A Deep Look into the Lays Chips Factory | How Fresh Potato Chips are made
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- Опубликовано: 19 дек 2022
- A Deep Look into the Lays Chips Factory | How Fresh Potato Chips are made
Hello, and welcome to today's video. In this video, we will be taking a deep look into Lays Chips Factory, explaining how potato chips are made in the factory. But before we begin, make sure you subscribe to this channel and give this video a like. Let us proceed.
So, Lay's is a brand and the name of the company that founded the chip factory in the United States. The factory is also sometimes referred to as Frito-Lay, and this is so because both Lay's and Fritos are brands sold by the Frito-Lay company.
All the potatoes would come directly from the field. Some of them are stored, and some get shipped for processing the chips. Regarding the manufacturing process, when the potatoes arrive at the plant, they are always examined and tested for quality. A half dozen or so buckets will be randomly filled. Some of the potatoes are punched with holes in their cores in order to track them through the cooking process. These potatoes will be perfectly examined for blemishes and green edges. They will now weigh the pile of defective potatoes. During the weighing process, if the weight exceeds a company's preset allowance, it is highly possible for the entire truckload to be rejected.
The potatoes move along a conveyer belt to the various stages of manufacturing. These conveyor belts are powered by gentle vibrations to keep breakage to a minimum. After this is done, the potatoes will be loaded into a vertical helical screw conveyer. This makes stones fall to the bottom and pushes the potatoes up to a conveyer belt to the automatic peeling machine. After the peeling has been done, the potatoes will now undergo a complete washing process. By this, they'll get the starch off, rinse or soak the potatoes for about an hour. This process will help remove some of the starch from the surface and prevent the sugars from browning before the potatoes are processed.
After the washing process, the potatoes are now sent to a peeling machine using a professional electric potato peeler. This peeling machine makes quick work of all potato peeling needs with an incredible output capacity. The electrical components are always protected in a sealed box to ensure safe operation. The potatoes pass through a revolving presser that cuts them into paper-thin slices. There are straight blades that produce regular chips, while rippled blades produce ridged potato chips. The slices also fall into a second cold-water wash. This also helps remove the starch released when the potatoes are cut. Most manufacturers who market their chips as natural do not always wash the starch off the potatoes. There are times when the potatoes need to be chemically treated to enhance their color. This is where the process is done. The potato slices are immersed in a solution that has been adjusted for hardness, pH, and mineral content. Manufacturers treat potatoes with chemicals, including phosphoric acid, citric acid, hydrochloric acid, or calcium chloride. This helps in reducing the sugar level and the product's color. The bags are designed and printed, stored on rolls, and brought to the assembly line as necessary.
So, once the potatoes are peeled, they are now ready for cutting with a cutting machine. With this cutting machine, those potatoes will be cut with ease, no matter what shape of potato the factory wants to cut. This cutting machine will cut the potatoes effectively in half the size of a good chip.
During this packaging process, the potato chips are conveyed to a packaging machine with a scale. However, the preset weight of chips will initially be measured. Once it's measured, a metal detector checks the chips once again ore for any foreign matter. At times, some metal pieces could have come with the potatoes or been picked up in the frying process. So, this metal detector checks this very well. After that, the bags flow down from a roll, and a central processing unit code on the bag informs the machine how many chips should be released into the bag.
Also, the filling process needs to be accomplished without letting an overabundance of airflow into the bag. This helps prevent the chips from breaking. Although many manufacturers utilize nitrogen to fill the space in the bags, it isn't a bad strategy. The sealed bags are then conveyed to a collator and then hand-packed into cartons. Also, some companies pack potato chips in I-O cans of different sizes. After this, the chips flow down a chute into the cans. And then, the workers weigh each can and make all necessary and important adjustments or corrections.
Once the work is perfect, they now attach a top to the can. It's as simple as that.
Finally, you should understand that potato chips show no sign of declining in terms of popularity. However, the public's high demand for low-fat foods has put most manufacturers on a fast track to manufacture a reduced-calorie chip. 
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AND if you’re lucky, you’ll get at least 5-6 chips in your bag of air!
