The two main types of processing for producing potato chips are continuous and batch. Batch processing is a simpler, more traditional, and more common process.

This is when all the ingredients are combined in a large container, processed, and packaged for distribution after the desired recipe has been achieved for the entire batch. Because all of the ingredients are mixed together and processed at the same time, the operator can ensure that the entire final batch of the product meets quality standards before packaging.

By Heat and Control

Continuous processing, as the name implies, involves an unending stream of ingredients mixed together, processed, and then packaged for distribution. At any given time, the product can be found at different stages of completion. Just as there is a steady stream of raw ingredients being added and processed, there is a steady stream of the final product being packaged.

Continuous processing is much more efficient than batch processing because there is little downtime between batches, providing a higher volume of products in a shorter period. It is also less labor-intensive because it requires fewer people to operate. Continuous processing is a popular option for larger-scale operations.

Conveying Systems

Likewise, there are two main types of conveyors: vibratory and horizontal motion. Vibratory conveyors, sometimes referred to as shakers, were the first sanitary conveyors more than 50 years ago and are used in the potato world, both for chips and for fries. Vibratory conveyors move the product forward by bouncing/shaking it. Different magnitudes of amplitude (vertical lift) and frequency (forward pitches) produce different product travel rates. Because they bounce/shake product, vibratory conveyors can be used effectively to help separate product pieces and spread product across pan width.

Horizontal motion conveyors, like the Heat and Control FastBack introduced, 25 years ago, have rocketed in popularity, supplanting vibratory conveyors as the number one technology for the finished product. Horizontal motion conveyors convey with a slow forward and fastback motion that gently glides the product down the pan. This smooth motion virtually eliminates product breakage and cracking; does not shake off coatings, breadings, or seasonings; and minimizes the buildup of seasonings, oil, and other coatings, reducing downtime needed for cleaning. In addition to being the preferred conveying type for finished products, horizontal motion conveyors now have speedy travel rates, and reverse capability, and are being used increasingly in the processing area for laning, sizing, and other processes. Heat and Control pioneered horizontal motion conveyors and continues to pioneer the way for others in the industry.

You can read the rest of this article in your complimentary e-copy of the September/October 2022 Issue of Potato Processing International magazine, which you can access by clicking here.