Wastes from the Potato Chip Industry

Author(s): Ralph Porges and W. W. Towne

Source: Sewage and Industrial Wastes, Vol. 31, No. 1 (Jan., 1959), pp. 53-59
Published by: Water Environment Federation
Stable URL: http://www.jstor.org/stable/25033794
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 WASTES FROM THE POTATO CHIP INDUSTRY
By Ralph Porges and W. W. Towne

Robert A. Taft Sanitary Engineering Center, Public Health Service,

Department of Health, Education, and Welfare, Cincinnati, Ohio

During recent years the potato chip and slicers were developed and proc
industry has grown into a food-proc essing proceeded from batch to semi
essing prodigy. In 1957, 45 million continuous and continuous operation.
bushels of potatoes?nearly 12 per cent By 1936, three million bushels of
of the entire crop?were processed into potatoes were chipped; in 1946, 15
chips (1). This fast growth has million bushels; and in 1956, 45 mil
hastened the change from intermittent, lion bushels (4). Statistics for 1957
batch processes to continuous, virtu indicate that nearly 12 per cent of a
ally automatic, operations. Associated total potato crop of 394 million bushels
with this growth are new waste dis was used for chips (1).
posal problems and larger demands on
water supplies.
Baw Materials
This study was undertaken because The potato is the most important
of the interest shown by industry, item in the science and art of chipping.
regulatory agencies, and others con
It must produce a light-colored chip
cerned with water use and waste dis
with eye appeal and have a solids con
posal; and because of the paucity of
tent that assures a profitable enter
reported data. An earlier report of
prise. High sugar content and nitrog
waste loadings from potato chip proc enous portions of the potato cause the
essing (2) was limited to a study of
a condition
undesirable dark chip,
one small plant.
which is controlled by selection of po
The goal of the present study was to
tato variety, growing conditions, and
facilitate industry's understanding of
type of storage.
plant processes as they relate to water
use
For economical processing, the po
and wTaste discharges, and to per
tato should have a high density wrhich
mit evaluation of the wastes produced
can be determined by analysis or esti
from a knowledge of the process, the
amounts of raw materials mated from the specific gravity. Since
utilized, and
specific gravity can be more easily as
the finished product.
sayed and is indicative of production
Processes and Waste Sources volume, the potatoes are re
usually
ceivedat the plant with their specific
Historical
gravity recorded. The Department of
The potato chip originated at Agriculture states (5) that the cor
"
Moon 's Place," Lake Saratoga, N. Y., relation between specific gravity and
around 1853 (3). The paper-thin dry matter has usually been found to
slices of potatoes, chilled in ice water, be very high, with correlation coeffi
dried, and fried in boiling fat, became cients varying from 0.85 to 0.95. It
known as Saratoga chips. It was not indicates that results computed by the
until 1925 that a company was organ following formula developed by Von
ized solely for making the chips. With Scheele, Svensson, and Rasmussen seem
increasing sales, mechanical peelers to approach analytical results:
53
 54 SEWAGE AND INDUSTKIAL WASTES January 1959

= 211.04
Percentage dry matter tions in all the plants visited during
X specific gravity - this survey were of the
207.709.. (1) essentially
continuous type and, except for minor
Similarly, the starch content may be
variations, may be represented by the
estimated from the specific gravity by flow diagram in Figure 1.
the formula given by Von Scheele et The potatoes, in 100-lb sacks, are
al. (5) : taken from storage and conveyed to a

Percentage starch = 199.07 peeler equipped with high-speed abra

sive disks. The are then
X specific gravity - 201.172. . (2) potatoes
washed, trimmed, and sliced, yielding
The estimated solids and starch con 15 to 20 slices per inch. The slices
tent of potatoes at a given specific are moved to a wash cage that rotates
gravity is found in Table I. in a tank or trough of water. Un
wanted starch is removed by a double
TABLE I.?Calculated Solids and Starch rinse to prevent matting or sticking
Content of Potatoes at Various
of the chips. After partial drying, the
Specific Gravities
slices are dropped into the deep-fat
Specific Solids Starch Starch in
cookers. The chips are then salted
Gravity (%) (%) Solids (%) and packaged.
There are, of course, variations in
1.06 15.99 10.16 63.3
1.07 18.10 12.15 67.2 the process. Some plants discharge
1.08 20.21 14.15 70.0 the final rinse to the wash tank which
1.09 22.32 16.14 72.3
1.10 24.44 18.14 74.2
WATER STORAGE

A standard potato may be assumed

to contain about 20 per cent solid mat PEELER
ter and 80 per cent water; the starch
content ranges from 65 to 75 per cent
of the dry weight (6). Other infor JTRIMMINGBELT

mation indicates that the solid matter

may average as high as 25 per cent
The of potato influences SLICER
(2). variety
these values although the 20-per cent
figure might prove a more realistic
WASHER
average. The varieties best for chip
ping include Russet Rural, Russet Bur
bank, Smooth Rural, Irish Cobbler, 1st RINSE
New Kennebec, Canus, Sebago, Katah
din, and Cherokee (3) (4).
After the potato the next important 2nd RINSE
raw material is the cooking oil. This
oil is generally a high-grade vegetable
COOKER
product.