Exactly right
💯 best comment
That are smashed and broken--
Air is heavy.lol
The .OZ on the bag are the weight of the chips. Air is so the product doesn’t crumble. Air is weightless
In 1st grade my class took a field trip to the local potato chip factory. It was the greatest day of my life.
I don’t know if that is a good thing or not
@@jizzyboof8166How is that a bad thing??
Lay's has too many flavors , some gross , and today there's more air than chips in the bags ! I buy a bag , it's not even half full yet the bottom has tiny pieces in it making the weight cause there aren't 7 some ounces in a bag ! Now they stop putting a price on the outside to charge any price !
How many potatchip they gave yiu?
@@Prisedoesanimations if that’s the greatest day of his life that’s pretty sad 😂
My first job was working for a stationery company who had the Frito account. Fritos off the line every visit. At 77, this memory still drags me to the Frito rack every time!
I bet they are so much better off the line than once they hit the stores.
Packet filled with 30% Chips and 70% Air😀😁😂
Frrr i wanna know what fresh junk food tastes like😋@jacobshort5378
When growing up in south Alabama in the 60s, we all grew tons of potatoes that went to Lay's and Golden Flake.
All those fields and potato sheds where the field trucks would take the potatoes to be prepared for shipping are gone now and filled with suburban houses.
And thoes day you could buy a family size full bag of Lays chips for .59 cents.
Now you buy a bag of air for 6.99!
And I remember growing up the commercial slogan for Lay's chips was." BET YOU CAN'T JUST EAT ONE." Well, you can now. Because that's all that comes in a bag!!!
Ok, they are yummy, because they are full of flavour, but they have absolutely no nutritional value in them whatsoever. In fact, they are very unhealthy, and if eaten regular, or even over periods of time, along with other junk food, it can and will cause all sorts of health problems. I know I'm a kill joy, but I've cancer, (and am starting to cure it.) There will be no junk food for me for a very long time 🙅♀️.
I'm more amazed that humans actually invented that entire production line from scratch.
Yes, and then an AI bot described it for this video... :(
We did not invent production lines from scratch.
I'm more amazed that humans created artificial sweetener, a great contribution to the Galaxy.
@@madnessbydesign1415right… ruins the entire video…
Packet filled with 30% Chips and 70# Air😀😁😂
1972 found me starting my career as an engineering draughtsman in a Scottish company who made food machinery including chip/crisp plants, nice to see the up to date version and yet not a lot has changed in fifty years.
If ain't broke right? LoL 🤣
Me too but I was a draftsman. I later used that training as a recruiter for the Marines.
I was once addicted to Lay's Bar-b-que potato chips. Scrumptous!
Still my favorite chips since I was a kid lol with some Valentina sauce taste even better
my wife beats me
Eating them rn
So, the oils got cheaper and the price went higher. That's my deep look at Lay's.
I would love if they created a separate version using butter rather than seed oils.
Meantime, I make my own :-0)
There'd be a correlation there if the only cost was oil.
Electricity prices have gone up, as did transportation and price of food.
That means higher production costs, even after deducting oil price.
I used to work for them in the truck shop and on my break i would go in the back door of the plant and get me a hat full of hot fresh chips right off the line, they were dam good.
you just stuck your hat right in there?
yes that was 1982 i dont think they would let anybody to it today@@wassytrini
@@wassytriniand that’s how Covid started
😂😂😂@@kidgoku23
Respect 😂
Potato chips are my kryptonite - can't have them in my house. And Lays is the absolute best. I love these types of videos to see how things are made/done.
Same. They are addictive .
A man was applying for a job at "Lays". The interviewer had a half filled glass of water on his desk. He asked the man who was applying for a job "Do you see a half empty glass or a half full glass?". The man said I see a full glass! ". "Your hired" was the immediate reply.
You're, not "your."
I see a glass that is twice as big as it should be .
Their bags of chips are only half full too.
right, I know better @@rand49er
@@mikehunt-fx7sfThat's why the guy got hired
Having adhd is like: I’m going downstairs to get a sheet, “humm I have Lays, I’m going to eat”, “how are they made?”, video, video ends, my potatoes too and now I feel guilty because I totally diverted the focus of my day
Im supposed to be doing masters degree work but instead my brain sees this video on youtube and says this is much better!
I am amazed by how much was skipped, how much was shown that wasnt what he was talking about at that time, and how little was actually shown.
