This is a plant of PepsiCo, where chips Lay’s are produced. It has been opened recently in the city Azov of Rostov region. Let’s go over the whole sequence of production.
Uploading, washing and temporary storing of potato
Daily about nine 20-tonned trucks are discharged here. Then via the belt potatoes go to the washing machine, where they are cleaned by recycling water. There are just three such automatic washers in the world. Washing goes in a closed tank and is impossible to be photographed. Then potatoes go to the bins for temporary storing and are taken from them to production when needed.
Peeling, assortment and cutting potato
Before potatoes go to the cutting machine workers check if there are any defects on the vegetables or not. If there are some they are cut out.
There are special sorts of potato, which are acceptable for chips-making, such sorts have higher content of starch.
All the workers regularly have a medical and a certificate that they are healthy, and they all wash their hands before working.
Peeling does in the abrasive barrels with periodical moving. First needed quantity of potato is weighed in a special bunker to go to the barrel.
Cutting, each piece shouldn’t be thicker than 2mm.
The very “heart” of chips production line – a frying bath. The whole world has no analogous equipment, it has been made specially for PepsiCo and forbidden to be shown.
Thin potato pieces are fried during 3 minutes at temperature 180 degrees Celsius. Oil and potato of high quality – guarantee of good taste of chips.
Check of quality is necessary daily.
That’s the stage when all additives are added to the chips. Their main constituent is salt.
Chips of three different tastes maybe made simultaneously.
The factory may produce 50 thousand tons of ready product annually. Sounds fantastic!
As you may see not many people work here. The process is automated. It’s for the better, none of us would like to know that different people have touched your food…
Dried crust production at the same factory
12 tons of ready product each day
Stuff of the factory
The factory itself
Location: The Rostov Region