Liquid and supercritical CO2 extraction of oil from potato chips
Pilot-scale method for selective fat removal from potato chips using liquid and low-pressure supercritical CO2. Targets greater than 90% fat reduction while preserving texture, color, and flavor. CO2 is used as a tunable, food-safe solvent, with capture and recycling to support process economics and sustainability. Validation is planned via systematic pilot experiments across multiple operating conditions and parallel technical and economic feasibility assessments.
Overview
This research proposes a selective fat extraction process for potato chips using liquid and low-pressure supercritical carbon dioxide (CO2). The goal is to produce low-fat chips with more than 90% fat removal while preserving the product's texture, color, and flavor. By leveraging CO2 as a tunable, food-safe solvent, the approach aims to deliver a healthier snack product without the quality compromises associated with conventional fat-reduction methods.
Technical specifications
Process approach:
- Uses liquid and low-pressure supercritical CO2 as the extraction medium for selective fat removal
- Operates on a pilot-scale system with approximately 5 kg batch capacity
- Captures and recycles CO2 to improve process economics and sustainability
Planned experimental parameters:
- Extraction pressure range of 100 to 1000 psi
- Operating temperature range of 0 to 100 degrees Fahrenheit
- CO2 to chips ratio ranging from 0.5 to 10
- Extraction time between 10 and 60 minutes
Analytical scope:
- In-house characterization of chips and extracted fat properties
- Evaluation of texture, color, and flavor to confirm quality retention
The research team has prior experience in multistage selective extraction and fractional separation of bioactive compounds from pomace using supercritical CO2, providing a relevant technical foundation for this work.
Technology readiness level
The project is at an early-to-mid stage of development. No preliminary data currently exists for fat extraction from potato chips using liquid and supercritical CO2, though the team brings demonstrated expertise from related supercritical CO2 extraction projects. Validation will proceed through systematic pilot-scale experiments across multiple operating conditions, with parallel technical and economic feasibility assessments. The near-term objective is to generate the process data required for scale-up and to optimize extraction and separation conditions for commercial viability.
About East Carolina University
East Carolina University is a comprehensive public research university in eastern North Carolina, combining broad academic breadth with a strong public-service mission. Integration with a major regional health system and teaching hospital enables clinically grounded collaboration and faster translation. Coastal field sites provide Atlantic test beds, and shared core labs and prototyping spaces support scale-up and validation. The university engages industry through flexible contracting, sponsored research, and tailored workforce partnerships. Research is backed by competitive federal funding, including NIH, NSF, and DoD, with state and industry support, and a dedicated technology transfer office manages IP, licensing, and startup formation.
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