By Jonathan Thomas

It is largely for this reason that the term ‘clear label’ is also sometimes applied, as ‘less is more’ is what consumers are demanding from manufacturers. This trend has been evident of late in markets such as potato-based snacks and frozen potato products. 

According to Persistence Market Research, the global market for clean label food ingredients was worth USD52.5bn in 2025. This figure is forecast to grow by an annual average of more than 7% in the period leading up to 2032, reaching a value of almost USD85bn. The European region accounted for a leading 40% of global market value in 2025, due mainly to the existence of stringent regulations governing what ingredients can be used in food and beverages, as well as the increasing consumer trend away from ultra processed foods (UPFs), although North America is experiencing the fastest growth at present. The market’s largest sector is bakery goods, which accounted for a 35% share in 2025. 

The US-based company Ingredion (which supplies a range of ingredients to the global food industry) has also conducted research regarding the concept of clean label, surveying the opinions of around 14,000 people in 29 countries. One of the key findings was that although cost remains a key purchasing consideration, consumer behavior is being influenced to a greater degree by health goals, lifestyle choices and personal values. The research found that many consumers would pay up to 20-30% more for food and beverages making health and clean label claims, with levels of willingness especially high amongst millennials and Generation Z consumers. Furthermore, many people appear to be trending away from food ingredients they do not recognize or understand. 

According to a 2023 report on the subject by FMCG Gurus, almost 80% of consumers like to see the claim ‘100% natural’ on food packaging. Some of the most important attributes associated with clean label products include naturalness (mentioned by 68% of respondents), the presence of recognizable ingredients (mentioned by 63%) and knowing the origins of ingredients (mentioned by 61%). The future appears bright for the clean label sector – the Ingredion research predicted that these products should account for up to 70% of overall product portfolios for food and beverage manufacturers by the end of 2026, up from 52% in 2021. 

One of the main issues facing the industry at present is that ‘clean label’ is a term which, although used with increasing frequency, lacks a specific legal definition. Although a strong overlap exists with other health claims such as ‘natural’, ‘organic’ or ‘free from’, the absence of any legal definition means there is a strong emphasis upon consumer trust, with the result that food and beverage manufacturers marketing their products as clean label need to be truthful and transparent regarding the provenance of their ingredients. If the term clean label is applied, consumers will often expect this to be backed up with scientific evidence. 

From a supply perspective, the global market for clean label ingredients is dominated by the world’s leading manufacturers of food additives. Many of these are especially strong in sectors where the presence of artificial ingredients has diminished, examples of which include flavors and colors. Leading suppliers of clean label food ingredients include Cargill, Ingredion, Tate & Lyle, Kerry Group, Sensient Technologies, Corbion and ADM.

Although the global market for foods positioned on a clean label platform is projected to continue expanding, various barriers do exist for manufacturers considering introducing natural additives and ingredients into their products. One of the most significant is the relatively high cost of natural ingredients compared with their synthetic or artificial counterparts, which can adversely impact upon margins. On a related note, the availability of certain natural ingredients may vary, as many are sourced from fruits or vegetables. This means that supply can be compromised by weather or climate patterns, such as droughts or poor harvests. 

The removal of artificial ingredients from foods can also compromise their functionality. One of the best examples is artificial preservatives, which are most frequently used to extend the shelf-life of food products and one of the most common targets for reduction or elimination by manufacturers. Without preservatives, food is likely to spoil at a faster rate, thereby increasing the likelihood of wastage, which does not sit well with claims relating to sustainability and ethical strategies. Other potential obstacles to future market growth include regulatory hurdles governing what can and cannot be used in food manufacture, as well as consumer skepticism questioning how ‘natural’ some of the ingredients in their foods truly are. 

Read the rest of this feature in the complimentary e-copy of the November / December Issue of Potato Processing International, which can be accessed by clicking here.

According to recent industry data, this trend is particularly strong among younger demographics. Frito-Lay’s 2023 Snack Index revealed that over 60 percent of millennials are eager to try new chip flavors. Generation Z and Generation X followed closely behind, with more than half of respondents in each group also interested in flavor experimentation. In contrast, less than 40 percent of baby boomers preferred to step outside the boundaries of traditional or familiar tastes. This generational divide speaks volumes about the future direction of snack product development.

The American market illustrates this perfectly. While classic flavors such as plain salted and barbecue still dominate in terms of volume, the appeal of globally inspired and seasonal variants has grown steadily. The same Snack Index found that nearly three-quarters of U.S. consumers find the idea of trying new variations of their favorite snacks exciting. An additional report from FMCG Gurus showed that more than 80 percent of North American consumers are open to exploring flavors from other parts of the world, particularly those associated with street food or regional cuisines.

In the UK, the trend toward more expressive and globally influenced chip flavors is just as strong. KP Snacks, for instance, expanded its McCoy’s range with Nacho Cheese and Spicy Salsa, and followed up with regionally themed flavors like Chip Shop Curry and Bangin’ BBQ. Walkers, the leading brand under PepsiCo, introduced new additions to its ridged Max line, including Bold BBQ Ribs and XXL Chicken & Chorizo. In Germany, Intersnack’s Funny-Frisch brand released a Chili Cheese Fries variety following a consumer competition, a move that underscored the importance of engaging directly with flavor-savvy audiences.