Yeah… huge disappointment!
Ya, like what temp do they fry the chips at for how long.
My part of the process was shown.
I'm wondering if this is even a Lay's factory or did a bot just get a bunch of stock chip manufacturing clips from google and stitch them together with an A.I. script. Suddenly at ~4:50 they're now in India, as Kurkure is an Indian brand of chips. Pretty incoherent all around.
watch again at 4:20
the filled bags are sealed
then the chips fall in the bag
There’s a Lay’s factory right by our house. We drive past it all the time. On the days that they’re cooking the smell is divine.
Also, though I’ve never tried it, I’ve heard that if you have them fresh from the factory you’ll never want to eat store bought again.
You can recreate fresh from factory by putting ur bag of chips in oven at 250 for 7 minutes
They fry everyday along with numerous other types of chips(I’m a fry operator for frito lay)
Can I just position my wide open mouth at the end of the potato chip conveyor belt?😅
@@psoteriou3884 Let me know if they let you. I'm in! :0]
I bet they taste better fresh 😭 I made fresh chips before though at home and they indeed were quite good
In Russia a 140 grams (4.9 oz) Lay's package priced at $1.90. A standard wage is $179 a month. So one month wage buys just 94 packages of Lay's.
That’s three whole bags a day everyday! What a steal
Must suck to be Russian.
Lays, nobody can eat just one. 😋❤
Nitrogen is usually added into the bag before sealing to help keep the chips from going stale, as well as to turn the bag into a pillow so the chips don't get crushed during handling.
Tech shoot? That looks like we might meet to take photos of snack food deserts together! Yes!
I absolutely love Frito-Lay’s products. It brings back memories of a time my family would go on picnics or trips. The conversation we had while snacking doing housework or homework. Yea Frito-Lay has been in or family and hold something very dear to me and my heart. My family.
Same.
bot account
LAYS PEOPLE CAN LOVE
I live in an area that grows potatoes and many of them are sold to Lays. Lays are the best chips out there , hands down. All versions, but I'm especially fond of the Classic, barbecue,, and ketchup chips, which, as far as I know, are only sold in Canada. I love Lays products.
I love eating chips but when Lays started charging over $5 a bag I quit. Wise and Utzs make some good chips that don't cost 5 bucks.
Martin's Kettle Cooked are superior to Lay's.
Ketchup chips are sold in canada only pretty sure all dressed are only in canada too
@@carlbrutananadilewski Kettle cooked 'potato chips' are a bastardaizaiton of the art of potato chips. Thank you.
Old Dutch and herrs are really good too. Dare I say better than lays
Lay's classics , a true theobromine.
A Lays Chip bag freshly opened is the BEST
Lay’s Classic will always be the standard by which I rate all others.
They also have what I consider the most successful advertising catch phrase in ‘ No one can eat just one’ . I still repeat it in my head every single time I eat them, because when you first start and subconsciously decide how much you are going to have, you can automatically rule out just one
I always knew the slogan as "Betcha can't eat just one"
Sorry to hear that.
Lies again? Polite Chef Potato Chips
After watching this I'll make my own chips!!!!!!!
This reminds me when I worked at General Mills. How we packaged bags of chips. Very fast paced
Hi Everyone @ Tech Shoot I Really Enjoy Lays Salted And My Favourite Lays Chips Is Spring Onion And Cheese And The Salted Ones Are Delicious Too Sooooo Deeeeeelicious And Sooooo Frrrrrreeeeesssshhh 👍👍❤️❤️ Thank You So Much For Sharing Your Beautiful Video 👍👍📸📸📷📷👍👍❤️❤️ @ Tech Shoot
Their chips are too greasy and too salty. Not to mention crushed to bits. 😣
Not at all, but mine are from Walmart, and they are fresh and good. I'm not saying yours weren't stale or broken, but where did you buy them? Was it in a high turnover store?
A bag full of air gives the impression that the bag is full. As I discovered yesterday the family size was only half full!
