FOOD PRESERVATION (STM 3302)

DR FISAL BT HAJI AHMAD

PRESERVATION TECHNIQUE (POTATO CHIPS)

No Name Matric No

1 Azraaie bin Azaharuddin (Leader) S41684

2 Syazana binti Mat Said S44188

3 Anis Syazwani binti Zuridi S41639

4 Nor Syamhariah binti Satari S42897

1.0 BACKGROUND

Potato chips are thin slices of potato, fried quickly in oil and then salted. According to
snack food folklore, the potato chip was invented in 1853 by a chef named George Crum at a
restaurant called Moon’s Lake House in Saratoga Spring, New York. Angered when a customer,
some sources say it was none other than Cornelius Vanderbilt, returned his French fried potatoes
to the kitchen for being too thick, Crum sarcastically shaved them paper thin and sent the plate
back out. The customer, whoever he was, and others around him, loved the thin potatoes. Crum
soon opened his own restaurant across the lake and his policy of not taking reservations did not
keep the customers from standing in line to taste his potato chips.

The popularity of potato chips quickly spread across the country, particularly in
speakeasies, spawning a flurry of home-based companies. Van de Camp's Saratoga Chips opened
in Los Angeles on January 6, 1915. In 1921, Earl Wise, a grocer, was stuck with an overstock of
potatoes. He peeled them, sliced them with a cabbage cutter and then fried them according to his
mother's recipe and packaged them in brown paper bags. Leonard Japp and George Gavora
started Jays Foods in the early 1920s, selling potato chips, nuts, and pretzels to speakeasies from
the back of a dilapidated truck.

The chips were commonly prepared in someone's kitchen and then delivered immediately
to stores and restaurants, or sold on the street. Shelf life was virtually nil. Two innovations paved
the way for mass production. In 1925, the automatic potato-peeling machine was invented. A
year later, several employees at Laura Scudder's potato chip company ironed sheets of waxed
paper into bags. The chips were hand-packed into the bags, which were then ironed shut.

Potato chips received a further boost when the U.S. government declared them an
essential food in 1942, allowing factories to remain open during World War II. In many cases,
potato chips were the only ready-to-eat vegetables available. After the war, it was commonplace
to serve chips with dips; French onion soup mix stirred into sour cream was a perennial favorite.
Television also contributed to the chip's popularity as Americans brought snacks with them when
they settled before their television sets each night.
 In 1969, General Mills and Proctor & Gamble introduced fabricated potato chips, Chipos
and Pringles®, respectively. They were made from potatoes that had been cooked, mashed,
dehydrated, reconstituted into dough, and cut into uniform pieces. They further differed from
previous chips in that they were packaged into break proof, oxygen-free canisters. The Potato
Chip Institute (now the Snack Food Association) filed suit to prevent General Mills and Proctor
& Gamble from calling their products chips. Although the suit was dismissed, the USDA did
stipulate that the new variety must be labeled as "potato chips made from dried potatoes."
Although still on the market, fabricated chips have never achieved the popularity of the original.

Today, potato chips are the most popular snack in the United States. According to the
Snack Food Association, potato chips constitute 40% of snack food consumption, beating out
pretzels and popcorn in spite of the fact that hardly anyone thinks potato chips are nutritious.
Nonetheless, the major challenge faced by manufacturers in the 1990s was to develop a tasty
low-fat potato chip.

1.1 PRODUCT DETAILS

URC Snack Foods (Malaysia) Sdn. Bhd was first incorporated in 1982 and commercial
operation started in 1984. The first product that was produced and sold by URC Malaysia was
Jack ‘n Jill Potato Chips. Over the many years of continued success, they have added other
brands to their stable such as Roller Coaster, Jigs, Corn Curls, Cloud 9 and many more.
Therefore, we have focused on the product Jack ’n Jill potato chips. It contained five type of
flavors such as spicy tomato, light salted sour cream, barbecue and spicy chilly.

The basic chips are cooked and salted, additional varieties are manufactured using
various flavoring and ingredients including herbs, spices, cheeses, other natural flavors and
additives.
Table 1 shows nutrition information of Jack ‘n Jill potato chips.