Despite the move toward flavor adventure, traditional tastes continue to enjoy robust popularity. In markets like the United States, plain salted chips still account for the largest share of sales, and brands that have attempted to discontinue long-standing flavors have often faced consumer backlash. Walkers’ decision to remove Beef & Onion and Worcester Sauce from its UK lineup in 2023 prompted a wave of negative reactions across social media. What this shows is that while innovation drives growth, legacy flavors retain a deep emotional connection with consumers and continue to serve as a vital anchor in any brand’s portfolio.

The increasing interest in world cuisines has helped shape the current flavor landscape. Mexican influences, such as lime, jalapeño, chipotle and cheese, are deeply embedded in the North American market and are also gaining ground elsewhere. Caribbean-inspired varieties are growing in both visibility and acceptance, especially in the UK, where the popularity of jerk seasonings, fruity spice combinations and ingredients like coconut milk and mango has helped Caribbean cuisine grow to a market size of around £100 million annually. Brands have also experimented with more niche offerings, such as chips flavored with Pickapeppa Sauce, a uniquely Jamaican condiment that blends sweetness, spice and tang from ingredients like ginger, orange peel and vinegar.

Other regional cuisines are also carving out a space. African-inspired snacks featuring ingredients from Morocco, Ghana and Nigeria are on the rise. U.S.-based Green Sahara, for example, launched chips flavored with Sahara spice blends and East African barbecue chili. In Asia, consumers continue to embrace local flavors such as soy sauce, seaweed, spicy crayfish and oyster. China’s Lay’s lineup now includes picks like Pickled Fish and Roasted Garlic Oyster. Meanwhile, fusion trends combining elements from Korean, Japanese, and even Mexican cuisines are gaining popularity as global palates become more adventurous.

The Science Behind the Taste

At the heart of every chip seasoning lies a blend of several core components that work together to deliver taste. A base layer of salt provides the initial savory hit. This is often balanced with acids—such as powdered vinegar or citric acid—that add brightness and keep the flavor from feeling flat. Savory depth comes from flavor enhancers like monosodium glutamate or yeast extract, both of which amplify other notes in the seasoning. These elements create the foundation upon which spice blends are layered. Herbs such as dill, thyme and parsley, and spices like paprika, garlic and chili powder, give character and complexity to the overall flavor profile. Seasoning development draws from both culinary traditions and technical understanding of how flavors behave during manufacturing and frying.

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By Jonathan Thomas

Fries and chips account for up to a third of global market value. Aside from the convenient nature of these foods, market growth is also likely to be driven by the introduction of healthier products (e.g. low-fat and clean label solutions) and those capable of being cooked in air fryers. 

For households, frozen potato products represent a convenient meal option, either as a side dish or, increasingly, a hot-eating snack or buffet component. In the foodservice sector, frozen potato products are relatively easy to store and economical to base menus around. Future demand should also benefit from the anticipated expansion of the quick service restaurants (QSRs) sector throughout the world – for example, McDonalds aims to reach 50,000 outlets by the end of 2027, which will involve the opening of 10,000 new restaurants. 

Retail Trends

McCain remains leader of the global market for frozen potato products, supplying a wide range of options. One of its most notable recent introductions was the launch of the Vibes range in the UK at the start of 2025. Described as a hybrid between a chip and a crisp, the Vibes brand was targeted at snacking and teatime occasions and represents an example of the way frozen potato products are now being aimed at new audiences. The range was launched in Salt & Vinegar, Firecracker Chilli and Mango Chutney flavours, thereby offering a bold taste. 

The Vibes range is also marketed as being suitable for cooking in air fryers, which is another recent trend within the category. McCain’s UK range had already included Air Fryer branded products (examples of which include French Fries, Hash Brown Bites and Crispy Dippers), launched during 2024. The Air Fryer range is also available in the Australian market, while McCain’s US business supplies Quick Cook branded products, which are also suitable for cooking in air fryers. It is estimated that 38% of all European households now own an air fryer, rising to 66% of UK adults. According to the Good Food Nation study, air fryers are the third most popular appliance in UK kitchens, trailing only toasters and microwave ovens.

Manufacturers continue to experiment with new flavours, introducing chips and fries incorporating influences from cuisines such as American and Asian. McCain’s UK range, for example, includes Season & Bake Fries, which are sold in varieties such as Chicken Salt and Smokeshack BBQ. Another driver of new product activity is the rising demand for products with a more rustic and/or artisanal appearance and taste, of which skin-on varieties represent a leading example. Aside from their visual appeal, skin-on products offer an enhanced flavour and texture, as well as carrying health and nutritional benefits, given that potato skins are rich in fibre, potassium, vitamin C and various antioxidants. 

Foodservice Trends

The foodservice industry remains a major consumer of frozen potato products. QSRs such as McDonalds and Burger King account for a sizeable percentage of global sales, while demand is also high from full-service restaurants (FSRs) and pub chains. Aside from the QSR sector, dishes such as fish and chips remain a popular option in FSRs and pubs, especially in European markets such as the UK and Ireland. 

