Sneak Peek Inside Lays Factory

According to a traditional story, the original potato chip recipe was created in Saratoga Springs, New York on August 24, 1853. Agitated by a patron's repeatedly sending his fried potatoes back complaining that they were too thick and soggy, resort hotel chef, George Crum, decided to slice the potatoes even thinner. Contrary to Crum's expectation, the patron (sometimes identified as Cornelius Vanderbilt) loved the new chips and they soon became a regular item on the lodge's menu under the name "Saratoga Chips". [wikipedia]

Lays potato chips have been in production since 1938. Today the company, Frito Lay, is one of the leading manufacturers of salty snacks in the world as well as in Russia. Delivery of chips, namely Lay's, in Russia began in the mid 1990's, and in 2002 opened its first factory, Frito Lay Kashira near Moscow.

Sneak Peek Inside Lays Factory
1. Topic of today's reportage - a plant of PepsiCo for the production of potato chips Lay's, recently opened in the city of Azov, Rostov region. In addition, the plant produces crisps Hrusteam. Walk sequentially along the entire line production and consider it in detail.


Unloading, cleaning and temporary storage of potatoes

Sneak Peek Inside Lays Factory
2. Every day here is unloaded nine 20-ton truck with potatoes. Potato conveyor conveyor enters the washing machine, which is used to clean water recirculation. Anything in the world, there are three such automatic car wash. The process of washing to remove physically impossible, everything is done in closed containers. After washing the potatoes are in temporary storage in bins - special tanks, from which, as appropriate, applied to the production.


Cleaning, sorting and cutting potatoes

Sneak Peek Inside Lays Factory
3. Before, the tubers fall into a special machine for cutting, the inspector visually inspect the tubers going to tape, and if necessary remove visible defects.

Sneak Peek Inside Lays Factory
4. By the way: For the production of chips is not suitable any potatoes. There are so-called chipsovye potato varieties that contain high amounts of starch.

Sneak Peek Inside Lays Factory
5. All employees undergo periodic medical examinations and have a medical book, it is done to a sick man did not get to production. In addition, before entering the shop, everything must wash their hands.

Sneak Peek Inside Lays Factory
6. Shoe potato occurs in abrasive drums batch. First, boot from the required number of potatoes in the weigh hopper, then there unloading the drum.

Sneak Peek Inside Lays Factory
7. Directly cutting occurs mechanically by the rotation of a conical bottom of the drum. Inside cutting machine eight pairs of sharp blades that cut the tuber into thin slices. The thickness of each slice of less than two millimeters.


Roasting

Sneak Peek Inside Lays Factory
8. After cutting potato slices are received in the heart of the production line of chips - frying bath roasting slices and obtain basic chips. This equipment has no analogues have been created specifically for the plant PepsiCo and show it to be.

Sneak Peek Inside Lays Factory
9. Thinly sliced potatoes come in a bath of oil, which are fried for three minutes at 180 degrees Celsius. Quality oil, as well as high-quality potato - the basis of the taste of potato chips.

Sneak Peek Inside Lays Factory
10. The factory has been improved recipe, using a special blend of vegetable oils, including sunflower oil vysokoolinovogo local production, through which 25% reduced content of saturated fat in the final product.

Sneak Peek Inside Lays Factory
11. Daily at the plant being tested quality products. Check how the basic chips, only coming out of the oven, and fully packed bags.


Adding spice

Sneak Peek Inside Lays Factory
12. At this stage in fried potato chips are added to the special aroma and flavors, which are based salt.

Sneak Peek Inside Lays Factory
13. Simultaneously, the production line can go in three flavors.


Packing

Sneak Peek Inside Lays Factory
14. By the way: The plant is designed to produce 50,000 tons of finished products per year. Some kind of fantastic figure, in my opinion.

Sneak Peek Inside Lays Factory
15. For the three conveyors ready chips fed to the packaging. First is the distribution and weighting.

Sneak Peek Inside Lays Factory
16. BTW: Please note that the entire length of the line are very few employees. Here we use modern equipment that works in a fully automated mode. In addition, it is important that as little as possible people in contact with the finished product.

Sneak Peek Inside Lays Factory
17. Weight machine weigh multiple portions and calculate the best combination of weight, which is the most accurate weight in order to comply with and listed on the package weight.

Sneak Peek Inside Lays Factory
18. If we consider that the net weight of one packet is 28 grams, you can submit a precision adjustment of the equipment.

Sneak Peek Inside Lays Factory
19. The weighted portion is unloaded at the packing line.

Sneak Peek Inside Lays Factory
20. Portion control is the presence of impurities (metal detector) and falls into the bag, which by this time prepared the packaging machine of the packaging materials (foils). Before foil lids seam in the package supplied food nitrogen, which helps secure the necessary shelf life. Weighing and packaging equipment operates synchronously at speeds up to 80 packages per minute.

Sneak Peek Inside Lays Factory
21. Packed packet of crisps goes to operators who manually stacked packages in cardboard boxes.

Sneak Peek Inside Lays Factory
22. Boxes of chips formed on the pallets and transported to the warehouse.

Sneak Peek Inside Lays Factory
23. Weighting


In parallel, there is a line of crackers Production

Sneak Peek Inside Lays Factory
24. Flour mixture with water is fed into the extruder, is heated and mixed thoroughly. Dried out from the extruder in the form of bundles, which are cut to size with rotating knives.

Sneak Peek Inside Lays Factory
25. The next stage of biscuits are dried in an oven and hit the area causing seasonings.

Sneak Peek Inside Lays Factory
26. Packaging line is identical to that which produces chips.

Sneak Peek Inside Lays Factory
27. Pouring in machine.

Sneak Peek Inside Lays Factory
28. Weigh-in takes place in a similar weight machine, which generates several portions, and selects the best combination for sealing the package.

Sneak Peek Inside Lays Factory
29. Ready-made croutons.

Sneak Peek Inside Lays Factory
30. Performance of a single line - 12 tons of finished products per day.

Sneak Peek Inside Lays Factory
31. Employees are forbidden from wearing watches and jewelry, nail polish and banned artificial nails, hair must be covered mesh so that nothing fell on the conveyor.

Sneak Peek Inside Lays Factory
32. In addition to palatability and visual matching slices of the accepted standards, is check the quality of packaging. The seam should be flat and opened a pack should be one motion exactly along the seam, without breaks.

Sneak Peek Inside Lays Factory
33. Packing test.

Sneak Peek Inside Lays Factory
34. Factory team. By the way, the production line open around the clock in three shifts.

Sneak Peek Inside Lays Factory
35. View of Plant

Sneak Peek Inside Lays Factory
36. Appearance of the plant .


*Don't Miss Any New Posts-Get By Email-Send Email Address Below*
Click activation link in email
Check spam folder if you don't see email
Plus we have been known to give out a free OMGshots T-Shirt Randomly :)

Short URL for sharing


Related:

  • Cool Potato Powered Alarm Clock
  • Creative packaging design for olive oil bottles
  • Mouth Watering Gourmet Recipes You Have To See
  • 3 years old boy rescued from washing machine
  • Unusual Product Lines For Brand Name Companies


  • blog comments powered by Disqus

    privacy policy