portion is controlled by the presence of extraneous impurities (metal detector) and falls into the package, which by this time is prepared by the packaging machine from packaging materials (foil). Food nitrogen is supplied to the package of seam to the package, which allows you to provide the necessary product storage period. Weight and packaging equipment works synchronously at speeds up to 80 packets per minute.

21. Packaged package with chips enters operators that manually fold packages in cardboard boxes.

22. Boxes with chips add up for pallets and transported to the warehouse.

In parallel there is a line by Production of Sukharikov

24. A mixture of flour with water is supplied to the extruder, heats up and thoroughly mixed. From the extruder, the crackers are in the form of harness, which are cut in size with rotating knives.

25. The next stage of crunches is dried in the furnace and fall on the decay site.

26. The packaging line is identical to the one on which chips produce.

28. Weighing occurs in a similar weight machine that generates several portions and selects the best combination for sealing into the package.

29. Ready crackers.

30. The performance of one line is 12 tons of finished products per day.

31. Employees are forbidden to wear clocks and decorations, manicure and false nails are prohibited, the hair must be closed with a grid so that nothing fell on the conveyor.

32. In addition to the taste and visual compliance of slices adopted standards, the quality of the package checks here. The seam must be even and the pack must be opened by one movement exactly along the seam, without breaks.

34. Collective of the plant. By the way, the production line works around the clock in three shifts.

36. Appearance Plant.

37. Enjoy your appetite!

Brand: Lay's

Tagline: "Cool - do not hold!" Lace - Want? " "Bright moments are tastier with a lace!" "Come on!"

Industry: Food

Products: potato chips

Company owner: Frito-Lay (Pepsico Inc.)

The basis of the base of the brand Lay's: 1944

Headquarters: USA

Lay's - Brand for a variety of potato chips, founded in 1938. Crisps Lay's Positioned by Frito-Lay owned by Pepsico Inc. Since 1965. Other Frito-Lay brands include Fritos, Doritos, Ruffles, Cheetos and Breesl Rold Gold.

Brand history

Brand chips Lay's An American Hermann V. Lay (English Herman W. Lay) came up with his business in 1932 by a small community for the sale of potato chips in Nashville. The 24-year-old Kommersant was then selling the Gardner's Chips of Barrett Food Products, located in Atlanta (Georgia).

Lay was faithful by Barrett Food Products Gardner trademark until 1944. In 1944, he decided to change the name of potato chips on Lay's Potato Chips. This year is considered the year of the birth of the brand Lay's.

The representative office of Frito Lay opened in Russia in 1995 in 10 years, in 2005, more than 500 people worked in it. Official sales of Lay chips "S began on the Russian market in 1996. Then the company had no own production in Russia, and imported all products from Poland, Greece, Turkey, Belgium, Hungary, England, the Netherlands. For the first year of office, growth Sales amounted to about 400%. Strong success at the start and excellent prospects made a company to build a private factory in Russia.

In 2002, Frito Lay finished the factory in Kashire. The first production line for the production of potato chips was launched. The first packs of chips Lay "S.Made in its own production appeared in stores in October 2002. In 2005, two lines for the production of potato chips and two lines for the production of extruded chips worked at the factory. The total volume of production is more than 18 thousand tons per year.

Almost every year, Frito Lay, given the increasing demands of Russian consumers to the assortment of chips, brought new tastes of their products to the market.

1996 Chips with the tastes of "salt", "Paprika", "Bow", "Bacon".

2000 Chips with the taste of "dill", Lay's Max come to the market.

2002 Chips with the tastes of "cheese", "barbecue".

2003 Chips with the taste of "Pizza".

2004 Chips with the tastes of "Fresh Dill", "Salt and Oil", the extensive taste of potatoes, designed specifically for the Russian consumer.

2005 Chips with the tastes of "sour cream and greens", "Crab", Lay's Max taste for "ham and cheese".

2007 Chips with taste of "kebab", "White mushrooms with sour cream".

2009 Chips with the taste of "Red Caviar", also appeared "Lay's Sensations" with taste "Thai chili pepper in a sweet sauce", "Sardinsky lambs with grilled eggplants and dried tomatoes", as well as "Mozarella Buffalo with pesto sauce."