Although fish and chips arguably remains Britain’s number one dish, the category appears to be struggling at present, for reasons such as the imposition of fishing quotas and poor potato harvests, which have both adversely impacted upon the supply of ingredients. According to data from leading trade body Seafish, the number of fish and chip meals served out of home in Great Britain during the year ending September 2024 fell by 21% to 36.6 million servings. During this time, fish and chip shops accounted for 56% of all fish and chip servings outside the home in Great Britain, ahead of pubs (23%), FSRs (8%) and QSRs (7%). 

The popularity of fish and chips amongst British consumers remains heavily skewed towards the older age groups, with the over 50s accounting for 77% of all servings. Dinners on Fridays and Saturdays are the most popular time for fish and chips, accounting for a combined 43% of all servings, rising to 46% for fish and chip shop purchases. Although consumption remains heavily skewed towards certain demographic groups and eating occasions, there is believed to be further potential for growth for fish and seafood (and therefore frozen potato products) in the eating out market, since this appears to be a meal option relatively few consumers regularly cook at home. 

One of the main drivers of demand within the foodservice industry is the continued expansion of the European market for online food deliveries. According to Grand View Research, sales were valued at USD73.8bn in 2024, with Europe accounting for almost a fifth of the global market. In the years leading up to 2030, annual growth is expected to average almost 8%, with sales forecast to reach USD111.6bn. Much of this growth is being driven by increased penetration of the internet and devices such as smartphones amongst the European population, as well as the emergence of apps, user-friendly platforms and the deployment of AI-enabled technologies capable of creating customised and/or personalised menus. Another feature of the market has been the development of cloud or ghost kitchens (sometimes called ‘virtual restaurants’) where the sole focus is upon the preparation and delivery of meals, which can help to keep costs down for operators. 

Many of the sector’s leading operators appear well-placed for further expansion. The Dutch-based Just Eat, for example, was acquired by Protus of South Africa in 2025, in a deal valued at EUR4.1bn (although the deal remains subject to reviews from the EC). Just Eat operates in many European countries and works with around 356,000 connected partners. Elsewhere, the US-based DoorDash agreed to acquire Deliveroo in the summer of 2025, for a sum of GBP2.9bn. Deliveroo has up to 80,000 restaurant partners and a food delivery app in nine countries. Another recent market development has been food delivery operators working in partnership with grocers and food retailers, thereby diversifying outside the foodservice industry.

To capitalise on this growth, manufacturers of frozen potato products have been developing products geared towards home delivery applications, specifically those capable of staying hot and crispy for longer periods. One leading example is Aviko, which competes in the market via its SuperCrunch fries. These have a unique coating which acts as a barrier against moisture and ensures they stay crispy for longer periods – according to the company, they remain significantly crispier than rival products even after half an hour spent in a delivery box. SuperCrunch fries are available in varieties such as Thin Cut, Thick Cut, Steakhouse, Chunky and Pure & Rustic.

Also present within this market is McCain, whose foodservice range includes SureCrisp fries, available in varieties such as Thin Cut, Julienne and Gourmet Chips. The fries feature a unique coating that ensures they stay crispy for 20 minutes. Another leading supplier to the European market is Lamb Weston, which produces fries marketed as extra crispy and therefore suitable for home delivery applications. Examples include Stealth Fries and Frenzy Fries, both of which feature a coating to retain crispiness. Frenzy Fries, which are a relatively recent addition to the company’s portfolio, also have a unique three-sided rough cut design. 

The complimentary e-copy of the July / August Issue of Potato Processing International, can be accessed by clicking here.

While Australia is making significant strides in expanding its processing capabilities, New Zealand is focusing on enhancing efficiency and value addition amidst production challenges.

Australia: Scaling Up Through Strategic Investments

Australia’s potato industry has recently achieved a milestone, surpassing a USD 1 billion production value, marking a 24% increase from the previous year. This growth is underpinned by substantial investments aimed at bolstering processing capacities and meeting rising domestic and international demand.

In 2022, Simplot Australia announced a significant investment of AUD 100 million (approximately USD 70 million) to upgrade its Bathurst manufacturing facility and acquire farming land in New South Wales. This initiative aims to transform the Bathurst site into a frozen vegetable center of excellence, enhancing production capacity and boosting both local and export volumes.

Further amplifying Australia’s processing capabilities, Dutch frozen potato product manufacturer Farm Frites has proposed a USD 425 million facility at the Wimmera Agriculture and Logistics Hub in Dooen, Victoria. This factory is expected to process up to 500,000 tonnes of raw potatoes annually, sourced from Victoria and South Australia, into approximately 300,000 tonnes of finished products. The project is anticipated to create 245 permanent jobs and 750 construction jobs, with operations slated to commence in early 2027.

New Zealand: Enhancing Efficiency Amidst Production Declines

Contrasting Australia’s expansion, New Zealand’s potato industry has faced a 13.7% decline in production over the past five years, equating to a reduction of 72,800 tonnes. Despite this, the industry has demonstrated resilience, with the overall value increasing by 16.3%, amounting to a growth of USD 177.4 million.

