Ep 2. Crisps

Inside the Factory is a BBC television series that takes us behind the scenes of some of Britain's biggest and most fascinating factories to explore the manufacturing process, from raw material to finished product. In season 2 episode 2, titled "Crisps," we dive into the world of potato chips.

Hosts Gregg Wallace and Cherry Healey take us to the largest crisp factory in the world, Walkers in Leicester, where they produce 11 million bags of crisps every day. The episode is a fascinating look at the complex and highly automated process of making crisps.

We start with the potato harvest, where we learn about the importance of using the right variety of potatoes to make crisps. Walkers use a combination of potatoes grown in the UK and abroad to get the perfect mix of taste, texture, and consistency. The potatoes are then transported to the factory, where they are sorted, washed, and peeled. We watch as the potatoes are sliced into thin, even slices, using state-of-the-art machinery.

The crisps are then cooked in hot oil until they are just the right level of crispiness. This is where things get interesting, as we learn about the science behind making crisps. Walkers use a range of different oils, temperatures, and cooking times to create different textures and flavors. We also learn about the importance of using the right amount of seasoning, and how Walkers use a special coating process to ensure that every crisp is evenly coated.

Next, the crisps are sorted and packed into bags. We learn about the different types of packaging used for crisps, and how Walkers have to carefully balance the need for freshness and shelf life with the desire to minimize packaging waste.

The episode also touches on some of the challenges facing the crisp industry, such as the trend towards healthier snacking and concerns over the environmental impact of packaging. We learn about Walkers' efforts to reduce packaging waste, including a trial of compostable bags made from potato starch.

Overall, "Crisps" is a fascinating and informative look at a product that many of us take for granted. The episode is packed with interesting facts and insights into the manufacturing process, and is sure to make you think twice the next time you reach for a bag of crisps.