Study of a new energy efficient process for French fries production

A new, energy efficient production process for French fries was developed and evaluated. Superheated steam (SHS) was used for evaporation of water instead of pre-drying with air and par-frying with oil. The product was frozen by vacuum cooling. Unfortunately, with this process it was not possible to reach the quality of conventional French fries. Sensory analysis indicated that the main quality defect was a tough crust with a fatty appearance. Confocal Scanning Laser Microscopy showed that this was caused by skin formation on the surface during both SHS drying and vacuum cooling. A frying step was necessary to obtain a porous crust. A satisfactory product quality was feasible after drying with SHS instead of air. Due to the concessions made for the product quality, the final energy reduction was limited. Nevertheless, this study has gained more insight into how processing affects potato tissue on micro-scale and it has shown that a porous structure is essential for good quality French fries.