A notable development in New Zealand’s processing sector is the expansion of Bluebird Foods, a leading potato chips manufacturer. The company secured a USD 66 million investment to enhance its production capabilities, reflecting a commitment to meeting growing consumer demand and improving operational efficiency.

Additionally, New Zealand’s potato industry has achieved remarkable efficiency, with the country projected to attain the world’s highest potato yield in 2022, averaging 50.9 tonnes per hectare. This surpasses traditional leaders such as the United States and Denmark, highlighting New Zealand’s focus on maximizing output from existing resources.

You can read the rest of this article in your complimentary e-copy of the May / June Issue of Potato Processing International, which you can access by clicking here.

By Jonathan Thomas

Consumer health concerns remain one of the most important drivers in the global food industry, with potato-based products being no exception. One of the most important drivers of innovation from a health perspective has been the growing adoption of certain diets, of which vegetarian and vegan represent two notable examples. People adopting plant-based diets usually do so due to strong concerns over animal welfare and the belief that eating meat is morally wrong, as well as for various health reasons. Furthermore, it is often claimed that following a plant-based diet is more sustainable and kinder to the environment, for reasons such as lower greenhouse gas emissions and more efficient use of land and water. 

Over the last decade, more people have started either cutting down on the amount of meat in their diets or given it up altogether. Globally, there are currently thought to be around 88 million vegans, equivalent to 1.1% of the total population. This figure differs according to source, however, with some claiming the percentage is closer to 3%. Globally, the share of the total population taken by vegans is highest in India and Mexico, at around 9%, decreasing to 5% in Israel and Canada. India also has a high percentage of vegetarians, at 30% of the population, though it should be noted that the widespread adoption of plant-based diets in this part of the world can largely be attributed to religious factors. At the other end of the scale, the percentage of the population taken by vegans is well below 1% in countries such as Russia and China. 

In Europe, around 30% of people now identify as flexitarians, i.e. people who primarily follow a plant-based diet but occasionally eat meat or fish. This figure decreases to 4% of the European population for vegetarians and 2% for vegans. The number of vegans in Europe is projected to increase from 6.2 million in 2023 to 8.25 million by 2033, while Germany represents the region’s fastest growing market for vegan foods. The UK market is also one of the region’s largest, despite some slowdown in growth over the last year – in 2024, data from GFI Europe indicated that consumers purchased an average of 9.1 million plant-based foods during a typical week. As of 2025, an estimated 6.4 million people (or 12% of the UK population) followed a meat-free diet in some form. At 4% or over, the share of the total population taken by vegans is especially high in European countries such as Ireland, Denmark, Sweden and Norway. 

In regions such as Europe, the adoption of plant-based diets is heavily skewed towards younger age groups such as millennials and those belonging to Generation Z. One of the major drivers within the market is the growing proliferation of social media influencers promoting the benefits of plant-based foods. These include celebrities, chefs, activists and health and fitness gurus, offering content such as recipes, cooking tips and vegan lifestyle advice. Some of the leading social media influencers for vegan and plant-based diets include Tabitha Brown (a popular figure on platforms such as TikTok and Instagram), Rachel Ama, broadcaster Fearne Cotton, TV star and model Lucy Watson and Niomi Smart, who has over 1 million Instagram followers.

In many parts of the world, plant-based foods have steadily entered the mainstream as vegans and vegetarians have become more prevalent. As the market has developed, it has steadily overcome some of the previous barriers to growth. In the past, the sector was associated with a limited range of products, many of which did not score highly in terms of taste appeal. However, this situation has changed in recent years, with more companies having entered the market (therefore improving the choice of products on offer), while advances in technology have helped to lower prices at the retail level. 

Potato-based Snacks

Snacking remains as popular as ever amongst consumers in regions such as Europe and the US. More people, especially within the younger age groups, are now more inclined to replace main meals with snack foods, as eating patterns have become more flexible and consumers are placing more emphasis on when they eat, rather than what they eat. Skipping meals has become increasingly commonplace amongst large sections of the global population, with breakfast and lunch representing the meals most likely to be skipped and/or replaced with snacks. Much of the recent growth within the snacking market has taken place during occasions such as breakfast time and in the evening. 

Although much of the appeal of snack foods lies in their convenient nature, health concerns have advanced up the agenda as the global market has developed. Much of this is due to concerns over the health of Europe’s population and the associated healthcare costs. According to data from Eurostat, over half (53%) of adults in the EU region are classed as overweight according to body mass index (BMI) assessments. To date, much of the innovation taking place within the snack foods market geared towards addressing the concerns of consumers and the health lobby has taken the form of removal of various ingredients and additives (e.g. salt, saturated fats and sugar), as well as the development of clean-label varieties and products suitable for gluten-free diets. 

On the other hand, claims such as ‘suitable for vegans’ or ‘suitable for vegetarians’ have not been as commonplace or readily apparent within the market for potato-based snacks compared with other sectors of the food industry. The basic ingredients frequently used to make potato crisps and chips are potatoes, salt and vegetable oils, all of which are suitable for those following a plant-based diet. However, many of the market’s leading brands offer a range of flavours to cater towards different tastes, some of which are unsuitable. While meat and fish-based flavours are obvious examples, others include those featuring cheese or sour cream (as vegans will not eat dairy foods) and some varieties of Salt & Vinegar. 

