French Fries Process Line in industry.pptx

Attached Presentation declared all the major steps for the process of French Fries Production at industrial level.

Muhammad Ahmad
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1. French Fries Muhammad Ahmad BS ( Hons ) Food Science & Tech FSSC 22000 V 5.1 Lead Auditor Raw Material Process Flow Utilities By Products

2. Raw Material Potato Lady Rosetta (L.R) Sante Asterix Mozika Russet Vegetable Oil (Palm oil, Palm Olean)

3. POTAOES Quality and variety of potatoes plays a major role in the final product quality of French fries. There are multiple varieties of potatoes in Pakistan market used for the production of French fries L.R, Sante , Mozika Astrex , Alverstone etc. Lady Rosetta (L.R) is the most used potato in the industrial line manufacturing potato chips, Potato sticks, and French fries. High Dry solids (24% - 26%) in L.R makes this variety more crisp and attractive with it’s golden brown color at the consumer end. Other Potatoes varieties like Sante , Mozika , Astrex etc having less dry content (18-20%) and high moisture comparative of L.R that makes them less crisp and taste difference at consumer end Lady Rosetta (L.R) SANTE Mozika

4. Its two major uses are for making French fries and use as a baking potato. Russet Burbank is probably the most studied potato cultivar in North America and is considered standard of comparison for French frying. It is an indeterminate variety whose vine is large, vigorous and spreading, and has a late maturation. Having low sugar. Taste  -- rates very high in taste testing panels for both frying and baking Storage  -- Stores very well for a long period; sugars kept low RUSSET BURANK

5. Process Flow Peeling & Trimming Drying Cutting or Slicing Blanching Par Frying Blast/Quick Freezing Packing Sliver Removal

6. PEELING & TRIMMING Peeling is the process in which Potatoes skin is removed with continuous washing. Peeling loose is minimum with smooth potatoes. Peeled and washed Potatoes trimmed manually during which process residual skin, eyes and green portions removed.

7. CUTTING or SLICING Peeled Potatoes are cuts into sticks, lengthwise to get long cuts. The Cross Section of sticks ranges between 8 to 10mm and the length of sticks can be 6 to 8cm.

8. SLIVER REMOVAL The sticks are graded to size, Too short and thin sticks are removed

9. BLANCHING The sticks are blanched in water 70 to 95 o C for several minutes to inactivate enzymes. The procedure also results in removal of some sugars from the surface of sticks, resulting in uniformity of color ins sticks. This step also contributes major part for making inside softness in final product.

10. Drying After blanching, sticks are partially dried to remove excess moisture. Water content should be around 70-75%

11. PAR FRYING Frozen French fries are par-fry at process line before final frying for consumption, The sticks are fried at 160 o C to 180 o C for 1 to 3 minutes

12. BLAST & QUICK FREEZING The Final step is blast freezing of the sticks. Blast freezing is the method that freezes the French fries which travel down on the wire conveyor using air to cool down sticks temperature. Blast Freezing took the sticks temperature to -20 to -25C

13. PACKING Frozen French fries are than packed into bags as desired weight e.g 0.5 kg, 1 kg, 2 kg etc. French Fries stored at maximum of -18 o C

14. UTILITIES Two major utilities are required for the plant operations Electricity Gas Water (RO)

15. BY PRODUCTS Here are too many products that can be processed with the sliver removal of sticks & rejected potatoes during grading. Following are some examples of by product: Potato Samosa Potato Nuggets Potato Smilies