2010 Lay's Max "Mega Bacon", "Maxi sour cream and bow".

2011 Lay "s tasteful" Lightweight cucumbers with dill ", Lay" s Max tasteful "super sour cream and cheese."

For the production of chips Lay "S. In the factory in Kashira use Dutch potato varieties, and only selected tubers with a certain content of starch and sugar are in the case. In a year, chips production processes over 80 thousand tons of potatoes. The whole technological process is built to get a product that meets high standards. Lay "S.. Before delivery to the factory, potatoes are carefully wash and check. In the factory, these processes are repeated, after which the tubers are cleaned. Purified potato is cut by thin slices of necessary thickness and roasted in vegetable oil. Then in chips add salt, spices, flavor additives and pack. Already packaged products are checked again, and part of it is taken to the sample.

Promotion

Frito Lay uses various chips promotion channels Lay "S.: Advertising on television, radio, on the Internet, outdoor advertising, advertising in the press. It sponsors the evening television broadcasts of feature films, places a logo in popular television weekly.

In television promotions use different motifs. For example, in advertising with the participation of "good guy Vasi" the idea was played, the main thought of which - chips Lay "S. So tasty that in their form a person is experiencing a burning desire to eat them immediately. The roller had a great success among adolescents and young people, which caused sales growth. Since 2004, the company has expanded the target audience and launched a new video on television, addressed to people who often conduct leisure into a family circle.

The promotion of the updated LAY "S MAX was accompanied by a display on television of a new dynamic video with a bearing of a fashionable computer theme and a new hero - modern, decisive, sports, the image of which, according to the company, more corresponds to the image of the target audience.

To participate in television rollers Lay "S. The world stars are also involved. Thus, the well-known footballer Ronaldinho became the hero of advertising on the television screens of many countries.

In its Marketing Policy, Frito Lay also actively uses the prizes. In 2003 to promote Lay "S. Consumers of chips were invited to participate in the drawing of cash prizes. In 2004, a trip to Namibia and numerous road tourist wallets were played among the buyers. And in September-December 2004, a promotion campaign "TV-mania" was held: Chips buyers who gathered four advertising strips from packaging, which when adding gave an image of the prize, became its owners. Items of drawing were 10 plasma TVs, numerous dishes for chips and unique TV pillows,

In early 2005, in the largest universities, 15 cities of Russia held an action to promote Lay chips "S Max. In educational establishments Teams of "Fighters of Light Hunger", equipped with suits with the Lay "S Max emblem, were sent. Special simulator devices, they" measured "the level of light hunger and all hungry to distribute the packets of Lay" S Max chips with new tastes additives. The action covered a huge student army of 600 thousand people. In 2005, a national campaign was organized "Share music with friends!", Which is directed to modern and keeping up with the time of people. Each participant could win one of the thousand I-POD Mini or Euroset Content card for 7 units, with which you can download musical novelties from the Internet.

For this program, Frito Lay used various channels of promotion of Lay chips "s: TV advertising, online advertising, stocks in stores, sponsorship support. One of the latest sponsorship support was on the entertainment television channels" MTV "(transfer" 12 evil spectators ") and "MUZ TV" (sending "SMS Chart"). These channels were chosen as the most popular, in order to maintain the latest fashion trends and interest at the target audience.

Values \u200b\u200bof Brand

Potato chips - "Food garbage", which tightly entered the life of adults and children. They are snacking, taken in parallel with alcohol, used as an additive in salads. This is one of the best-selling goods in the world and the least useful product by food value. But there are no benefits only in store chips. Therefore, it is important to know how to make chips at home.

If you cook their homes, you can get almost harmless delicacy. The main thing is to choose a good recipe with a small amount of harmful components. The second rule is to choose the way to prepare.

