Course:FNH200/Projects/2025/Lay's Potato Chips

Introduction & History

Lay's Potato Chips

The potato chip’s origin is traced to George Crum, who made ultra-thin fried potato slices in 1853 at Moon’s Lake House in Saratoga Springs, New York, to satisfy a customer complaining about soggy fries. Those crisp, salted slices, quickly became known as “Saratoga Chips” and grew into a beloved American snack.

In 1932, Herman W. Lay launched his potato chip business in Nashville, Tennessee, selling chips directly out of his car. By 1939, he acquired a small Atlanta-based manufacturing company and renamed it H.W. Lay & Company. By the late 1930s, Lay's was the first snack food producer to advertise on television and distribute chips throughout the Southern United States.

Manufacturing & Processing

Lay’s potato chip manufacturing process begins with sourcing high-quality potatoes from dedicated growers and ensuring consistency in size, sugar content, and texture. According to PepsiCo, most potatoes are harvested and delivered to the factory within 24 hours to maximize freshness, with 40% going directly from the field to processing without storage. In fact, PepsiCo has invested in developing thousands of potato varieties annually to meet strict standards for chip-making.

At the factory, the potatoes undergo a cleaning and peeling process. Dirt and debris is removed through washing. They are then peeled using high-speed abrasive machines. After peeling, the potatoes are sliced into thin and uniform pieces using rotary slicers. These slices are then rinsed again to remove surface starch that can negatively affect texture during frying.

The next step is frying. The potato slices are fried in sunflower oil which is known for its high smoke point and neutral flavour for frying chips. It was introduced by Lay’s in 2006 as a healthier alternative to eliminate trans fats. The slices are cooked in continuous fryers under carefully controlled temperatures to ensure they achieve the ideal crispiness and golden-brown colour. After frying, the chips move through automated quality control systems where high-speed cameras and air jets remove burned or flawed chips. Human inspectors also check samples regularly to maintain taste and texture standards.

Seasoning follows the inspection process. Chips enter large seasoning drums, where they are sprayed with oil and coated with flavor powder while tumbling to ensure an even distribution of seasoning across every chip. After seasoning, the chips are sent to the packaging area where they are measured, bagged, and flushed with nitrogen gas.

Packaging

Multihead Potato Chip Weigher

Chips are fed from a conveyor belt onto a multi-head weigher, and the weighers select the best combination of heads to achieve the desired packet weight. The chips drop into an open packet chute, which is then sealed top and bottom by heated jaws and cut to length by a knife. As the chips fall into the packet, a check is performed to reject any packs containing foreign bodies.

Potato Chip Bag Structure

The Lay’s bags are made from Biaxially Oriented Polypropylene (BOPP) on the inside, a low-density polyethylene (LDPE) in the middle, another middle layer of BOPP, and an outer layer of Surlyn, a thermoplastic resin. Both BOPP and LDPE are resistant to oils and grease, and BOPP is an excellent moisture barrier. To further strengthen the material, some chip bags feature a thin aluminum coating on the inside.

Lay’s packaging must adhere to Division 23 of the Food and Drugs Act and Regulations, Section B.23.001. Each packet of chips is stamped with a special code so Lay’s can trace when and where the products were made, along with a best-before date.

Nutritional Values

Potato Chip Nutritional Values

Lay’s potato chips are primarily composed of three key ingredients: potatoes, vegetable oil (such as sunflower, corn, or canola), and salt. While simple in formulation, the chips are calorie-dense and high in fat and sodium, making them a snack best enjoyed in moderation.

A standard 28-gram (1-ounce) serving of Lay’s Classic Potato Chips contains approximately:

• 160 calories
• 10 grams of total fat, including
  • 1 gram of saturated fat
  • 0 grams of trans fat
• 170 milligrams of sodium
• 15 grams of carbohydrates, with
  • 1 gram of dietary fiber
  • 0 grams of sugar
• 2 grams of protein

The majority of calories in Lay’s chips come from fats and carbohydrates, with minimal protein or micronutrient content. They are not a significant source of vitamins or minerals, although trace amounts of potassium or iron may be present depending on the potato variety and preparation process.

Lay’s are also gluten-free, making them suitable for individuals with gluten intolerance or celiac disease, provided that cross-contamination is not an issue during manufacturing.

