Potato chip processing method based on spraying and baking and product
By combining vacuum frying, spraying, and baking, the problems of high oil content and unstable flavor in potato fries have been solved, resulting in potato fries with low oil extraction and long-lasting flavor.
Patent Information
- Application Number
- CN202511594588.2
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-11-03
- Publication Date
- 2026-01-16
AI Technical Summary
Existing potato fry processing technology poses health risks due to high oil content, flavor compounds are easily lost, and oils are unstable, affecting product appearance and shelf life.
The method employs a combination of vacuum frying, spraying, and baking, including pretreatment, vacuum low-temperature and low-pressure frying, spraying with flavor slurry, baking and curing, and finally nitrogen filling and packaging.
It significantly reduces oil content, locks in flavor compounds, improves oil stability, extends shelf life, and enhances product quality and stability.
Smart Images
Figure CN121336981A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of food processing technology, and more specifically, relates to a method and product for processing potato fries based on spraying and baking. Background Technology
[0002] In existing potato fry processing technologies, while atmospheric pressure frying can give products a golden and crispy texture, it poses health risks due to its high oil content (typically 30%-40%) and is prone to producing harmful substances during frying. Furthermore, traditional dry powder mixing methods rely on simple physical adhesion, resulting in weak bonding of flavor compounds to the fries, which easily detach during transportation and consumption. This not only leads to uneven flavor intake for consumers (e.g., some areas are too bland, others too salty) but also leaves a large amount of residual powder in the packaging, affecting product appearance and hygiene. Simultaneously, during storage, internal oils are easily affected by temperature fluctuations and gravity, migrating to the surface, resulting in an oily appearance, deteriorated taste, accelerated oxidation and rancidity, and shortened shelf life. Although vacuum frying or baking technologies attempt to address the oil content issue, they often struggle to simultaneously achieve a crispy texture, a rich and lasting flavor, and long-term oil stability. Therefore, avoiding this phenomenon is key to solving the problem, necessitating a potato fry processing method and product based on spraying and baking. Summary of the Invention
[0003] Technical problems to be solved To address the shortcomings of existing technologies, this invention provides a potato fry processing method and product based on spraying and baking. The potato fry product prepared by this invention has low oil content and good flavor retention and oil stability.
[0004] Technical solution To solve the above problems, the technical solution adopted by the present invention is as follows: The present invention provides a method for processing potato fries based on spraying and baking, comprising the following steps: (1) Provide pre-treated potato fries; (2) Vacuum frying the pre-treated potato strips to obtain pre-fried potato strips; (3) Spray the slurry containing flavoring substances onto the surface of the pre-fried French fries; (4) Bake the coated fries; (5) Cooling and packaging.
[0005] Furthermore, the pretreatment in step (1) includes washing, peeling, cutting into strips, blanching and freezing.
[0006] In the above steps, blanching is used to inactivate enzyme activity and prevent browning; freezing is intended to disrupt cell structure through ice crystals, forming micropores that facilitate subsequent dehydration and the formation of a loose texture.
[0007] Furthermore, the pre-treated potato strips in step (2) are vacuum fried in a low-temperature and low-pressure environment, wherein the oil temperature is 90-110℃ and the vacuum degree is 0.8-0.9MPa.
[0008] In the above steps, the pre-treated potato strips are vacuum fried in a low-temperature and low-pressure environment, which can significantly reduce the oil content of the potato strip products and form a pre-fried base.
[0009] Furthermore, in step (3), the slurry is made by mixing and homogenizing sauce, powder, binder, water and other auxiliary materials.
[0010] Furthermore, the sauce and powder contain a variety of substances that can achieve film-forming and curing, such as maltodextrin, xanthan gum, carrageenan, and pregelatinized starch.
[0011] Furthermore, the spraying method in step (3) includes: spraying the sauce liquid first, then adding powder; spraying the powder first, then adding the sauce liquid; spraying the sauce liquid first, then adding powder, and finally spraying the sauce liquid again; spraying the powder first, then adding the sauce liquid, and finally spraying the powder again, etc., and many other different combinations of spraying methods.
[0012] Furthermore, the baking in step (4) includes various methods that can provide heat sources to dehydrate and solidify the slurry, such as hot air, infrared, and microwave.
[0013] Furthermore, nitrogen-filled packaging is used in step (5).
[0014] In the above steps, nitrogen-filled packaging can further extend the product's shelf life.
[0015] Beneficial technical effects Compared with the prior art, the beneficial effects of the present invention are as follows: (1) Excellent overall performance of the product. Due to the use of vacuum frying, the oil content of this product is significantly lower than that of products fried under normal pressure. After the batter is baked and solidified, a dense coating is formed on the surface of the potato fries, which firmly locks in the flavor substances and is not easy to fall off, giving the product good flavor stability. In addition, the coating formed after the batter is baked and solidified can also act as a physical barrier, effectively inhibiting the migration and precipitation of internal oil to the surface, extending the shelf life, maintaining the product's refreshing appearance and stable taste, and improving the product's high quality and stability.
