Crunch Job: IIA’s On-Site Scanning Services Help Potato Chip Manufacturer Fix Fryer Issues
In addition to that salty, satisfying crunch, consistency is key in store-bought potato chips. You know exactly what you’re getting every time you pop open a bag of your favorite chips.
As part of routine annual maintenance, potato chip manufacturers inspect fryer pans for various issues to determine whether repairs are needed or, in extreme cases, a complete replacement is warranted. To prevent batch inconsistencies and low product yield, one leading snack maker enlisted the help of Industrial Inspection & Analysis (IIA).
The Suspect: A Less-than-Flat Frying Pan
After batch inconsistencies came to light at their Colorado facility, the manufacturer began by taking a closer look at the frying pan. The main concern was that age and previous repairs may have caused slopes, bumps, or dips in the pan floor. Such deviations cause turbulence, which affects the flow of oil through the pan and impacts the delicately balanced frying process.
While a slightly uneven frying pan may sound like a minor issue, even a few millimeters of deviation from design parameters can lead to variations in chip color, flavor, crispness, and moisture content. These are the types of issues that cause batches to be scrapped, revenue to be lost, and production schedules to fall behind.
The Solution: On-Site 3D Scanning
Working with the original equipment manufacturer (OEM), the manufacturer began its investigation by performing hand measurements and basic dimensional mapping of the frying pan floor. When it became clear that more advanced scanning capabilities were needed, they turned to IIA, a leading provider of 3D scanning and other lab services for food and beverage companies.
In the field and in the lab, IIA’s ISO-accredited metrology labs work with a range of devices and methodologies to ensure the optimal approach for each job. When measurement is needed on items that are permanently installed — or too large or fragile to ship — IIA takes its team and technologies on the road to provide precision measurements at customer locations.
Experts from IIA’s Minnesota Metrology Lab traveled to the customer’s Colorado plant in concert with the customer’s time-sensitive annual maintenance shutdown. Using portable Trackscan and Laser Range Scanning systems, our team captured highly accurate dimensional data on the bottom of the fryer pan, which measures 40’ long x 10’ wide.
IIA generated a detailed, user-friendly report featuring a color-coded 3D digital replica of the frying pan. This allowed the customer to see precisely where the pan was not perfectly flat. The data provided by IIA allowed the customer to make informed decisions about the repair, modification, or replacement of the fryer pan at its facility.
Craving Quality Solutions?
At IIA, we understand that there is no room for error when it comes to the safety and quality of consumable products. From preliminary discussions to the final report, our team listened carefully to the customer's needs to ensure a smooth inspection process.
Impressed with IIA’s scanning capabilities and responsive service, the customer requested additional measurements of fryer pans for similar inspections at plants throughout the U.S. and Canada.
Much like the potato chips produced by this snack company, IIA provides services and solutions that keep manufacturers coming back for more.