Lay’s chips are an calorie-dense snack with high fat and sodium content but limited nutritional value in terms of protein, fiber, and essential nutrients.

Preservation & Storage

Preservation

Lay's potato chips are primarily preserved through a method known as nitrogen flushing, a common technique in the food packaging industry. This process involves replacing the oxygen inside the chip bag with nitrogen gas, which helps maintain product quality and extend shelf life. Although often mistaken for regular air, the gas inside a Lay's potato chip bag is nearly pure nitrogen.

The use of nitrogen prevents oxidation, a chemical reaction in which oxygen reacts with fats and oils in the chips, leading to rancidity and staleness. Since nitrogen is a non-reactive gas, it does not contribute to these chemical changes. Secondly, the nitrogen gas creates a cushion inside the packaging that helps protect the chips from damage during handling and transport. The establishment of a "nitrogen atmosphere" is beneficial for products prone to oxidation, such as potato chips. This technique allows products like Lay’s potato chips to retain their original texture and taste throughout their shelf life.

Storage Methods

Potato chips should be kept in cool, dry environments to prevent staleness and moisture absorption. Packaging must remain tightly sealed to limit exposure to atmospheric air, which can lead to oxidation and loss of crisp texture. This can be achieved through using airtight containers or by minimizing excess air within the original packaging . In regions with high humidity, refrigeration or freezing is sometimes used as an alternative storage method to provide dry and cool environment that does not result in chip thawing or texture changes.

Health Effects

Lay’s potato chips, like most fried potato snacks, have notable health drawbacks stemming primarily from their high fat, sodium, and carbohydrate content. Potato chips typically contain up to 43 % fat and over 64 % carbohydrates, with saturated fatty acids accounting for more than 39 % of total fats. Their lipid profiles often display poor unsaturated-to-saturated fat ratios and elevated atherogenic and thrombogenic indices, which are strong correlated with increased cardiovascular risk.

Moreover, chips frequently include degraded and trans fats formed during repetitive frying, which can promote inflammation and further elevate heart disease risk. High sodium levels contribute to hypertension, another driver of heart disease.

The chemical process of frying at high temperatures also leads to the formation of acrylamide, a compound considered potentially carcinogenic and neurotoxic, even though its role in human cancer remains under study.

Importantly, regular consumption of fried potato chips raises the risk of developing type 2 diabetes by 20% for those eating them three times per week.

Regular intake of Lay’s potato chips contributes to increased risks of obesity, cardiovascular disease, and type 2 diabetes due to their high levels of unhealthy fats, sodium, and processing-derived compounds.

Potential Exam Question

Question: After deep-fat frying, potato chips are prone to quality deterioration due to oxidation. Which of the following strategies is MOST effective in preventing oxidation and preserving chip quality?

A. Using transparent, resealable plastic bags to allow consumer inspection

B. Incorporating oxygen absorbers and flushing packages with nitrogen gas

C. Storing chips in high-oxygen environments to prevent microbial growth

D. Coating chips with additional oil to create a protective barrier against air

Correct Answer: B. Incorporating oxygen absorbers and flushing packages with nitrogen gas

Explanations to Incorrect Options:

A. Transparent bags allow light exposure, which can accelerate oxidation and cause light-induced rancidity. Resealable bags may not be airtight, allowing oxygen to enter after each opening, speeding up spoilage.

C. High-oxygen environments increase the rate of oxidation, which is the opposite of what’s needed to preserve chips. Also, microbial growth is not a major concern in low-moisture foods like chips, oxidation is the bigger issue.

D. While oil might superficially reduce contact with air, it actually introduces more fat that can itself oxidize, making the problem worse. It also doesn’t effectively block oxygen from reaching the chip surface.

Why Should this Question be on the Final Exam?

This question should be on the Final Exam as it incorporates topics learned in class relating to oxidative rancidity (Lesson 5) as related to the development of rancidity in deep-fried foods due to the reaction of oxygen with fats. Also, this question incorporates the drying method of deep-fat frying (Lesson 8) as to how the chips are manufactured when the hot oil causes the water in the food to evaporate rapidly, thus giving potato chips a low water content but a high oil content. It also relates to the ideas of packaging requirements for dehydrated foods (Lesson 8) as packaging materials should prevent interactions with oxygen and light and further protect against moisture absorption.