I Am In South Africa Just In Case You Are Wondering How Far These Beautiful Delicious Chips Can Travel Fresh And All In One Piece Thank You So Much For Sharing Your Beautiful Video @ Tech Shoot 👍👍📷📷📸📸👍👍❤️❤️
My two cats who are a year old absolutely love Lay’s Classic chips. It was accidental because I had dropped a chip on the floor and they ran to it and ate it. I have attempted to give them off brand Lay’s but they know the difference by smelling them and get mad and walk away. Lay’s are worth the price honestly but I wish they would lower them
Our Boxer Used to Love Chips but would not eat Pretzels..
Source: Google: The price printed on the front of chip bags is the manufacturer's suggested retail price (MSRP). This is the price recommended by the manufacturer, but it's ultimately up to the retailer to decide the actual selling price.
I love the lays sweet and spicy honey chips so amazing 😍🤩
It's amazing how heavy air is !!
I have worked in a Lay’s. In the potato storage room there were rats as big as cats running around all the time. They never did anything to kill them. If you have ever smelled a rotting potato that is what this room was like only worse. No more potato chips for me. They call this a deep look they didn't look deep enough.
As a kid, I loved factory tours. The best was the Hershey factory. Toured the Wise Potato Chip factory and was disappointed to only get a very tiny bag of chips.
Wise chips are known notoriously as being extra-greasy. They're definitely a distant 3rd or 4th place to Lay's.
How crappy Cheap of them to hand you the infant-size bag and pose as if they gave you something. 👎🏻😡
How y'all know my vice is a cold drink & Lay's potato chips!
(cell phone listening)😅
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I love Lay’s! Best bbq chips in the world! I can’t eat just one.
American classic wth ham and cheese sammy
A Deep Look into the Lays Chips Factory | How Fresh Potato Chips are made 1023am 30.9.23 i thought Lays was walkers under a different moniker..(?)
LOVE LIMLON LAYS POTATOE CHIPS❤
A bag of air, plus broken chips that are usually greasy!! Last week I got 20-30 pieces of broken chips. Took them back to the market and 5 other bags were all crushed!! Gonna try a different store!!
If I worked @ a factory that made Chips, I would eat their inventory and get fired 😅😂
who's watching here while eating Lays?
I hate it when a narrator says, "Before we begin, give this video a 'Like'...etc when we haven't even seen the video!
The potatoes used in Lays are a proprietary strain of the Russet. They developed this potato just for their chips.
You Cannot buy this in your supermarket. They grow and harvest all of them in their own fields. I worked in a FL
plant for 30 years. They use and insane amount of RR tank cars of corn and oil.
They probably are bred to have the highest salt content
@diytwoincollege7079 idk about that but I do know they have fields in MI and take those yields to the NC plant.
Well, I've picked up a 53' van load of (non Frito Lay) potato chips in Texas, and delivered them to what was supposed to be a Frito Lay in Los Angeles!
Frito-Lay is owned by PepsiCo
I love Lay's potato chips. The "lightly salted" ones are my favorite.
Same here-more spud-flavor, less salt flavor--
@@jackprier7727 Exactly! They're so good.
Beautiful, Holistic, Process of the creation of a single plastic bag of potato chips
Subbed & Liked! Enjoyed the video! Good work & God bless in ‘24!
They neglected to show the guy at the end of the line who squeezes every bag " Just to make sure they're full". 🙏❤☺
I'm the guy who stands at the chips isle not being able to decide between BBQ or regular Lay's chips so I buy both big size bags. 😑 lol
I don’t like people who pull burnt potato chips out. That’s like pulling the surprise out of Cracker Jacks.
Yeah, they should sell these in bags separately-
I just saw the green one that was in my bag!
I used to work for Tom's in the 70s! I already know!
The highest paid guy is the one who pumps all the air into the bag.
That's my favorite chip potato 🥔 but expensive as good to eat. 😊
I can't think of a more MIND NUMBING JOB than watching acres of chips flow by like a river.... hour after hour after hour. I wouldn't last even one hour at ANY payrate.
The special gmo tatas lovely
Me watching this while eating Lays Ripples chips 😋
2:58. Some nice acids there. Phosphoric acid is the principle ingredient of rust converter.
Nice one, I like that brand very much indeed, I thought they originally were from Romania.
Brave people for showing their faces here. They’re responsible for customers having half empty chip bags
Use to like these but now we get half as many chips for a higher cost! We no longer buy them. So sad……greed is there!