Plant Operation
SALT
The original recipe as carried in
the early cook books is still the basis
for successful chips. However, the PACKAGER SEWER
original batch process (2) is largely
superseded by semicontinuous or con FIGURE 1.?Flow of potato
diagram chip
tinuous operation. Production opera processing showing waste sources.
Vol. 31, No. 1 POTATO CHIP WASTES 55

overflows to waste. One plant strains industry responded promptly and

the peeler waste through burlap and willingly.
the residual solids plus those settled The data solicited included pounds
in the wash tank are collected by a of potatoes processed and their solids
farmer for hog feeding. Another content and specific gravity, volume
plant grinds all solids to facilitate of chips produced, oil content of the
water carriage of the waste. Most chips, number of employees, and de
plants favor wasting to the sewer as tails of the process. Earlier informa
a good housekeeping procedure. tion (2) was used to supplement the
The primary sources of wastes are new data collected.
shown in Figure 1. Wastes derive All results were compiled on the
from the peeler, trimming belt, slicer, basis of a production unit of 1,000 lb
wash, and rinse operations. Clean-up of potatoes processed. In addition, a
wastes, small amounts of waste oil, and laboratory determination was made of
sanitary sewage substantially comprise the BOD of potato solids permitting
the remainder of the total waste load. correlation of the observed BOD in the
sewer with that estimated from the
Method of Study
pounds of dry potato solids discharged
A series of studies of wastes from to the sewer.
potato chip plants was made by the
Results
Sewage Disposal Section of the City
of Cincinnati. These studies consisted Unit values relating to plant opera
of 24-hr per day sampling for four or tion and chip processing are shown in
five consecutive days. The weighted, Table II. An average of 250 lb of
average BOD, suspended solids, and chips is produced for each 1,000 lb of
discharge values were used in this potatoes handled. Actual production
study. Full recognition is made of the ranges from 240 to 260 lb. Forty per
cooperation of personnel of the Sewage cent of the final weight of an average
Disposal Section of the City of Cin chip consists of absorbed oil and the
cinnati who permitted the use of this moisture content runs from 2 to 2.5
information. per cent. Water used per 1,000
The individual potato chip plants pounds of potatoes varies from 1,450
were solicited, either through the co to 2,480 gal, averaging 1,990 gal.
operation of the National Potato Chip Pounds of BOD per 1,000 pounds of
Institute or by direct communication, potatoes range from 14.5 to 30.8.
for assistance in providing data on Pounds of suspended solids per 1,000
materials and production during the pounds of potatoes vary from 20.4 to
sampling period. In all instances, the 36.4.

TABLE II.?Plant Operation and Wastes Discharged per 1,000 Pounds of Potatoes Processed

Potato Waste BOD Suspended Solids

No. of
Month Chips* Flow
Employee (lb) (gal)
(ppm) (lb) (ppm)

July 0.9 240 2,480 730 15.0 820

Dec. 1.3 260 2,020 1,560 26.2 2,140
Oct. 1.0 240 2,000 1,850 30.8 2,190
Dec. 2.3 255 1,450 1,200 14.5f 1,700
1.4 250 1,990

*
Average weight of oil on finished chip is 40 per cent.
f Much solid material was removed manually and did not reach the sewer.
 56 SEWAGE AND INDUSTRIAL WASTES January 1959

TABLE III.?Solids Balance and BOD Relationship per 1,000 Pounds Potatoes

Chipsb Produced
Dry? Wt. Oil? in Dry Solids^ BOD* of BOD in
of 1,000 lb Solids6 Lost
Plant Chips Produced Solids Lost Sewer
Potatoes (lb)
Actual Wt. Dry Wt. (lb) (lb) (lb) (lb)
(lb)
(lb) (lb)

A 177 240 234 96 138 39 17.7 15.0

B 210 260 254 104 150 60 27.2 26.2
C 200 240 234 96 138 62 28.1 30.8
D 210 255 249 102 147 63 28.5 14.5?

Avg 200 249 243 100 143 56 25.4 25.0

a seasonal.
Dry-solids variation probably
b moisture content about 2.5 per cent.
Average
c 40 per cent oil.
Chip contains
d Subtract of oil from dry weight of chips produced.
weight
e of dry solids produced from dry weight of 1,000
Subtract weight lb of potatoes.
f of solids = 0.453.
BOD per pound
gOmitted from average as much solid material removed manually. Replaced by adjusted
value of 28.1.

