How Frito-Lay makes potato chips

we are piquillo Lee Connecticut manufacturing facility for frito-lay North America we make about 150 million pounds a year we made blaze ruffles Fritos Doritos smart food Tostitos and Santee de we service the entire service area from the tip of Maine to tip of New Jersey very early Pennsylvania here at Killingly we have a sustainability at the core value for the whole plant we wanted to continuously iminium eyes the usage and impact of those resources that we borrowing from the environment we used about 20 1,500 pounds of potatoes an hour it comes out to several million pounds per week it takes about four pounds of potatoes to make a pound of finished potato tip so we actually use a lot of potatoes after we bring them into the plant they go through a peeling process we have several inspection systems that can pull bad potatoes out of the process they go through those inspection systems and then they get sliced to the individual tips drops into a washing system from the water at some point that here are Killingly we are presently just on the potato chip lines we can save about 14 million gallons per year and altogether about 21 of water per year after the product goes through that washing system it goes directly into the fryer gets fried in hot oil we can make up to about 7,000 pounds an hour per line if we have two of those lines the extraordinary thing is that we don't use biofuels like oil to run our boilers we're using only the cogeneration boil about essentially what we use is a natural gas we determine so that provides us with all the heat that we need to actually create the steam which is eco-friendly we're off the grid on electricity we produce all the electricity that we can use here at the plant Trotter comes out of the fryer and then it goes to another vision system the passes through that vision system that vision system removes any defects under fried over fried product we want to be a zero valence waste to a local community so we take all the ways we can the rate and we send it to our farm for feed product comes out of that vision system it goes into either salted product or seasoned product we actually use all natural seeds brings down all that product then goes to a conveyor system and goes out into the packages also any of the bags any film that we generate we use it in our program that's TerraCycle program but we'll generate product like handbags and support from a impact into the environment is that front way to about 65 million tons of co2 that we no longer put it up in the system also equivalent to about seven thousand houses being off the electrical grid for one year so it's a great things we're doing for the local community as well as for the environment as a whole

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Id: ws_K9Cxs-uE

Length: 3min 8sec (188 seconds)

Published: Thu May 05 2011