From Potato to Pack: The 7 Stages of a Frozen French Fries Production Line

Stage 1: Receiving, Washing, and Peeling (Prep)

Potatoes are automatically unloaded into the Destoner and Washer to remove dirt, stones, and foreign material. The Peeling Machine (often Abrasive or the more efficient Steam Peeler for high volume) removes the skin. An Inspection Conveyor follows, where human operators manually remove any blemishes or green spots before processing.

Stage 2: Precision Cutting

The quality of the final product hinges on uniformity. The French Fries Slicer/Cutter Machine uses specialized hydro-jets or sharp-bladed wheels to cut the potatoes into precise, consistent sizes (e.g., 9 mm x 9 mm ).

Stage 3: Blanching (Color and Texture Control)

This is a critical chemical step. The sliced fries are immersed in hot water ( ~ 70 °C ) for several minutes.

• Goal 1: Deactivation. Stops enzyme activity that would otherwise cause undesirable browning (oxidation) and flavor change.
• Goal 2: Leaching. Washes out free starches, which prevents the fries from sticking together during freezing and reduces oil absorption later.

Stage 4: Drying

After blanching, the fries are transported through an Air Drying System. Removing excess surface moisture is paramount before frying. If moisture remains, it causes excessive oil splattering and contributes to high oil absorption.

Stage 5: Par-Frying (Setting the Crust)

The fries undergo Par-Frying in a Continuous Automatic Fryer. This is a shorter frying time at a lower temperature than full cooking.

• Goal: To fully gelatinize the starch on the surface, setting a thin, crispy crust. This crust protects the interior during the freezing process and ensures the fry holds its shape and cooks quickly when the consumer prepares it.

Stage 6: IQF Freezing (The Gold Standard)

This is the stage that separates a professional line. IQF stands for Individual Quick Freezing.

• The Technology: The par-fried product moves on a mesh belt through a cryogenic or forced-air freezer tunnel where temperatures drop rapidly (to -35 °C to -40 °C).
• The Benefit: Rapid freezing prevents the formation of large ice crystals inside the potato cells. Large crystals damage cell walls, leading to a mushy, poor-texture product when thawed. IQF ensures the fry remains light, fluffy inside, and crispy outside upon final cooking.

Stage 7: Packaging

The frozen fries are conveyed to the Multi-Head Weigh Filler system, which can be custom-designed to handle the cold and slightly sticky nature of frozen product. They are accurately weighed and sealed into moisture-proof bags using the VFFS  Machine.