Variation in unit values may be the oxygen-demanding properties of the

caused by seasonal influences on the gross waste material will also increase.
quantity of water used, the maturity Also, if solid materials such as peelings
and solids content of the potato, the and small pieces of potatoes are re
quality and exterior roughness of the moved for disposal by means other
potato, and the method of handling than water carriage, the waste load
peelings and other solid wastes. The will be reduced. Plant A (Table II)
month of sampling is shown in Table at the time of the study (July) was
II. handling a potato with low solids and
it will be noted that the quantity of
Discussion BOD produced was low. Plant D was
Solids Content?BOB removing solid material from the waste
Relationship
flow, with a corresponding reduction
The growth of the
chipping indus in the strength of the waste discharged.
try may be expected to continue, with Plants B and C were studied in the
a concomitant expansion of the water fall (October and December) and the
problem. Considering that 45 mil bu waste values were in close agreement
or 2,700 mil lb of potatoes are chipped and much than values for
higher
per year, the daily amount is roughly Plants A and D.
10 mil lb. Approximately 20 mil gal
It was decided to evaluate the proc
of water are required each day to
ess on a dry-solids basis and compare
process these potatoes.
a calculated waste load with the actual
The potato chip plants studied are
waste load. For
each plant, the fol
probably representative of the indus
lowing information, if available, was
try. They vary in size, processing
collected: (a) per cent dry solids in
from about 5,000 to 30,000 lb of po
potatoes processed or specific gravity,
tatoes per day.
Waste from a potato from which the solids content was de
chip plant
varies with the season as it influences termined, (b) pounds of chips pro
the types of potatoes used and, conse duced, (c) amount of oil in the chip,
the method of processing. It and (d) pounds of potatoes processed.
quently,
is reasonable to believe that as the The results of this evaluation are
solids content of the potato increases, shown in Table III.
Vol. 131, No. POTATO CHIP WASTES 57

The BOD of a raw potato was de (7) show dehydration wastes to con
termined in the laboratory. Two indi tain 40 lb of BOD per ton of potatoes
vidual runs were made with the follow processed, amounting to 120 popula
ing results: tion equivalents per 1,000 pounds.
lb BOD/ Jones (8) reports a population equiv
Run Solids (%) BOD (ppm) lb Solids alent of 12,000 for 40 tons of potatoes,
A 18.57 84,000 0.452 or 150 per 1,000 pounds, which com
B 18.70 85,000 0.455 to results from the present
pares
Avg 18.64 84,500 0.453 and Ter
study. DeMartini, Moore,
hoven (9) reported on two separate
Notice that for each pound of dry
dehydrating plants. One plant dis
solids a BOD of 0.453 lb will be ex
charged 3.28 pounds of BOD per 100
erted. Thus, by multiplying the dry
pounds of potatoes, or a population
potato solids lost by 0.453 the quantity
equivalent of 198 per 1,000 pounds.
of BOD discharged can be computed.
The other plant discharged 4.57 pounds
The last column of Table III gives the
BOD obtained from an analysis of the per 100 pounds or a population equiv
alent of 274 per 1,000 pounds of po
waste. Comparison of the results of
tatoes.
determining the waste load by the two
The variation in these data probably
independent methods (last two col
umns of Table III) is extremely results from the variety and maturity
good.
results for Plant D because of potatoes used and the processing
Deleting
of manual removal of much of the methods employed. A smooth potato
solids and adjusting for the remaining with thin skin produces less waste than
the calculated BOD a rough potato with thick skin. Eval
data, average
based on solids lost is 25.4 lb, while uation of the wastes from these proc
that obtained from an analysis of the esses on the basis of dry solids lost
waste in the sewer is 25.0 lb. The to the sewer would bring these studies
BOD for each to a common basis and might indicate
population equivalent
a closer
1,000 lb of potatoes processed with agreement.
the above characteristics would be
Waste Volume
about 150.
The volume of water used is a
Population Equivalent matter of importance both from the
A previous study of potato-chip water-cost and disposal viewpoints.
processing wastes (2) indicated a BOD Generally, a reduction in volume de
population equivalent of 65 per 1,000 creases sewage disposal costs, although
pounds of potatoes. This estimate is surcharges based on pounds of BOD
low when compared with the present or suspended solids probably will not
value of 150 per 1,000 pounds. How change. Some attempts have been
ever, that study was made on a batch made to reuse water, particularly that
process and some solid materials such clearer portion of the rinse waters.
as sprouts and possibly peelings were Filtering of the water prior to reuse
hauled to a dump. The report (2) has not proved practicable as the starch
stated that the data were limited to a particles rapidly clog any filter me
single plant and might not be truly dium. Application of the counter
representative of waste loadings at current principle appears promising
other plants. especially since the initial machine,
Several reports of wastes from po the peeler, does not require high
tato dehydration processes appear to quality water. It would seem that
be of interest since these wastes may considerable water could be saved by
compare grossly to the wastes from pumping the final rinse waters to the
chipping plants. Gray and Ludwig wash tank and using the wash-tank
 58 SEWAGE AND INDUSTRIAL WASTES January 1959