In chips that are purchased in the store, there is practically no benefit, but it is enough for harm. The fact is that the potato contains a large number of starch. It turns into glucose, which causes the organism's saturation. And glucose is capable of turning into acrylamide - a component dangerous to the body.

If you use it regularly, it can start developing cancer. The most vulnerable to this disease is 30-45 years old, since they have tumors in the field of uterus and ovaries.

Other reasons due to which potato chips are considered harmful, such.

  1. For cooking use the same oil when it needs to be changed after each batch of potatoes. Because of what the amount of cholesterol increases in the blood.
  2. Chemicals add to the product. Most often it is flavors, dyes, taste amplifiers. According to regulations, some proportion of these components is really permitted, but often manufacturers exceed this rate. This is reflected in the overall human well-being, fraught with a disorder of metabolism, the occurrence of allergic reactions, the destruction of the enamel of the teeth.
  3. The presence of an excessive amount of fats. This leads to obesity and impaired digestion. The appetite worsens, immunity is reduced.
  4. As part of a lot of salt. It interferes with the normal growth of hair, nails and bones, destroying vitamin C. Excessive use of such chips can result in heart problems.

But potato chips are not only harmful to human health. They also have some useful properties, among which are the satisfaction of hunger, improving the mood (especially when this product really wants to eat, i.e. comes emotional, psychological hunger).

How to prepare potato chips at home?

Potato chips at home is an excellent delicacy that can be used as a snack. To taste, they are completely different from the purchased product, regardless of the preparation method. And the most important thing - when cooking it is possible to adjust and control the amount of salt and seasonings, pour them out at will.

To prepare useful and delicious potato chips at home, it is necessary to correctly pick up raw materials. For this product, potatoes are needed with a large dry mass content (from 20%). If it is too watery, then crispy chips will not come out. Potato varieties are perfectly suitable:

  • Lady Rosette;
  • Bullfinch;
  • Fantasy;
  • Pushkin;
  • Story;
  • Saturn.

They are derived by selectors specifically to create this delicacy. In most cases, tubers have the same dimensions, therefore the chips will be appropriate.

To prepare useful chips on this recipe, you will need such ingredients:

  • 500 g potatoes;
  • 2-2.5 Art. l. vegetable oil;
  • butter;
  • salt and pepper (added to taste).

First, potatoes are clean and wash under cold water. Lay out on the towel so that it dries a bit (somewhere for 20-30 minutes, no more).

After that, in pour oil in large quantities. They give it enough to warm up and parallel the potatoes are cut with small circles (2-3 mm in thickness). You can use a special vegetable cutter, but it is quite possible to cope with the help of an ordinary kitchen knife.

Potatoes are laid out in a frying pan with preheated oil. Separate slices should not come into contact with each other, otherwise it turns out an ordinary fried potato.

When the chips become golden, they are removed from the frying pan, salted and sprinkled with spices. Lay out on a napkin or paper towels to remove excess oil. Chips are ready to eat!

In the oven

At first, you also need to clean the potatoes, thinly cut. But besides this component, you need greens (dill is best fit) and garlic. Therefore, after potatoes, garlic and dill are clean and finely.

Garlic needs to cut, because when using the press, garlic puree is obtained, which will not allow crispy chips.

On the stove put a small container where the oil is poured in a small amount. Inside throw chopped garlic and greens. Potatoes are laying inside the tank and shake slightly so that each slice is impregnated with spices with spices. Damfit for 30-40 minutes.

Take a baking sheet and flow the paper. Potatoes are laid, but only one next. The oven is pre-warmed up to 200 ° C, where chips are sent for 15-20 minutes. After that, they are checked for readiness. If you wish, you can put in the oven for another 15 minutes to get more crunchy.

When the chips prepare, they are allowed to cool 30-40 minutes, no less. Serve is recommended with sour cream.

To prepare chips in this way, you only need 3 components - 25 ml of oil, 300 g of potatoes and spices. Such a portion is enough for 1 adult.

The sequence of actions is as follows.