As vegetarian and vegan foods have entered the mainstream, however, new product activity amongst manufacturers of potato-based snacks has stepped up. At the start of 2024, UK market leader Walkers introduced a new limited-edition range of crisps titled Unbelievable Vegan! for Veganuary, the traditional time of year when people are generally more willing to try out plant-based diets as part of a lifestyle change. The range was made up of three flavours, namely Grilled Cheese Toastie, BBQ Pork Rib and Flame Grilled Steak and marked the first time that Walkers had launched potato crisps specifically promoted on a vegan platform. 

Another UK-based supplier that has made some efforts to tap into this market is Kettle Chips. Its range of hand cooked potato crisps includes Vegan Sheese & Red Onion which, as its name suggests, is targeted at those following a plant-base diet. Other flavours within its range are promoted as suitable for vegans (e.g. Thai Sweet Chilli and Sea Salt & Crushed Black Peppercorns), as well as other snacks such as Lightly Salted Veg Crisps and Focaccia and Naan Bites. 

It is perhaps significant to note that other manufacturers of savoury snack foods have been targeting those following plant-based diets, a trend that may spread to sectors such as potato crisps and chips as the market develops further and competition intensifies. In the UK market, Crave supplies sweet and savoury snack foods targeted at those following vegan and gluten-free diets. Its savoury range includes Pickled Onion Noughties, Smokey Bacon Streakers and Hot & Spicy Hot Dawgs. A similar example from the US market is Hippeas, whose range comprises snacks made from chickpeas and yellow peas. The range was extended in the spring of 2025 with Cheezy Cheddar Puffs, which were marketed as being suitable for those following a plant-based diet.

You can read the rest of this article in your complimentary e-copy of the May / June Issue of Potato Processing International, which you can access by clicking here.

While some countries have since adopted regulatory measures, others lag behind, leaving food manufacturers to choose whether to proactively adapt or merely meet the minimum legal standards.

In the potato processing industry—where frying remains a central step in the production of French fries, chips, and extruded snacks—the challenge is particularly acute. Eliminating trans fats without compromising product texture, taste, or operational efficiency is no small feat. 

The Functional Role of Trans Fats in Frying Oils

Before exploring solutions, it’s essential to understand the technical rationale behind the widespread use of trans fats. Partially hydrogenated oils (PHOs), which contain trans fatty acids, were developed to enhance oil stability at high temperatures, improve mouthfeel, and extend shelf life. In frying applications, these oils helped maintain consistent performance over multiple cycles, making them especially appealing to potato processors operating large-scale continuous fryers.

However, the health implications of iTFAs—elevated LDL cholesterol levels, increased inflammation, and heightened risk of heart disease—prompted a public health reckoning. As of the end of 2023, the WHO reported that only 53 of 195 countries had adopted best-practice policies to eliminate iTFAs from food products, covering just 46% of the global population.

In this context, voluntary leadership by ingredient suppliers becomes essential. Companies with global footprints have a unique opportunity—and some would argue, a responsibility—to implement and distribute safer alternatives, especially in regions where legislation is still evolving.

Cargill: A Global Commitment to iTFA Elimination

In January 2024, Cargill became the first global edible oil supplier to fully align its portfolio with the WHO’s iTFA limit of no more than two grams per 100 grams of fat and oil in food products. This milestone reflects years of strategic investment, cross-functional collaboration, and a clear vision for public health impact.

According to a recent press release, Cargill earned the top spot in the inaugural Edible Oil Supplier Index by the Access to Nutrition Initiative (ATNi), a global nonprofit organization. The index evaluated eight of the world’s largest edible oil suppliers across 19 indicators. Cargill led with a score of 81.4%, well ahead of the second-highest scorer at 14.2%.

Cargill’s achievement wasn’t confined to countries with regulatory mandates. The company committed to removing iTFAs from its entire global portfolio, including in markets without legal requirements. This approach demanded more than regulatory compliance; it required rethinking entire product categories, upgrading production facilities, and investing significantly in R&D.

“Being recognized by ATNi reinforces our responsibility to lead with purpose—delivering safe, sustainable nutrition through the food and ingredient solutions we provide,” said David VandenEinde, Vice President of R&D for Food North America at Cargill. “This achievement is the result of decades of innovation, close collaboration with customers […], and investment in improved edible oil solutions.”

The technical barriers encountered in product reformulations mirror those faced by French fry and chip manufacturers: oils must perform under high-heat, continuous-use conditions while delivering consistent flavor, crispiness, and shelf life. To address these needs, Cargill has turned to a mix of established industrial methods:

• High-oleic oils (such as sunflower and canola) that naturally resist oxidation.
• Interesterified fats, enzymatically modified to replicate the functionality of PHOs without forming trans fats.
• Blends of fully hydrogenated oils with liquid oils, customized to each customer’s performance targets.

The company’s cross-market approach emphasizes scalable solutions that can be tailored to regional supply chains and product requirements—critical for globally operating potato processors with diverse geographic footprints.

