How Lay's chips are made? - Factories in Poland скачать в хорошем качестве

How Lay's chips are made? - Factories in Poland

Potato chips is a treat which was popularized in the 19 th century by the Americans. Today chips are enjoyed all over the world, and have become the staple of every party, being a favorite snack, e.g. when watching soccer games. We wanted to see how the popular Lay’s chips are made and decided to visit the PepsiCo production plant in Grodzisk Mazowiecki. Before we enter the premises, it is necessary to observe the current pandemic-related restrictions and requirements. Thanks to them the plant has been able to safely continue the manufacturing process throughout the lockdown and beyond. In order for chips to be made, we need potatoes. PepsiCo is one of the biggest buyer of the crop in Poland. Each year the company contracts approx. 240,000 tons of Polish potatoes. The unloading of potatoes is fully coordinated with the manufacturing process. Fresh potatoes are processed on an ongoing basis, therefore there is no need for storage. Initial sorting and washing are carried out at the provider’s site, i.e. at the farmer’s. Lay’s chips are made using the highest quality potatoes sourced from 70 farms located across Poland. In 1993 PepsiCo initiated the farming program which provides for close cooperation with Polish farmers. The company offers its partners the required know-how, seed potatoes, and tools required to farm potatoes. Using transmission belts the unloaded potatoes are moved to the washing station. Potatoes are driven using water as the transmission agent, which helps to remove any foreign material. The water necessary for the process is re-used. It’s time to peel the potatoes. Having weighed the required amount, the potatoes are moved to the peeling machine which is a cylindrical container. The walls of the drum are covered with an abrasive surface over which the potatoes move. This is how the thin layer of the potato skin is removed, retaining the nutritional values found directly under the skin. The peeled potatoes are transported to a quality control station. A state-of-the-art machine rejects produce with visible defects, such as dark spots or grazing, which may be detrimental to the final look of a chip. The selected potatoes are then carried to the cutting heads placed in drums. The walls of the drums have special blades installed. These can be flat, for making regular, traditional chips, or corrugated, for making wavy chips. On entering the drums potatoes are set to rotate and the blades cut the potatoes with high precision – to the hundredth part of a millimeter, which then ensures uniform frying and the required texture of the chips. The plant manufactures 5 types of chips in over 40 different flavors. The chips are then dried and transported to the chips fryer machine. They are fried in a hot blend of sunflower and canola oils. The chips fryer features a state-of-the-art quality control mechanism which photographs every single chip. The product must meet the highest quality standards. The fried chips must now be seasoned. Natural blends of seasoning are used, including chili, pepper, or dill. A few rotations of a special drum are enough for the chips to be well coated with seasoning. As the chips are hot, the seasoning easily sticks. From the drum the chips are transported to the packaging line. This is where the chips are weighed. Each of the scales is equipped with 16 trays. The computer-controlled dosing units move chips from the trays so the actual package weight corresponds to the value shown on the pack. Individual flavor packaging film rolls are used and chips are pushed to a foil sleeve which is then formed using a special flange. Once the required dosage has been made, the pack is heat-sealed at the top and cut off. 3 kilograms of potatoes need to processed to produce 1 kilogram of chips. The ready packs are placed in cartons. One of the 14 autonomous robots places the cartons on pallets. The product is then moved to the storage area. Each day over 100 trucks containing potato chips leave the PepsiCo plant in Grodzisk Mazowiecki, to be delivered to customers across Europe. -- Factories is a journey through production plants. We are visiting industry. We were inspired by the popular program "How it's made?" Known from the Discovery television channel. Every week, together with our viewers, we visit the production plant to check how the selected production process is going. Every week, our channel receives a documentary film, from which you learn how things are produced. Among others machines, rope slings, yachts, wires, windows, railroad switches, radiators, polystyrene etc. You are probably also interested in how food is made? On our channel we showed, among others frankfurters, Pepsi, kebab, salty sticks, mustards, ketchup, mayonnaise, cheese and many more. It's amazing how exciting production can be. Science and technology carry so much interesting information. Every week you get to know with us the curiosities of factories. The factory has no secrets for us.