  1. Potatoes are clean, wash and cut into small slices. Leave in cold water for 15-20 minutes to get out starch.
  2. Slices dried with paper towels and sprinkled with selected spices (sometimes enough add just salt and pepper).
  3. Take a flat container and decompose on it slices of potatoes in 1 row.

The cooking time of chips in 4-5 minutes. Provided that the maximum preparation temperature is exhibited. 2 minutes from the beginning of cooking chips need to be turned over.

Chips are considered ready if the golden brown shade appears on them. Then they should be taken from the microwave and give cool, otherwise they will just burn.

In fryernice

The number of components depends on the type and size of the fryer. Usually grabs 1 kg of potatoes and 1-2 liters of oil. As spices take your favorite spices - Khmeli-Sunnels, salt, pepper, paprika, red pepper, etc.

With potatoes do the same as in previous recipes. When it is sliced \u200b\u200bwith thin circles, the fryer fill with oil. The device includes the necessary program activate. A special signal will notice when potatoes can be immersed inside the art and when it can already be removed.

Finished chips are laid out on paper to glass extra oil. Only after that they sprinkled with spices. Serve better with homemade sauces (cheese, barbecue, ketchup, etc.).

When I want something delicious, you can cook home chips. Excellent version of the snack for both children and adults. Do not require multiple components (usually need 2-4 ingredients). For children, fruit and vegetable are suitable for children, for girls on proper nutrition - from the pita, for men - potato.

Some young moms or girls who are followed by health, do not want to eat fatty and calorie potato chips, and think about how to make chips without harm to the body. Then you can cook useful and delicious treats from fruits and vegetables.

Kiwi, apple, mango, pumpkin, Sicilian and ordinary oranges, grapefruits, zucchini and other foods are used for ecoctipes. Sometimes they take even leaf lavash. And such a snack can be cristed even in the evening without harm to health and figures!

From apple

They are better to do in the oven or a special drying machine. Cooking time takes about 2 hours, of which 15-30 minutes goes to the preparation of components and 1.5 hours on cooking.

For apple chips need:

  • 5 small apples with a dense pulp;
  • 80-90 g of sugar;
  • 200 ml of water;
  • 0.5 h. Spoons of citric acid.

First stage - cooking syrup. For it, sugar and citric acid are taken, which are poured with warm water. The container with these components put on fire and bring to a boil. When sugar is completely dissolved, the syrup is removed from the fire and give to cool.

The second stage is the blank of apples. They are cut with thin circles (1-2 mm) and remove the core. Slices are placed in syrup and leave it to be for 15 minutes.

You can immerse in the tank with syrup not all apple mugs. Often it makes stages. The quality of ready-made chips from this will not suffer!

Turning out apple mugs from syrup, they are put on paper towels to remove excess moisture. 5-10 minutes enough.

The third stage is the placement of slices on parchment paper. Put in 1 row a little distance from each other.

The fourth stage is the installation of the oven in the oven. It is pre-warmed up to 60 ° C.

It is better to put a baking sheet for the middle level. So apple chips will be impregnated evenly and quickly.

The fact that slices prepared are evidenced by their wavy edges.

Take 2-3 young zucchini, which cut rings or long slices. Put in a bowl of 100 g of flour and stirred.

In order for each slice to be covered on top of flour, it is better not to take a container, but a package. It can be treated, with the result that all pieces will be evenly sorrodied.

The following stages.

  1. Parchment paper lubricate with oil. To lay out pieces of zucchini in 1 row.
  2. Little tray to put in the oven for 200 ° C. On average for cooking you need 15-20 minutes, but there is no accurate time. The main landmark is a roasted crust from above.
  3. At the request of snacks sprinkled with solid cheese. After that, they are sent to the oven for 10 minutes. When a golden crust appears, removed and allow to cool.

From Banana

Often banana chips are made using lemon. You need 2-3 banana and 1-2 lemon.

Bananas are cleaned from the peel and cut along either in the cross. Initially, the oven is heated to 85-90 ° C. After that, the banana rings laid on a baking sheet on parchment paper. From lemons squeeze juice, which splashes future chips.

