Pulsed electric field technology for reducing oil uptake in potato chips

Overview

This solution applies Pulsed Electric Field (PEF) technology to whole potatoes before slicing, creating a more porous internal structure that fundamentally changes how chips fry. The result is a potato chip with significantly reduced oil content — targeting a 30% oil reduction and a final product with only 20g of fat per 100g — while maintaining the colour, texture, and crunch consumers expect. Beyond health benefits, the technology delivers operational advantages including easier slicing, less breakage and waste, longer slicer durability, and reduced starch load in wastewater. It also mitigates seasonal variability in raw potato quality, enabling more consistent chip production year-round.

Technical specifications

How PEF works on potatoes:

• PEF treatment applied before slicing induces pore formation within the potato tissue
• The porous structure enhances mass and heat transfer during frying
• Faster water evaporation and increased water vapour pressure during frying limit oil absorption
• Smooth cut surfaces on PEF-treated slices reduce adhered oil after frying
• Shorter frying times at lower temperatures are achievable with PEF-treated slices

Key benefits demonstrated:

• Up to 30% oil reduction compared to untreated potatoes
• Lower energy density and increased satiety in the final product
• Crunchier texture and more uniform brown colour
• Reduced potato breakage and waste during slicing
• Consistent chip quality regardless of seasonal sugar variations in raw potatoes
• Validated at lab scale and in factory settings up to 20 tons per hour

Technology readiness level

The technology has been validated through an integrated study spanning 2014–2022, with trials completed both in laboratory and commercial factory environments at throughputs up to 20 tons per hour. Future validation will focus on optimising PEF processing parameters and frying conditions for different potato cultivars, oil types, slice thicknesses, and fryer types at the researcher's PEF pilot facility. The team is seeking partnerships to supply diverse potato cultivars and frying oils, funding for key personnel, and access to industry facilities for commercial-scale validation. The approach also opens opportunities to use potato varieties previously considered unsuitable for chipping.