You can read the rest of this article in your complimentary e-copy of the May / June Issue of Potato Processing International, which you can access by clicking here.

Ensuring compliance with international standards such as the BRCGS Global Standard Food Safety is not simply about passing audits. It is about embedding a culture of vigilance and continuous improvement across every layer of the organisation.

According to Fortress Technology, a key part of this culture is recognising the distinction between inspections and audits—and the role each plays in verifying food safety protocols. As they explain, a food safety audit systematically evaluates factory documentation and operational data over time to assess whether procedures are effective. By contrast, a food inspection is a snapshot of what is occurring on the production floor at a specific moment, usually over a two- to four-day period. Both provide valuable insights, but their scope and focus differ.

“Food safety is reliant on continuous improvement,” says Phil Brown, Sales Director at Fortress Technology. “Once any changes are reviewed and implemented, HACCP plans should be modified. This ongoing effort drives advances in processes and efficiency, as well as enhancing product quality.”

Audits, whether internal or external, are a practical tool for identifying gaps, validating the effectiveness of internal controls, and building customer trust. Typically lasting up to three hours depending on the size of the facility, these audits examine documentation, practices, equipment, premises, and operator competence. Fortress emphasises that an audit checklist should include signs of pest infestation, hygiene standards, food handler training, temperature control, and machinery inspection.

The Strategic Role of BRCGS Certification

From the perspective of the BRCGS (Brand Reputation through Compliance Global Standards), certification represents more than a badge of compliance; it is a commitment to global best practices. “BRCGS is a global consumer protection organisation that provides robust certification programmes to ensure and protect product integrity in the food industry,” explains Merce Sanchez, Food Programme Manager at BRCGS. “Our Global Standard Food Safety provides a comprehensive framework that helps companies meet regulatory requirements and build consumer trust.”

You can read the rest of this article in your complimentary e-copy of the May / June Issue of Potato Processing International, which you can access by clicking here.

• Congratulations on the inauguration of Elea’s new headquarters. What does this milestone represent for the company, both in terms of physical expansion and long-term vision? 

Thank you very much! The inauguration of our new headquarters marks an exciting and significant milestone for Elea. Our new headquarters has been designed to support both the growth of existing applications and the exploration of new ones. It offers increased space for our growing team of PEF experts and service professionals. The building also features dedicated spaces for seminars and hands-on training. In the long term, the new Home of PEF represents our vision to further establish Elea as a global leader in PEF innovation — driving sustainable food processing and unlocking new opportunities across a wide range of industries.

• The “Discover PEF Day” during the event focused on drying and snack applications. Are these the most promising growth segments for Elea’s PEF technology in the coming years, or are there other application areas you are strategically targeting? 

Indeed, drying and snack applications are among the fastest-growing segments for Elea’s PEF technology. These sectors are largely driven by small and medium-sized enterprises that can benefit significantly from PEF. Improved slicing and cutting, increased yield, and reduced drying or frying times all contribute to resource and energy savings — resulting in a rapid return on investment. Our “Discover PEF Day” is designed to foster dialogue between current users, potential customers, and leading PEF experts. The event showcases real-world success stories, highlights process improvements, and offers a platform for exchanging experiences and insights. However, our strategic vision extends well beyond drying and snacks. The event also features presentations and live demonstrations of emerging applications — such as yield enhancement in extraction processes for natural colourants, wine, and plant oils, as well as innovative uses of PEF in biotechnology.

• Elea has deployed more than 300 PEF systems globally. What have been the key factors driving adoption in different regions, and how do you tailor your approach across varied food industry landscapes? 

The key drivers behind the adoption of PEF worldwide have been its strong commercial viability and the clear sustainability gains it offers. Across regions, openness to innovation and the development of new products have also played a crucial role. For more complex applications such as drying enhancement or processing of olives and grapes, an even more localised approach is essential. That’s why we have built a strong network of regional partners in our key markets. This not only ensures deep market understanding and improved customer support but also enables fast on-site service and reliable spare parts availability. To support testing and innovation, we’ve placed about 25 of our flexible PEF pilot systems at universities and R&D centres worldwide and maintain a fleet of rental units for commercial trials. This infrastructure allows us to stay close to our customers and tailor our solutions to quickly respond to their needs.

• With the new facility now operational, how will this impact Elea’s R&D capabilities? Are there specific innovations or new product lines we should expect from your expanded lab and demo center? 

With the new building, our R&D capabilities have been significantly enhanced, allowing us to broaden the scope and pace of our innovation pipeline. Besides pilot-scale testing in potato and snack applications, the expanded laboratory and demonstration centre enable us to offer extended options for drying, infusion, and extraction — key processes to develop tailored and efficient processing solutions for our partners. Upcoming innovations include AI-based process monitoring tools for inline cutting quality and slice thickness control. Additionally, the new lab and pilot hall facilities support the exploration of biotech applications, unlocking exciting avenues for innovation in areas like micro- and macroalgae or insect processing.

• Sustainability is a major driver in food technology investments today. How does PEF continue to position itself as a solution for energy and water efficiency, and how do you communicate these benefits to processors still hesitant to adopt it? 

