How are SunChips made?

The journey of a SunChip begins with harvesting corn kernels. These kernels are sent to a mill where they are cleaned to remove any impurities, such as dirt or metal pieces. The kernels are then tempered to adjust their moisture content, making them more suitable for milling. Next, the kernels are de-germed, where the germ, which contains the oil, is removed. The endosperm, which is the starchy part of the corn kernel, is then ground into coarse flour.

Step 2: Dough Preparation

The corn flour is mixed with water and salt to form a dough. The water content is crucial as it affects the texture and crispness of the chips. The dough is kneaded until it reaches the desired consistency and texture.

Step 3: Extrusion

The dough is then fed into an extruder machine. Think of an extruder like a giant syringe that forces the dough through various nozzles. The nozzles shape the dough into different forms, such as wavy, ridged, or straight chips. As the dough passes through the heated extrusion barrel, it undergoes pressure and temperature changes, which causes it to expand and take on its familiar shape.

Step 4: Frying

The continuous strands of shaped dough directly enter a continuous frying system, where they encounter high-temperature vegetable oil. The chips are fried until they are golden brown and crispy. The oil temperature and frying time are carefully controlled to achieve the perfect balance between color, texture, and taste.

Step 5: Seasoning

After frying, the hot and crispy chips proceed to the seasoning station. Various flavors and seasonings are applied to the chips. These can range from classic salt and vinegar to more adventurous flavors like barbecue or sour cream and onion. The flavors are precisely applied to ensure a consistent taste experience.

Step 6: Quality Inspection and Packaging

Before packaging, the chips pass through a series of quality checks. Machines carefully inspect for any defects, such as broken chips, incorrect shape, or inadequate flavor coverage. Chips that meet the quality standards are then packaged into bags, ready to find their way to store shelves.