Ever wondered how those crispy, flavorful plantain chips end up on store shelves? Commercial production blends precision equipment and time-tested steps to create consistent, tasty snacks—here’s the breakdown.
First, raw material selection is key. Factories pick under-ripe green plantains with stiff, starchy flesh (ripe ones get soggy!)—varieties like Saba or Nendran are popular for their texture. Workers sort out blemished or immature fruit to ensure quality.
Next comes prepping the plantains. They’re blanched in 65–90°C water to soften peels for easy removal. Automatic peeling machines then strip the skin without damaging the flesh, a huge upgrade from hand-peeling for large batches.
Slicing follows, using banana cutting machine that cut uniform 1–5mm slices—thickness controls crispiness. The slices go through a quick water removal step: either air-drying with high-pressure fans or dehydration machines. This prevents oil splatters and makes chips crispier later.
Frying is make-or-break. Clean vegetable oil (corn, sunflower, or coconut) is heated to 170–200°C. Continuous fryers with double mesh belts keep slices submerged, while built-in filters remove crumbs to keep oil fresh (reused oil kills antioxidants). After 2–3 minutes, golden chips move to vibration de-oiling machines to cut greasiness.
Then seasoning adds flavor. Drum machines toss chips with salt, spices, or sweet coatings like honey—some even use syrup dips before frying for extra taste. For unique flavors, factories might add paprika, garlic powder, or ranch seasoning.
Finally, packaging. Chips are cooled and sealed in nitrogen-filled bags to stay crisp and extend shelf life (up to 6 months if dried properly). Metal detectors check for impurities before boxes head to stores.
From green plantains to crunchy snacks, every step balances efficiency and quality—no wonder these chips are loved worldwide!