Cooking takes 1-1.5 hours. The temperature in the oven is 180 ° C. But if after this time the chips will not be ready, they continue to bake.

For cooking only ripe and fresh bananas are needed. Not too soft will not fit.

From Lavasha

Such chips often make girls who adhere to principles proper nutrition. This is an excellent snack when you want something salty, but not harmful.

For the preparation of such home chips, 100 ml of vegetable oil, 2 thin pellets-pita and spices to taste are needed. Cooking time - 20 minutes.

While the oven is heated, Lavash is cut into squares, triangles, other figures. Place in the container where we are wetted and dip in spices. After that, lay out on the tray and leave for 15 minutes in the oven at a temperature of 220 ° C.

You can spread the pita in several rows.

From cheese with breast

Excellent snack for beer or wine. In comparison with the shopping chips less calories.

Supports such ingredients:

  • 200 g cheese;
  • 70-80 g chicken breast;
  • 2 cloves of garlic;
  • 10 g of dill or other greenery.

Initially, the cheese rubs on a large grater, and chicken breasts are cut by thin slices. Add grated garlic and chopped dill. Mixed and small portions lay out on the baking sheet. In the oven at a temperature of 220 ° C left for 15 minutes.

Fruit and vegetable chips are best prepared in the oven. So fruits and vegetables will not lose beneficial features and vitamins. Their use will not affect the figure or work of various organs.

Keep such chips better in fabric bags, glass jars, paper bags. The suitability period is usually equal to 3-6 months, after which the chips lose their beneficial properties and gradually deteriorate.

After cooking, the delicacy must be left to cool for 15-20 minutes. It is necessary so that the chips are really crispy.

Conclusion

Chips are an excellent snack, but often the store product is not particularly utility. If a person is a lover of such harmful snacks, it is better to do snacks at home. As the main ingredients take zucchini, potatoes, apples, pumpkins, cheese and breast, etc. The main principle is less spices and oils.

Mother two children. We have been holding a household for more than 7 years - this is my main job. I love to experiment, constantly try various means, methods, techniques that can make our life easier, modern, saturated. I love my family.

It is believed that chips appeared more than 150 years ago in the United States. The legend says that in one of the elite American restaurants, the client (railway magnate Vanderbilt) did not like the branded dish of the restaurant "Potato Friend" and he returned it to the kitchen, with a claim that potatoes are too thick. The chef of the restaurant decided to make fun over the client and cut potatoes on the finest slices and roasting in the oil filed to the table. Surprisingly, the client did the dish especially liked, and since the restaurant's menu has appeared a new dish - chips.

Lay's chips are produced since 1938. Today, Frito Lay is one of the leading manufacturers of salt snacks both in the world and in Russia. The supply of Lay's chips to Russia began in the mid-90s, and in 2002 the first Frito Lay plant was opened in Kashira near Moscow. Now the chips are supplied in thousands of shops, as well as restaurants in Moscow and other cities of Russia.

(37 photos)

1. The topic of today's report is the factory of PepsiCo for the production of potato chips Lay "S, recently opened in the city of Azov, Rostov region. In addition, the plant produces crackers KharTeam. We will pass consistently along the entire production line and consider it in detail.

Unloading, washing and temporary storage of potatoes

2. Nine 20 ton trucks with potatoes are unloaded here. Potatoes on the ribbon conveyor enters the washing machine, where recycling water is used for cleaning it. In total, there are three such automatic sinks in the world. The process of washing is physically impossible to remove, everything happens in a closed container. After washing, the potatoes go to temporary storage in Bins - special containers, from where it is necessary to produce.

Cleaning, sorting and cutting potatoes

3. Before the potato tubers fall into a special car for cutting, the inspector visually inspect the tuber-running tape and, if you need to remove visible defects.

4. By the way: no potato is suitable for chips production. There are so-called chipseed varieties of potatoes, which are distinguished by increased starch content.