[0016] (2) A potato fry product based on spraying and baking according to the present invention is obtained by the processing method of the present invention and has all the beneficial effects of the processing method of the present invention. Attached Figure Description
[0017] Figure 1 This is a process flow diagram of the potato fries of the present invention. Detailed Implementation
[0018] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention are described clearly and completely. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.
[0019] To better understand the above technical solutions, the following will provide a detailed explanation of the technical solutions in conjunction with the accompanying drawings and specific embodiments.
[0020] Example 1 This embodiment provides a novel process for making honey butter fries, the preparation method of which specifically includes the following steps: (1) Using the Atlantic potato variety, potato strips with a specification of 9×9mm were obtained by washing, peeling, cutting, blanching and freezing. (2) The pre-treated potato strips were vacuum fried in a low temperature and low pressure environment, with an oil temperature of 110℃, a vacuum degree of 0.9MPa, and a frying time of 45min to obtain pre-fried potato strips; (3) The sauce containing honey, butter, syrup and flavoring and the powder containing honey butter seasoning powder are sprayed onto the surface of the pre-fried French fries by first spraying the liquid sauce and then spraying the powder. (4) Bake the coated fries at 135°C for 25 minutes. (5) Cool to room temperature to obtain a new process of honey butter fries.
[0021] Example 2 This embodiment provides a novel process for preparing original-flavor French fries, the specific steps of which include: (1) Using the Atlantic potato variety, potato strips with a specification of 9×9mm were obtained by washing, peeling, cutting, blanching and freezing. (2) The pre-treated potato strips were vacuum fried in a low temperature and low pressure environment, with an oil temperature of 110℃, a vacuum degree of 0.9MPa, and a frying time of 45min to obtain pre-fried potato strips; (3) The sauce containing syrup and flavoring and the powder containing salt powder are sprayed onto the surface of the pre-fried French fries by first spraying the liquid sauce and then spraying the powder. (4) Bake the coated fries at 135°C for 25 minutes. (5) Cool to room temperature to obtain a new process of original flavor French fries.
[0022] Comparative Example 1 This comparative example provides a commercially available honey butter standard fries made using a conventional drum mixing method.
[0023] Comparative Example 2 This comparative example provides a commercially available, standard-flavor French fry made using a conventional drum mixing method.
[0024] Comparative Example 3 This comparative example provides a commercially available, conventional drum mixing method for baking French fries.
[0025] Performance testing (1) Flavor fastness test: The French fries obtained in Examples 1-2 and Comparative Examples 1-3 were subjected to flavor fastness test. The French fries were shaken for 5 minutes under the same conditions, and the powder that fell off was collected and weighed. The powder falling off was calculated as (weight of powder falling off / total weight of product × 100%). Under the same conditions, the number of French fries with uniform seasoning was selected and weighed. The uniformity was calculated as (weight of uniformly seasoned French fries / total weight of product × 100%). The test results are shown in Table 1.
[0026] Table 1: Flavor fastness test
[0027] As can be seen from Table 1, the French fries obtained in Examples 1-2 have higher mixing loss rate and uniformity than those obtained in Comparative Examples 1-3, exhibiting good flavor retention and significantly improving product quality.
[0028] (2) Oil stability test: The French fries obtained in Example 1 and Comparative Example 1 were stored under accelerated oxidation conditions (37°C constant temperature chamber), and the weight of the separated oil was measured periodically (0, 1, 3, 5, 7, 9, 11, 13, 15 days). The test results are shown in Table 2.
[0029] Table 2: Oil Stability Test
[0030] As shown in Table 2, the oil extraction rate of the fries obtained in Example 1 was consistently much lower than that of the fries obtained in Comparative Example 1. Throughout the 15-day observation period, the new process for the fries obtained in Example 1 reduced the oil extraction rate by approximately 60%-65%, a very significant improvement. In the initial stage (0-5 days), the oil extraction rate was relatively fast for both processes, resulting from the rapid migration of surface and shallow free oil. In the later stage (5-15 days), the oil extraction rate slowed down, transitioning to the slow migration of internally encapsulated oil. The oil extraction rate of the fries in Comparative Example 1, which used ordinary feed, still showed a significant increase in the later stage (after day 11), while the oil extraction rate of the fries in Example 1 using the new process became more gradual, indicating better oil stability. At 15 days, the oil extraction rate of the fries obtained using the conventional mixing method in Comparative Example 1 reached as high as 6.54%, meaning the product surface would appear greasy, the taste might deteriorate, and the oil would be prone to oxidation and spoilage, affecting shelf life. In contrast, the oil extraction rate of the fries obtained using the new process in Example 1 was controlled at a low level of 2.41%. This indicates that the process successfully locked in the internal oil, greatly improving the product's quality stability and storage performance.