Nutrition information

Serving size: 15 g

Serving per package: 4

Per 100g Per serving

Energy 551 kcal 83 kcal

Protein 6.5g 1.0g

Carbohydrate 52.9g 7.9g

Fat 34.8g 5.2g

Cholesterol 0mg 0mg

Sources from Jack ‘n Jill potato chip packaging

2.0 PRESERVATION AND TECHNIQUE

In this product, the potato were processed into fabricated potato chips. “Fabricated” refers
to food products made from doughs that contain flour, meal, or starch derived from tubers,
grains, legumes, cereals, or mixtures thereof (Ekanayake et al, 2008). The potato mash were
used to form dehydrated potato products such as flakes, flanules, granules, agglomerates, sheets,
pieces, bits, flour, and particulates. The food products made from the mash and/or from the
dehydrated products produced therefrom have improved potato flavor and improved texture.
Especially preferred is an improved fabricated chip (Villagran, Yang, Chang & Evans, 2004).

In this process, fresh potatoes are washed, peeled and trimmed then ground to form
mixture of fine solid particles in liquid. The ground potato mixture were fermented using yeast to
lower reducing sugar levels and prevent excessive browning during frying (Ekanayake et al,
2008). This mixture is heated to gelatinize a major portion of starch present and thereby increase
the viscosity. Gelatinization is usually evidenced by increased translucency of the starch and
increased viscosity of the solution. Starch also loses it birefringence when gelatinized (Hui &
Evaranuz, 2015).
 The potatoes are subjected to a reduced cooking procedure to soften them for mashing.
According to the reduced cooking procedure of the present invention, the potatoes are cooked for
an amount of time sufficient to achieve partial starch gelatinization and partial inactivation of
enzymatic and non-enzymatic browning enzymes, yet maintain the hardness of the potatoes at
significantly higher levels as compared to conventional cooking processes (Villagran, Yang,
Chang & Evans, 2004).

The resulting potato flakes process when rehydrate with hot water produce mashed
potatoes. After cooling, the mixture is formed into chips shapes by extruding and cutting. The
chips were dried to increase the solid content and fried in hot oil. The resulting product had a
friable texture with excellent flavour (Lusas & Rooney, 2001). Next, the cooked potatoes are
comminuted to produce a wet mash. Comminution of the cooked potatoes may be accomplished
by any suitable means, such as but not limited to ricing, mashing, shredding, or a combination
thereof (McArthur et al, 2006).

Various additive such as citric acid, sodium acid pyrophosphate, sodium bisulphate and
antioxidant may be mixed with the cooked potatoes before drying to preserve colour and flavour.
Monoglyceride emulsifiers are added to facilitate release of the dried potato sheet from the drum
and to complex the free starch (Lusas & Rooney, 2001). Emulsifiers can provide various
benefits. For example, emulsifiers can coat free starch, thus reducing stickiness and adhesiveness
of the mash on the drier. Emulsifiers can also provide lubrication and thus reduce potato cell
damage caused by excessive shear during processing. (Villagran, Yang, Chang & Evans, 2004).

Adding salt to foods can also cause microbial cells to undergo osmotic shock, resulting in
the loss of water from the cell and thereby causing cell death or retarded growth (Davidson,
2013) It has also been suggested that for some microorganisms, salt may limit oxygen solubility,
interfere with cellular enzymes, or force cells to expend energy to exclude sodium ions from the
cell, all of which can reduce the rate of growth (Shelef and Seiter, 2005). In this product, salt are
added to give taste and to maintain its food safety by creating an environment resistant to
spoilage.

After forming the mash, the mash is dried to form dehydrated potato products. These
dehydrated potato products can be in any form, such as but not limited to flakes, flanules,
granules, agglomerates, sheets, pieces, bits, flour, or particulates (Villagran, Yang, Chang &
Evans, 2004). Once prepared, the dough is then formed into a relatively fiat, thin sheet. Any
method suitable for forming such sheets from starch based doughs can be used. For example, the
sheet can be rolled out between two counter rotating cylindrical rollers to obtain a uniform,
relatively thin sheet of dough material. Any conventional sheeting, milling and gauging
equipment can be used (Villagran et al, 1995). The potato flakes moisture from about 5% to
about 14%, preferably from about 5% to about 12%, more preferably about 6% to about 9%, and
still more preferably from about 7% to about 8% moisture.

Typically, a loose, dry dough is prepared by thoroughly mixing together the ingredients
using conventional mixers. Preferably, a pre-blend of the wet ingredients and a pre-blend of the
dry ingredients are prepared; the wet pre-blend and the dry pre-blend are then mixed together to
form the dough (Villagran, Yang, Chang & Evans, 2004). Hobart® mixers are preferred for batch
operations and Turbulizer® mixers are preferred for continuous mixing operations. Alternatively,
extruders can be used to mix the dough and to form sheets or shaped pieces (Ekanayake et al,
2008).