5. All workers periodically pass a medical examination and have medical records, this is done so that the sick person does not get into production. In addition, before entering the workshop, everything is necessarily washed.

6. Potato cleaning occurs in abrasive drums of periodic action. First, the required amount of potatoes in the weight bunker is loaded, then unloading to the drum occurs.

7. Directly cutting occurs mechanically by rotating the cone-shaped bottom of the drum. Inside the cutting machine, eight pairs of acute blades that cut the tuber on thin slices. The thickness of each slice is less than two millimeters.

Roast

8. After cutting, potato slices come to the very "heart" of the chips production lines - a frying bath for roasting slices and obtain basic chips. This equipment that has no analogues was created specifically for the Pepsico plant and it is impossible to show it.

9. Thin chopped potato slices come into the bath with oil, in which they are roasted for three minutes at a temperature of 180 degrees Celsius. High-quality oil, as well as high-quality potatoes - the basis of the taste of chips.

10. The plant has improved the formulation, using a special mixture of vegetable oils, including highly fat sunflower oil oil, due to which a 25% reduced the content of saturated fats in the final product.

11. Daily at the factory is checked product quality. Check as basic chips, only out of the furnace, and completely packaged packages.

Adding spices

12. At this stage, special aromatic oils and taste additives are added to roasted potato chips, the basis of which is salt.

13. At the same time, the production of three flavors can go on line.

Packaging

14. By the way: the plant is designed to produce 50 thousand tons of finished products per year. Some kind of fantastic figure, in my opinion.

15. For three conveyors, ready-made chips come on packaging. First, the distribution and weighing occurs.

16. By the way: Please note that there are very few workers on the entire length of the line. It uses modern equipment that works in a fully automated mode. In addition, it is important that as few people can come into contact with the finished product.

17. Weighing machines are weighing at the same time several servings and calculate the best weight combination, which has the most accurate weight in order to match the standard and specified on the packaging weight.

18. If we consider that the net weight of one pack is 28 grams, you can present the accuracy of the equipment setting.

19. Weighted portion is unloaded on the packaging line.

20. The portion is controlled by the presence of extraneous impurities (metal detector) and falls into the package, which by this time is prepared by the packaging machine from packaging materials (foil). Food nitrogen is supplied to the package of seam to the package, which allows you to provide the necessary product storage period. Weight and packaging equipment works synchronously at speeds up to 80 packets per minute.

21. Packaged package with chips enters operators that manually fold packages in cardboard boxes.

22. Boxes with chips add up for pallets and transported to the warehouse.

In parallel there is a line by Production of Sukharikov

24. A mixture of flour with water is supplied to the extruder, heats up and thoroughly mixed. From the extruder, the crackers are in the form of harness, which are cut in size with rotating knives.

25. The next stage of crunches is dried in the furnace and fall on the decay site.

26. The packaging line is identical to the one on which chips produce.

The topic of today's report is a PepsiCo plant for the production of Potato Chips Lay's, recently opened in the city of Azov, Rostov region. In addition, the plant produces crackers Khartemteam. Going consistently along the entire production line and consider it in detail.

It is believed that chips appeared more than 150 years ago in the United States. The legend says that in one of the elite American restaurants, the client (railway magnate Vanderbilt) did not like the branded dish of the restaurant "Potato Friend" and he returned it to the kitchen, with a claim that potatoes are too thick. The chef of the restaurant decided to make fun over the client and cut potatoes on the finest slices and roasting in the oil filed to the table. Surprisingly, the client did the dish especially liked, and since the restaurant's menu has appeared a new dish - chips.

Lay's chips are produced since 1938. Today, Frito Lay is one of the leading manufacturers of salt snacks both in the world and in Russia. The supply of Lay's chips to Russia began in the mid-90s, and in 2002 the first Frito Lay plant was opened in Kashira near Moscow.

Unloading, washing and temporary storage of potatoes

2. Nine 20 ton trucks with potatoes are unloaded here. Potatoes on the ribbon conveyor enters the washing machine, where recycling water is used for cleaning it. In total, there are three such automatic sinks in the world. The process of washing is physically impossible to remove, everything happens in a closed container. After washing, the potatoes go to temporary storage in Bins - special containers, from where it is necessary to produce.