[0031] (3) Final oil content test: The final fat content of the French fries obtained in Example 2 and Comparative Examples 2-3 was determined using standard methods such as Soxhlet extraction. The test results are shown in Table 3. Table 3: Final Oil Content Test of Products
[0032] As shown in Table 3, the fries obtained using vacuum frying technology in Example 2 have a much lower oil content than the atmospheric pressure fried product of Comparative Example 2, but slightly higher than the baked product of Comparative Example 3. However, combined with its superior taste, it demonstrates a balance between health and flavor. This is because the boiling point of water is lowered in the vacuum environment of the fries obtained in Example 2, and the water evaporates slowly at low temperatures, preventing the formation of strong steam pressure inside the fries that "squeezes out" the oil, thus reducing oil penetration. Furthermore, the gentle dehydration process creates a smaller and more uniform internal structure, reducing the ability to absorb oil. In contrast, the atmospheric pressure fried product of Comparative Example 2 experiences rapid dehydration and hardening of the fries surface under high temperatures, forming a dense porous structure. The vaporization of internal water generates enormous pressure, "pumping" the oil into the interior. After being removed from the fryer, a large amount of oil adheres to the rough surface, making it difficult to drain completely, resulting in a higher oil content. In contrast, the baked product of Comparative Example 3 is not immersed in oil; the fat source is limited to a small amount of oil sprayed on the surface to improve taste and color. Its final fat content largely depends on the amount of oil added to the formula.
[0033] (4) Sensory test of French fries: Twenty random passersby were selected as evaluators to conduct sensory evaluations of the French fries obtained in Examples 1-2 and Comparative Examples 1-2 based on crispness, flavor intensity, flavor persistence, overall acceptability, and (low) greasiness. The scores were expressed on a 5-point scale, ranging from 1 (very disliked) to 5 (very liked). The samples were randomly numbered. The participants rinsed their mouths with warm water before and between tasting the first sample to reduce evaluation error. The scores were averaged. The test results are shown in Table 4.
[0034] Table 4: Sensory Tests of French Fries
[0035] As shown in Table 4, the French fries obtained using the new process in Examples 1-2 scored higher than or equal to those obtained using the conventional process in all attributes, especially in flavor intensity, flavor persistence, and overall acceptability. Specifically, the French fries obtained in Example 1 scored full marks (5.0) in flavor intensity, flavor persistence, and overall acceptability, and also had high crispness (4.8) and greasiness (4.6). The French fries obtained in Example 2 scored nearly full marks (4.9-5.0) in flavor intensity, flavor persistence, overall acceptability, and greasiness, and also had high crispness (4.9). The French fries obtained in Comparative Example 1 scored lower in flavor persistence (4.0) and greasiness (3.9), and had a relatively average overall acceptability (4.4). The French fries obtained in Comparative Example 2 scored poorly in flavor persistence (4.0) and greasiness (3.9), and had a low overall acceptability (4.3).
[0036] It should be noted that, in this document, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.
[0037] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.
[0038] Those skilled in the art should understand that the above descriptions are merely several specific embodiments of the present invention, and not all embodiments. It should be noted that many modifications and improvements can be made by those skilled in the art, and all modifications or improvements not exceeding the scope of the claims should be considered within the protection scope of the present invention.
Claims
1. A method for processing potato chips based on spraying and baking, characterized by, The method comprises the following steps: (1) providing pretreated potato strips; (2) vacuum frying the pretreated potato strips to obtain pre-fried potato strips; (3) spraying a slurry containing flavoring substances on the surface of the pre-fried potato strips; (4) baking the sprayed potato strips; (5) cooling and packaging.
2. The spray and bake based potato chip processing method according to claim 1, wherein, The pretreatment in step (1) comprises cleaning, peeling, cutting, blanching and freezing.
3. The spray and bake based potato chip processing method according to claim 1, wherein, In step (2), the pretreated potato strips are vacuum fried in a low-temperature and low-pressure environment, wherein the oil temperature is 90-110℃ and the vacuum degree is 0.8-0.9MPa.
4. The spray and bake based potato chip processing method of claim 1, wherein, The slurry in step (3) is prepared by mixing and homogenizing sauce, powder, adhesive, water and other auxiliary materials.
5. The spray and bake based potato chip processing method of claim 4, wherein, The components of the sauce and powder include malt dextrin, xanthan gum, carrageenan, pregelatinized starch and other substances that can achieve film solidification.
6. The spray and bake based potato fry process of claim 1, wherein, The spraying method in step (3) includes the following different combinations: first spraying sauce liquid, then spraying powder; first spraying powder, then spraying sauce liquid; first spraying sauce liquid, then spraying powder, and finally spraying sauce liquid again; first spraying powder, then spraying sauce liquid, and finally spraying powder again.
7. The spray and bake based potato fry process of claim 1, wherein, The baking in step (4) includes hot air, infrared, microwave and other methods that can provide heat source to dehydrate and solidify the slurry.
8. The spray and bake based potato chip processing method of claim 1, wherein, The packaging in step (5) adopts nitrogen filling packaging.
9. A spray and bake based potato chip product characterized by, The method is prepared by the processing method according to any one of claims 1-8.