After the snack pieces are formed, they are cooked until crisp to form fabricated chips.
The snack pieces can be fried in a fat composition comprising digestible fat, non-digestible fat,
or mixtures thereof. For best results, clean frying oil should be used. The free fatty acid content
of the oil should preferably be maintained at less than about 1%, more preferably less than about
0.3%, in order to reduce the oil oxidation rate (Villagran, Yang, Chang & Evans, 2004). Other
ingredients can also be added to the edible fats and oils, including antioxidants such as TBHQ,
tocopherols, ascorbic acid, chelating agents such as citric acid, and anti-foaming agents such as
dimethylpolysiloxane (Villagran et al, 1995).

Then the potato chips are packed in its design packaging. Conventional packaging for
potato chips typically is made up of at least 4 different layers, and each has a very specific
purpose. The innermost layer is almost always a polymer called BOPP sometime for second
layer too, which stands for bi-axially oriented polypropylene. It is the gold standard today in
terms of food-safe materials that protect package contents. BOPP is a great barrier for moisture,
oils, and gases that can contaminate the chips with bad odors and tastes (Trending Packaging,
2016). After a second layer of LDPE (low-density polyethylene). LDPE provides potato chip
packaging with strength and additional grease resistance. Finally, the outermost layer is usually a
thermoplastic resin whose trademark name is Surlyn. Manufacturers love Surlyn because it adds
strength and puncture resistance to the chip bag and can be heat-sealed shut very quickly and at
relatively low temperatures (Trending Packaging, 2016).

Potato chip bags are not full of air, but of nitrogen gas. This is done to prevent the chips
from oxidizing, which is part of what makes them go stale. Oxygen is very reactive, and likes to
combine with other molecules whenever it can, causing chemical changes to take place.
Nitrogen, however, is very stable and unreactive. A so-called “nitrogen atmosphere” is good for
storing foods that oxidize quickly, like potato chips and bacon (William, 2012).

3.0 ADVANTAGES & DISADVANTAGES

3.1 Advantages

For method to make potato chips, we use variety types of method. One of the oldest
method to preserve potato chips is by deep frying method. This method is to one of the fastest
method to remove the water activity inside the potato chips so that the microorganisms will not
grow on the chips. According to Lalas et al (2003), the effect of using a rosemary extract on the
stability of oil used for frying potato chips has been evaluated. Sliced potatoes were fried
intermittently in soybean oil containing a natural extract from rosemary. The conditions used for
frying were 185°C for 90s. Two separate experiments, with and without replenishment of oil,
were carried out. Oil samples were taken each day, not only from the frying pans but also by
extraction with hexane from the chips. Changes in the induction period of the oil (Rancimat
method) were determined. The induction period decreased as frying progressed. The reduction in
the induction period was higher in the oil free of rosemary extract, and the chips were much
darker in colour. The oil containing the extract showed greater antioxidant activity, and reduced
darkening and rancidity of the oil. Potato chips fried in the oil with added rosemary extract were
more acceptable than chips fried in the oil containing no extract until the last frying. The free
radical scavenging activity of rosemary extract in comparison to other natural antioxidants was
also determined by the reduction of O2 in a hypoxanthine/xanthine oxidase system.
 For packaging, potato chips in bags are the most commercialised packaging compared to
tin packaging. This is because chips in bags are cheaper than tin packaging. There are also silver
lining of aluminium that have been used by factories. The usage of aluminium lining is to
prevent threat of moisture and contaminate the flavour. They are puncture resistant and have
stronger film options. Inside the bags of chips contain nitrogen gas to prevent the chips from
oxidase and going stale. Nitrogen gas is a stable and unreactive gas. Some chips are design in tin
packaging. The reason of tin packaging so that it is easy to be stack. According to Baur &
Hawley (1970), this type of package is relatively inexpensive, provides little protection from
handling and shipping loads imposed on the fragile chips and thus it is quite common to find a
considerable number of broken chips, for example, can have a significant quantity of oxygen and
water vapour packaged with the chips and can also fail to completely prevent the entry of
additional oxygen and water vapour therethrough. The presence of oxygen and water vapour
within the package is undesirable since the oxygen tends to react with the frying fat retained by
the chips to cause the fat to become rancid and thereby impart an undesirable rancid odour and
taste to the chips to lose crispness and become stale in flavour.
3.2 DISADVANTAGES

In the market commercial, only few bag-type package has a zipper to keep the freshness
of the chips. When there are no zipper, the consumer need to finish the chips all at one once they
open the packaging. Unlike tin packaging, this type of packaging has a cap to maintain the
freshness of the chips.