Neither do I.
This looks like an Infomercial
Boulder Canyon chips cooked in olive oil beat anything Lays ever produced with their hydrogenated seed oils
Lays factory does a great job, it’s your distributors to the outlets to your merchandiser’s who mess it all up by the time it gets to your house, perfect that process and you will be excellent.
Footage did not match the narration but was still interesting
Selling air with some 5 to 6 chips is good business.
Fredo ban dito.
Remember as a kid being able to go in and get a bag off a belt right out of fryer. Try that today.
Interesting how the build the aire.
In my younger days, 60+ years, there used to be 2 full size bags within 1 big bag; I can’t say I remember the price of it, but 1 of those 2 bags was big enough for a family. We used to save the other bag for another night. I only wish that were the case nowadays…
ah yes.. the air factory
I’m so high rn & was looking at the back of my chip bag and i wondered if what ingredients they use
Packet filled with 30% Chips and 70% Air😀😁😂
Don't forget the dip,which is good
Lays always slaps
Wow. Chip
Would lays dare to comment on the nutritional aspects of their total process?
Of course not and read the ingredients on the back, it's full of chemicals
@@Y_hasswhich are edible and safe if you don't consume them by tonns
@@UsuallyDestroyer So is poison if you don't consume too much, but it will eventually catch up to you.
The FDA is corrupt and will approve anything that doesn't kill the rat or rabbit on the spot lol. Long term health effects and developing deadly diseases? who cares they say.
I've been eating them all my life, and I'm 64...I think potato chips are the least of our troubles...but if you have to use nutrition in a way that you think makes you seem intelligent, by all means...
@@UsuallyDestroyer
Each non-biological ingredient separately potentially could be safe, but there are hundreds of biological and non-biological ingredients that add up to more than 1500ppm of the average US diet. (The upper limit for the single additive BHT is 50ppm.) The synergistic effects of this combination is entirely unknown, no study has taken place to assess the impact, and when the known side effects are taken into consideration, it is not unreasonable to presume (guilty until proven innocent!) that these additives do real harm.
Its all bag of air,lol
My favorite chip!
Classic Lays are my favorite chips but I rarely if ever eat chips anymore. Can’t stop once I start 😂
I love potato chips potato 🥔 🍟
Me too. But to be honest, I love potatoes in any form.
The only thing this video doesn't explain, is which type of potato they use. They don't look like Russet potatoes. Which type of potatoes are used?
Wooow nice😊😊😊😊👍👍👍😋😋❤❤❤❤💜💜💜
In the UK they are called "Crisps", while chips as much the same as French fries.
Chips are just hit and miss. Sometimes you get a bag that doesn't seem too greasy and just are yummier. Then, other times, they just don't cut the muster. Or they change an ingredient. 'Natural' Ruffles with Sea Salt are a prime example. When they came on the market (around 2000), they used an expeller-pressed oil of some kind, potatoes, and sea salt. Now they're not as good. Why? They changed to a non-expeller-pressed oil. Cheaper for them but really killed the quality of the product. At nearly $5 a bag I expect more.
The biggest fault is when the oil is not changed often enough, and it tastes rancid.
@@mrsillywalk They use hydrogenated seed oils so all their products are poison from the start
They sure are good
My favorite Chips are swiss Zweifel chips ;)
I want to work at that factory
I used to love bbq Krunchers.
They really are paying attention to nutrition minus faltu additives taste enhancers or chemicals, good, at least some value in these snacks
When u begin to enjoy the chips it finishes. U do not hv total satisfaction of enjoyment
Those are great
I’d be making my chips 🍟 at home from now on. They process them in rancid oils like vegetable or sunflower oils at high temperatures and add artificial flavours to make them tasty
So what happens to the truck load that gets rejected? Is it just dumped somewhere or used somewhere else?
If I had to guess, it would go to animal feed
Few years ago i hauled bulk potatos and if they refused them they would go to another chip manufacture.@@xtremememestv1717
Probably bought by competition!
McDonald's?😅
Very Nice 🙂
I wish they would make a No Salt Lays chip. I know I tried the LOW Salt but I want NO SALT
I miss the flavors When Lay’s was made with Hidden Valley.
Lay's potato chips always been my favorite