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Production

For over 20 years we have been producing French fries, for over 10 years – potato pancakes, and for 5 years – potato flakes. We have extensive experience and knowledge in this field. However, on a par with the technology we put quality and safety of our products.

potato heart

A guarantee as to the highest quality and safety of our French fries, pancakes and flakes entails close control over the production and quality processes. 

We take potato to heart

Potato is the beginning of production process. We need over 200 000 tons of this material every year. We cooperate with the best Polish suppliers, because only they are able to meet our high standards. We have about 80 suppliers. They are mainly based in the north of Poland. Since 1994, our major supplier has been Farm Frites Poland Dwa Sp. z o.o.

When it comes to cooperation with our potato suppliers, we value long-term relationships and the fact that many of them have been supplying potatoes to our plant since 1990s is the best proof of that.

To ensure best product safety, our Company requires that its suppliers implement Good Agricultural Practice (GAP) standards and join GLOBALG.A.P. programme. Over 95% of potatoes supplied to our plant come from certified plantations guaranteeing safe food production.

All potatoes used for production are grown in Poland. However, the varieties we use, such as, among others, Russet Burbank, Innovator, Zorba do not come from Poland. Unfortunately, traditional Polish potato varieties are not suitable for production of long fries (and this is the variation of fries we want to obtain) mainly because of their oval shape.

It is very important for us to acquire potatoes in a sustainable way, which enables the production of safe, high quality food in a way that protects and even improves the state of natural environment, social and economic living conditions of farmers, farm workers and local communities.

We are a founding member of Poland's only non-profit initiative of companies representing different sectors of the value chain of food production that have a common idea of sustainable agriculture - Polish Association for Sustainable Agriculture "ASAP". In November 2016 we became a supporting member of the Association of Polish Potato, which integrates and supports the development of the potato industry.

We are only a member of Sustainable Agriculture Initiative (SAI) Platform – the organization which supports sustainable development of agriculture and European Potato Processors' Association (EUPPA) which unites potato processors.

From potato to French fries

Straight and crinkle-cut fries, straight and crinkle-cut slices, potato skin on wedges… Here is how they are made in our factory:

Washing, rinsing and peeling

Once potatoes are delivered and destoned, they are sent to the washing and peeling room. Tubers with too low dry mass are eliminated in the brine bath of adequate density. Potatoes, so selected and prepared, are then placed in the steam peeler, where their peel is removed by pressurised steam of a few bars. It takes from a few to several dozen seconds. Thanks to the steam peeling process, vitamins, minerals and other nutrients naturally present in potatoes are preserved.

Cutting and sorting

Peeled potatoes are then sent to the cutting and sorting room, where they are cut by the water knife cutting system into different shapes, depending on the current production schedule. Next, any French fries that are too short are eliminated on the length sorting machines and those with defects, such as dark spots, are also rejected with the use of very modern devices, equipped with cameras and 176 air valves, called optical sorters.

Blanching, drying and pre-frying

Cut and selected French fries are subsequently blanched, i.e. soaked in warm water. Blanching conditions, such as, among others, temperature and blanching time, depend on the quality of potatoes as well as the variation of fries to be produced.
Blanching process, if carried out properly, can ensure that natural taste of potato will be preserved and fries will have good texture.

Then, the French fries are dried to remove excess moisture. The drying process takes place in a special tunnel, where fries travel on conveyor belts while warm air of prescribed humidity is gently blown on them.

Next, the pre-dried French fries are placed in the fryer to be pre-fried in vegetable oil. Thanks to the pre-frying process they are crispy and golden and preparing them at home (also in an oven) takes shorter time.

Cooling and freezing

Both cooling and freezing of French fries take place in special tunnels. The process is very fast so as to prevent potato cells from being destroyed by crystallising water and to have proper texture and colour of French fries preserved after frying. The temperature of French fries leaving the freezing tunnel is about -12⁰C.

Packing, sorting and shipping

Our French-fries are packed automatically in packets and then put in cardboard boxes. Every single unit pack is checked with a metal detector. The packed product is labelled with a batch number. The cardboard boxes are placed in layers on pallets and automatically wrapped in stretch film to prevent any mechanical damage. The products are shipped from the plant’s warehouse and then transported in refrigerator trucks at -18°C.

From potato to potato pancake

Potato pancakes with onion, and garlic and marjoram. All types are gluten-free. Here is how they are made in our factory:

Washing, rinsing and peeling

Once potatoes are destoned, they are washed and soaked in brine and then peeled with the use of mechanical peeler.

Preparing batter

Peeled potatoes are divided into portions and grated. Next onion, potato or rice starch, salt and other spices are added and all ingredients are put in the mixer. The mixed batter is fed into the dispensing and forming system.

Forming and pre-frying of pancakes

The dispenser pours the batter into an oil-sprinkled frying pan, where the batter is given proper shape. Once a potato pancake is well fried on one side, it is turned to the other side. This gives the pancake a crispy skin and the pre-frying process shortens the cooking time at home.

Freezing

Once pre-fried, potato pancakes are conveyed to the freezing tunnel. As the freezing process is very fast, their taste and appearance after frying at home will be excellent.

Packing, sorting and shipping

Potato pancakes, so frozen, are put in bags or small cardboard boxes, weighed and then packed in large cardboard boxes. They are checked for contamination by metal shards simultaneously. When in the freezer, they reach the temperature of -18°C at which they are kept at each stage of distribution.

From potato to potato flake

Potato flakes we produce are not the end product, but can be added for the production of mash or chips. Here is how they are made in our factory:

Blanching and cooling

Small peeled potatoes and raw intermediate potato from the French fries line, go to the blancher, where heat makes starch granules swell but the potato structure remains intact. The blanching process also prevents potatoes from turning grey by inactivation of enzymes naturally occurring in the raw material. Next, during the cooling phase, the starch is hardened and forms a gluey layer (resembling wallpaper adhesive)

Steaming

In the steamer, the hardened cells are separated again and steam-cooking continues. As the cells stabilized in the cooler after blanching, any damage to their structure is but minimal and the puree is steam-cooked while the cell structure is preserved.

Rolling and breaking

Next, the puree is conveyed to a drying drum where water is evaporated, and turned into a thin sheet of dried potato mash. Then, these large sheets are broken into flakes of desired size in the machine called flaker. The flakes may be made even smaller in a special mill.

Packing

Flakes are transported to bulk containers used for temporary storage of finished flakes to ensure their uniform quality. The last stage is packing of the flakes into big-bags or paper bags. Potato flakes, unlike French fries or potato pancakes, are stored at temperatures above zero.