`According to Baur & Hawley (1970), the lack of using bag-type package is that it is
normally have short shelf life because of the onset of oxidative rancidity and staling. In addition,
the package is rather bulky because of the low density attendant with the random arrangement of
the chips packaged.

4.0 SUGGESTION FOR FUTURE IMPROVEMENT

1. Healthy chips
Chips are known for high calorie food, high in fat and high in sodium content. It is not
good for children and oldest people to consume it as it can lead to obesity and high blood
pressure. So it is good to produce a low calorie chips, low in fat and low in sodium
content so that people can consume it regardless of their age.

2. Frozen chips
Frozen foods are customer choice nowadays as people getting busy day by day. They
prefer a quick serving food such as frozen foods as they can instantly cook and eat the
foods while watching movies at home. It is good to have frozen chips so that people can
easily fry it at home whenever they want rather than go out at late night in order to buy
chips for late night snacking.

3. Baked chips
Chips are high in fat especially when it is cooked by deep fat frying. Baked chips are low
in fat that fried chips. At the same time, it can help to decrease the risk of some types of
cancer and Type 2 diabetes. Baked chips such as baked potato chips are high in potassium
content and vitamin C. So baked chips should be commercialized more in market.
4. Sealed packaging (zipper)
The most packaging used for chips are modified atmospheric packaging (MAP). It is
good as it preserved the chips perfectly but once the packaging is opened they need to eat
all the chips. If not the chips will deteriorate. Sealed packaging with the zipper is more
convenient for customer as they can zip the packaging and prevent the chips from
deteriorate.
REFERENCES

Baur, F. J., & Hawley, H. K. (1970). U.S. Patent No. 3,498,798. Washington, DC: U.S. Patent
and Trademark Office.

Davidson, P. M., Taylor, T. M., & Schmidt, S. E. (2013). Chemical preservatives and natural
antimicrobial compounds. In Food microbiology (pp. 765-801). American Society of
Microbiology.

Ekanayake, A., Bunke, P. R., Hammond, P. G., Prosise, R. L., Lin, P. Y. C., & Schnur, S. L.
(2008). U.S. Patent Application No. 12/012,319.

Fellows, P.J. (2003). Food Processing Technology: Principles and Practice. Second ed.
Woodhead Publishing Limited, Cambridge.

Hui, Y. H., & Evranuz, E. Ö. (Eds.). (2015). Handbook of vegetable preservation and processing.
CRC press.

Lalas, S., & Dourtoglou, V. (2003). Use of rosemary extract in preventing oxidation during deep-
fat frying of potato chips. Journal of the American oil chemists’ society, 80(6), 579-583.

Lusas, E. W., & Rooney, L. W. (Eds.). (2001). Snack foods processing. CRC Press

Mary F. McNulty “Potato Chips,” Jays Foods, Chicago, IL 60628. 773/731-8400.D Access on 20
April 2018 from http://www.madehow.com/Volume-3/Potato-Chip.html

McArthur, W. H., Elliott, S. D., & Killian, K. A. (2006). U.S. Patent No. 7,026,006. Washington,
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Shelef, L. A., & Seiter, J. (2005). Indirect and miscellaneous antimicrobials. FOOD SCIENCE
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Trending Packaging. (2016) .The Incredible Process of Packaging Potato Chips. Retrieved from
http://www.trendingpackaging.com/the-incredible-process-of-packaging-potato-chips/

Villagran, M. D. M. S., Li, J., Yang, D. K., Chang, D. S. J., & Evans, J. F. (2004). U.S. Patent
No. 6,703,065. Washington, DC: U.S. Patent and Trademark Office.
Villagran, M. D., Toman, L. J., Byars, K. D., Dawes, N. C., & Zimmerman, S. P. (1995). U.S.
Patent No. 5,464,642. Washington, DC: U.S. Patent and Trademark Office.

William, O. (2012). How Do Potato Chips Stay Fresh In The Bag?. Moment Of Science. Indiana
Public Media. Retrieved from https://indianapublicmedia.org/amomentofscience/potato-chips-
stay-fresh-bag/