Crisps: Inside the Factory—Introduction (02:13)
People in Britain consume 500,000 crisps in 24 hours. Greg Wallace and Cherry Healey will tour the largest crisp factory in the world and learn the science behind making crisps. Ruth Goodman will uncover who invented crisps.
Janaway Potato Farm (04:11)
Walkers produces over 40% of crisps consumed in Britain; cheese and onion is the best-selling flavor. Nearly all crisps produced in the U.K. are comprised of British potatoes. Gavin Janaway explains the farm's process for prepping potatoes for Walkers.
Potato Varieties (03:24)
There are over 230 varieties of potatoes grown in the U.K. Healey visits the National Agronomy Center to discover which variety makes the best crisp; learn the three key parts of a potato.
Walkers Crisp Factory (05:25)
The factory receives 25 truckloads of potatoes every day; one potato equals one packet of crisps. Workers test a sample before offloading the truck. Machines peel over 2,000 potatoes every minute.
Who Invented the Crisp? (04:28)
Americans claim George Crum invented the crisp in 1853. Goodman and food historian Regina Sexton explain the history of the potato in Britain and try a recipe in "The Cook's Oracle," published in 1817.
Slicing Department (03:30)
Machines ensure the potatoes are the correct size before they are sliced; the average potato is cut into 45 slices. Wallace helps replace the blades on a slicer. The slices undergo several washings to remove starch.
Frying Department (02:05)
The factory has seven industrial fryers filled with grapeseed and sunflower oil; temperatures adjust according to the product. A bag of crisps contains half a tablespoon of oil.
Savory Snack Production (04:47)
More than one third of these snacks in the U.K. are made from corn (maize). Healey visits a factory that turns 96 tons of corn into 12 million Monster Munch snacks every 24 hours.
Seasoning and Development (06:15)
Machines inspect the crisps before seasoning; the factory has 23 seasoning drums. Every new flavor of crisp starts as a real dish cooked at the factory. Wallace helps Ben Barlow develop a cheesy-beans-on-toast flavor; seasoning houses develop the flavor profile.
Product Tasting (03:59)
Panelists taste test new and existing flavors of crisps every day. Wallace undergoes a taste test and joins the panel of super tasters.
Experimental Psychology (05:36)
Charles Spence explains why foods taste better under certain circumstances. He uses experiments to better understand how our senses influence and confuse our sense of taste.
Weighing and Bagging (03:09)
Julie Biddles oversees the filling of crisp bags; 118 machines weigh crisps to determine the best combination for filling a 25 gram bag.
Crisps Popularity (03:19)
Steve Berry explains how crisps went mainstream after Frank Smith first sold to pubs in the 1920s. Cellophane bags replaced greased bags, increasing shelf-life. See a variety of crisp flavors.
Fresh Crisps (02:28)
In less than 20 minutes from arrival, a load of potatoes has become crisps in a bag. Machines add nitrogen to the bags before they are sealed.
Distribution Center (03:03)
A computer-controlled system moves 5 million bags of chips around the site every day. Chris Neville monitors the arrival, production, and delivery of products. Wallace reflects on the manufacturing and distribution process.
Credits: Crisps: Inside the Factory—How Our Food Is Made (Series 2) (00:33)
Credits: Crisps: Inside the Factory—How Our Food Is Made (Series 2)
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