Sustainability is at the heart of what we do at Elea. Pulsed Electric Field (PEF) technology directly addresses some of the biggest environmental challenges faced by food processors today: water usage, energy consumption, and product waste. In potato processing, for example, PEF has proven to deliver tangible sustainability results. On average, our systems reduce water and energy consumption by up to 90% in comparison to thermal processing. The technology helps to significantly increase yield, by reducing starch losses and waste product. Seeing the PEF effect firsthand is often what shifts the conversation from scepticism to adoption.

• With the new headquarters offering a larger footprint, do you have plans to scale your production capacity? Are you exploring new manufacturing or service models to meet increasing global demand? 

While scaling our production capacity is certainly part of the broader picture, it has not been the primary driver behind our facility expansion. The real focus of our expansion lies in enhancing the way we support our global customers. With our new headquarters, we’re significantly extending our service capabilities. We’re investing in a space where customers, partners, and our own experts can come together to innovate, prototype, and refine new solutions based on Pulsed Electric Field (PEF) technology. In short, the new building enables us not just to produce more, but to serve better — and to collaborate more closely with the food and beverage companies driving innovation around the world.

• PEF technology is often associated with premium or niche applications. Are you seeing movement toward adoption in large-scale or lower-margin segments such as bulk commodity processing or mid-tier brands? 

That’s a common perception, but it no longer reflects the current reality. While PEF was initially viewed as a niche or premium technology, it has firmly established itself in large-scale industrial use. PEF is therefore far beyond the pilot stage — it is firmly embedded in mainstream industrial food production. Interestingly, and perhaps unexpectedly for a high-tech solution, we’re now seeing strong demand not only from large processors, but also from small and mid-sized companies. The development trend is clearly moving towards more compact and versatile systems that meet the needs of snack producers and vegetable processors operating at lower volumes or with more specialised products. In addition to our high-throughput units capable of processing up to 100 tonnes per hour, we introduced the B 1 Mini. It brings the benefits of PEF — improved yield, texture, and energy efficiency — to processors who need flexibility, ease of integration, and a smaller footprint.

• Finally, what is your broader vision for Elea over the next five years? Are there industries beyond food and beverage where you see PEF having a disruptive impact? 

Over the next five years, our vision is to further establish PEF as a core technology in sustainable food processing, while expanding into adjacent sectors where it can deliver meaningful impact. In the food and beverage industry, we’re seeing significant growth opportunities in areas like juice and puree extraction, fruit oil recovery, and the valorisation of vegetable raw materials. PEF offers clear advantages in improving yield, preserving quality, and reducing energy consumption. One of the most exciting areas is PEF’s potential to support the decarbonisation of food processing. By replacing or reducing thermal preservation steps, PEF can drastically lower energy use and improve nutrient retention. Beyond the food sector, we’re also active in research and development for biotech and industrial applications. We see clear potential for PEF in sectors such as biorefining, cosmetics, and pharma. Ultimately, our aim is to continue building on our position as the global leader in industrial PEF applications.

Few crops have left a mark on global cuisine quite like the potato. Grown in over 100 countries and with approximately 380 million tonnes consumed in 2024, its appeal lies not just in its nutritional profile and affordability, but in its versatility across cultures, cuisines, and formats. From golden fries to delicately flavoured crisps, the potato continues to be transformed into some of the most popular food products worldwide. And with global consumption anticipated to rise to 398 million tonnes by 2035, that is showing no signs of slowing.

Testament to the humble potato’s enduring popularity is the fact that the Food and Agriculture Organization of the United Nations (FAO) has designated May 30th as “International Day of the Potato”. For 2025, the theme is “Shaping history, feeding the future.” — a fitting reflection of the potato’s evolving role within the food industry.

But it’s not just the role of potatoes in the global diet that is evolving. The food industry itself is facing rapid change. From shifting consumer habits to rising production costs and increasingly strict regulations, success now depends as much on innovation as it does on tradition. The ability to deliver high-quality, low-waste, and consistent potato products at scale is becoming a defining capability for food processing companies worldwide. The key? Smarter systems, more flexible lines, and tighter control of every stage of the process.

Cutting into the future

At the core of most potato snack or fry products lies a seemingly simple process: cutting. Yet this fundamental step has been revolutionised in recent years through the rise of hydro-cutting technology. Unlike traditional mechanical systems that rely on physical blades and variable alignment, hydro-cutting uses a high-pressure water stream to propel potatoes into an alignment tube and through a fixed knife block. This ensures each potato is cut lengthwise with precision and consistency.

Alongside uniformity in size and shape, this technology ensures smoother surfaces with less micro-serration. This matters because rougher surfaces tend to absorb more oil during frying. With hydro-cutting, processors can reduce oil uptake in their final products, creating a crispier, healthier product while also reducing overall oil consumption.

For processors dealing in high volumes, the performance benefits extend further. Systems like the tna conti-cut® are engineered for 24/7 uptime, featuring automatic switchers that cycle in new alignment tubes and knives without pausing production. It’s this combination of quality, efficiency, and reliability that allows manufacturers to keep up with demand while maintaining brand consistency.

Oil integrity: the underestimated driver of quality

Frying may be one of the oldest processing methods in the industry, but its technology never stood still. In today’s market, the pressure is on processors to improve both product quality and operational efficiency — and oil management sits at the heart of both.

