Tayto Group, UK
Tayto uses Elea PEF systems to increase yield by up to 2%, lower oil uptake by 10% and boost the crunchyness of their chips.
About Tayto
Tayto Group is the largest British-owned crisp and snack manufacturer, producing over five million packs a day across their five UK sites including their original factory at Tandragee Castle in the rolling hills of Northern Ireland.
Extra Crunchiness with PEF
Tayto, has installed Elea Pulsed Electric Field belt systems in their factory in Scunthorpe.
Elea PEF use resulted in smoother slicing and a yield increase of 1 – 2 %, a 10 % reduced oil uptake.
Additionally, less starch release leading to extra crunchiness, and a more consistent frying at lower frying time and at lower frying temperature allow better product colour and quality.
Elea PEF PEF Advantage B100-600 at Scunthorpe factory.
Elea With Tayto On The BBC
In April 2019, the British television channel BBC One published a feature about PEF-assisted crisp manufacturing at Tayto in the British documentary television series Supermarket Secrets (Series 3, Episode 3 “Loyalty”).
With special thanks to Brian Meyer, Tayto’s Process Improvement Manager, Tayto shared many interesting insights into how PEF enhances their snack production.
The Elea PEF systems installed at Tayto produce 100 tonnes of crisps per day, delivering major process improvements including significant energy and water savings.
Creating Crunchier Crisps
An additional benefit of using PEF is the production of crunchier crisps.
Brian Meyer, Tayto’s Process Improvement Manager explains:
“What the PEF unit does is it provides an electric current, which makes the potato slightly softer, and because it’s slightly softer, you can slice it in a more efficient, more reproducible way – much more consistency. And that then leads to better consistent frying, and ultimately a crispier, crunchier, better-quality chip.”
Improved Texture and Lower Oil Content
Brian Meyer further explains the impact of PEF on starch retention and oil reduction:
“Smoothness and the potato’s punctured cells have a huge effect on the amount of starch in the slice. One of the advantages through PEF treating is you leave some of the starch in, and that’s what creates the extra crunchiness.”
“So, one of the advantages through PEF treating is they’re also slightly lower in oil content, as well.”