Cleaning, sorting and cutting potatoes

3. Before the potato tubers fall into a special car for cutting, the inspector visually inspect the tuber-running tape and, if you need to remove visible defects.

4. By the way: no potato is suitable for chips production. There are so-called chipseed varieties of potatoes, which are distinguished by increased starch content.

5. All workers periodically pass a medical examination and have medical records, this is done so that the sick person does not get into production. In addition, before entering the workshop, everything is necessarily washed.

6. Potato cleaning occurs in abrasive drums of periodic action. First, the required amount of potatoes in the weight bunker is loaded, then unloading to the drum occurs.

7. Directly cutting occurs mechanically by rotating the cone-shaped bottom of the drum. Inside the cutting machine, eight pairs of acute blades that cut the tuber on thin slices. The thickness of each slice is less than two millimeters.

Roast

8. After cutting, potato slices come to the very "heart" of the chips production lines - a frying bath for roasting slices and obtain basic chips. This equipment that has no analogues was created specifically for the Pepsico plant and it is impossible to show it.

9. Thin chopped potato slices come into the bath with oil, in which they are roasted for three minutes at a temperature of 180 degrees Celsius. High-quality oil, as well as high-quality potatoes - the basis of the taste of chips.

10. The plant has improved the formulation, using a special mixture of vegetable oils, including highly fat sunflower oil oil, due to which a 25% reduced the content of saturated fats in the final product.

11. Daily at the factory is checked product quality. Check as basic chips, only out of the furnace, and completely packaged packages.

Adding spices

12. At this stage, special aromatic and flavor supplements are added to fried potato chips, the basis of which is salt.

13. At the same time, the production of three flavors can go on line.

Packaging

14. By the way: the plant is designed to produce 50 thousand tons of finished products per year. Some kind of fantastic figure, in my opinion.

15. For three conveyors, ready-made chips come on packaging. First, the distribution and weighing occurs.

16. By the way: Please note that there are very few workers on the entire length of the line. It uses modern equipment that works in fully automated mode. In addition, it is important that as few people can come into contact with the finished product.

17. Weighing machines are weighing at the same time several servings and calculate the best weight combination, which has the most accurate weight in order to match the standard and specified on the packaging weight.

18. If we consider that the net weight of one pack is 28 grams, you can present the accuracy of the equipment setting.

19. Weighted portion is unloaded on the packaging line.

20. The portion is controlled by the presence of extraneous impurities (metal detector) and falls into the package, which by this time is prepared by the packaging machine from packaging materials (foil). Food nitrogen is supplied to the package of seam to the package, which allows you to provide the necessary product storage period. Weight and packaging equipment works synchronously at speeds up to 80 packets per minute.

21. Packaged package with chips enters operators that manually fold packages in cardboard boxes.

22. Boxes with chips add up for pallets and transported to the warehouse.

23.

In parallel there is a line by Production of Sukharikov

24. A mixture of flour with water is supplied to the extruder, heats up and thoroughly mixed. From the extruder, the crackers are in the form of harness, which are cut in size with rotating knives.

25. The next stage of crunches is dried in the furnace and fall on the decay site.

26. The packaging line is identical to the one on which chips produce.

27.

28. Weighing occurs in a similar weight machine that generates several portions and selects the best combination for sealing into the package.

29. Ready crackers.

30. The performance of one line is 12 tons of finished products per day.

31. Employees are forbidden to wear clocks and decorations, manicure and false nails are prohibited, the hair must be closed with a grid so that nothing fell on the conveyor.

32. In addition to the taste and visual compliance of slices adopted standards, the quality of the package checks here. The seam must be even and the pack must be opened by one movement exactly along the seam, without breaks.

33.

34. Collective of the plant. By the way, the production line works around the clock in three shifts.

35.

36. Appearance of the plant.

37. Enjoy your appetite!

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