Maintaining high oil quality throughout continuous frying operations is essential. It affects everything from taste and texture to product shelf life and food safety. Continuous filtration systems have become standard in modern lines, removing crumbs and particulate matter before they degrade and contaminate the oil.

What’s changing is how processors monitor the oil itself. Intelligent oil management tools can now track key indicators such as free fatty acids (FFA), peroxide value, and overall oil turnover in real-time. These insights give operators the information they need to make proactive adjustments, whether that means partial replenishment or adjusting heat settings to avoid oil breakdown. The result is less waste, more consistent product outcomes, and easier regulatory compliance.

Different oil types bring different handling requirements. For instance, palm oil’s high stability makes it well-suited for frying, but it’s more costly compared to palm oil (<OPEX) and requires temperature management to prevent solidification in the line prior to start-up and shut down. Less stable oils like sunflower oil are more affordable, but degrade more quickly under heat, requiring tighter filtration and turnover schedules. The ability to handle this complexity through integrated control systems is giving processors a competitive edge.

Staying one step ahead

Beyond oil and hydro cutting, perhaps the most critical shift in modern potato processing is the drive for line-wide flexibility. Consumer tastes are evolving fast, and the ability for food processing companies to respond quickly without overhauling production infrastructure is no longer optional.

In markets like France, this agility has proven essential. The country’s frozen potato product market has reportedly grown by 25% since 2019, driven primarily by younger, convenience-focused consumers. As this trend accelerates, processors must be prepared to pivot product lines quickly and efficiently.

That’s where complete line solutions make a difference. By integrating functions like washing, slicing, frying, seasoning, and packaging into a single coordinated system, manufacturers can reduce waste, simplify maintenance, and accelerate product changeovers. It also enables data-driven insights from the entire process, allowing teams to continually refine performance and output.

Smart line design is especially vital when managing ingredient variability. Potato size, dry matter content, and regional variety all influence the success of a given cut or fry. Advanced systems can adapt parameters dynamically, ensuring consistency even with natural fluctuations in raw material. This is particularly valuable for global brands sourcing potatoes across multiple regions.

Honouring a legacy by investing in the future

The potato has earned its place as one of the world’s most important staple foods. But preserving that role in today’s market takes more than tradition. It takes investment in technologies that improve yield, protect resources, and enable consistent, scalable performance. For food manufacturers looking to futureproof their operations, the innovations driving potato line efficiency today are not just nice-to-haves. They’re becoming the new baseline. And with global demand continuing to rise, smart, flexible, high-performance processing systems will be what allows the next generation of potato products to deliver on both heritage and innovation.

As one of the nine core technologies of Industry 4.0, the Internet of Things is still a relatively new concept in industrial settings—but it already sets the stage for advancements toward Industry 5.0. In essence, IoT enables machines, workers, materials, and tasks to collect and exchange real-time data. Wireless communication standards, sensors, and RFID systems provide the infrastructure for these data flows, offering full visibility and traceability of manufacturing processes. Managers gain access to immediate information about operations, product flow, and equipment performance, allowing them to make faster and more informed decisions.

Today, companies are increasingly viewing IoT not only as a means of streamlining efficiency but also as a pathway to uncover new business opportunities. As IoT evolved, the term Industrial IoT (IIoT) emerged to highlight its applications in manufacturing. According to current industry projections, forward-looking processors will use IIoT to increase output, create hybrid business models, leverage intelligent systems for innovation, and restructure workforce roles to enhance profitability.

IIoT’s impact is amplified when paired with other technologies—cloud computing, robotics, big data, and semantic analysis—to form the digital backbone of smart factories. These Industry 4.0 factories combine networked machines and cyber-physical systems (CPSs) to analyze collected data in real time and make autonomous or assisted decisions.

At the core of IIoT is operational efficiency, achieved through tools like predictive maintenance that help minimize unplanned downtime. The integration of digital services, intelligent devices, and agile production techniques is ushering in a new era of growth and innovation in the potato processing industry.

Technical Aspects of IoT in Potato Processing Factories

A typical IoT system in a potato processing facility is built around three key components: sensors, connectivity, and data analytics platforms.

Sensors—such as those provided by Endress+Hauser—monitor essential parameters like temperature, pressure, humidity, and machinery status throughout the processing line. The Wernsing Food Family, which processes about 500,000 tons of potatoes annually, uses such sensors extensively at its Addrup/Essen site in Oldenburg, Germany. A significant volume of wastewater is generated during cleaning and processing. Endress+Hauser’s instrumentation helps Wernsing reuse as much of this water as possible while ensuring compliant disposal of the rest. Their wastewater treatment process integrates the Proline Promag P and W electromagnetic flowmeters, Liquiline CA80 analyzers for phosphate and ammonium levels, Viomax CAS51D sensors for nitrate detection, and Oxymax COS61D sensors for measuring dissolved oxygen content. These tools ensure consistent monitoring even under variable conditions, improving water recycling and environmental compliance.

You can read the rest of this article in Issue 1 of the Potato Business Digital 2025 magazine, which you can access by clicking here.