overflow to feed the peeler and then of some value. With suitable soil and
discharging it to the sewer. No filter proper land management, this method
ing or water conditioning would seem may prove satisfactory and results
to be necessary. from this installation should be of con
siderable interest.
Housekeeping Trickling filters have been employed
The method of housekeeping also for treating canning wastes although
influences the waste load. Where the seasonal operation of canneries
and solid wastes are removed makes it difficult to develop effective
peelings
for the waste treatment units. Year-round opera
manually dry disposal,
load is reduced appreciably. Plant D tion of potato chip plants should per
practiced this method and the BOD of mit more effective operation of trick
the waste was reduced to nearly 50 ling filters. Chemical coagulation has
per cent of that estimated from the been used for partial treatment where
solids balance. Other plant operators untreated wastes may overload small
feel that disposal to the sewer facili municipal treatment plants. With the
tates the handling of waste solids. increasing importance of satisfactory
As previously stated, the BOD esti waste disposal, industrial sites that
mated from the solids balance approx minimize the waste problem should be
imated that obtained from the liquid selected.

waste. Thus, a arises con

question
Summary
cerning the accountability of the sani
tary sewage and clean-up wastes. The The potato chip industry in 1957
amount of those wastes appears limited used 45 million bushels of potatoes or
and probably does not influence the 12 per cent of the total crop. Because
total load appreciably. The number of the interest in water usage and
of employees per 1,000 pounds of po waste disposal, a study was made of
tatoes averages only 1.4. In addition, several potato chipping plants to ob
some organic matter probably passes tain representative values of water use
out through the ventilating stack dur and waste strength. The study in
ing the cooking process. Cooking volved analysis of data from a survey
takes place at temperatures varying of chipping plant wastes and correla
from 375 to 325 ?F. When the raw tion of the data with production fig
chips reach the kettle, clouds of steam ures and processing methods.
are generated. The steam probably The potato chipping process consists
contains some oil and volatile organic of peeling, trimming, slicing, washing,
material from the potato. rinsing, drying, cooking, and packag
ing. Wastes originate primarily from
Disposal the peeling, trimming, washing, and
Probably the best method of waste rinsing operations.
disposal is discharge to a sewer for Representative data from a study
treatment with the municipal wastes. of four plants show that for each 1,000
This method was employed by the sev lb of potatoes handled the volume of
eral plants studied. Since chipping waste amounts to 1,990 gal; the BOD
wastes are similar to canning wastes, amounts to 25 lb ; and the suspended
treatment might be similar to that solids amount to 33 lb.
employed by canneries. A chipping Waste products vary with the po
plant is reported (10) as planning tato variety and method of processing.
to use a holding lagoon followed by If preliminary estimates of plant
spray irrigation. Odors from the la wastes must be made without a sam
goon will be controlled by aeration. pling study, it will be advantageous
Sodium nitrate applications may be to use as a basis for computation the
Vol. 31, No. 1 POTATO CHIP WASTES 59

dry solids lost in production. Excel water-carried disposal is a matter of

lent agreement was found between a economics and cleanliness, and is one
calculated and an "actual" BOD. that management must make.
The average BOD estimated from The residual amount of waste will
solids wasted per 1,000 pounds of po require disposal. Discharge to the
tatoes was 25.4 pounds. This com municipal sewerage system, with or
pares to the 25.0 pounds actually without pretreatment, is probably the
found in the sewer. best method. Other methods that
A dry solids balance can be com might be considered are lagooning with
puted using the solids content of the land application or spray irrigation,
potato and the pounds of chips pro and trickling filters. Industrial plant
duced after allowing for the oil and sites that minimize waste disposal
moisture content of the finished chip. problems should be selected.
Since it was found that each pound of
dry potato solids exerts a BOD of Acknowledgment
0.453 lb, use of this conversion factor
The cooperation of Arthur D. Cas
permits computation of the total BOD
ter, Principal Engineer, and Fenton H.
load from quantity of solids lost. If
Dobb, Supervising Industrial Waste
all wastes reach the sewer, the com
Engineer, Sewage Disposal Section,
puted value will reasonably approach
the BOD of the discharged City of Cincinnati, who provided sur
liquor.
Should some solids be removed for vey and laboratory data, and Dr. H.
manual the value must be D. Brown, Research Coordinator, The
disposal,
adjusted accordingly. National Potato Chip Institute, who
A counter-current principle of water assisted in contacting the industry, is
use would seem to hold promise for gratefully acknowledged. Also, the
reduction of water consumption and cooperation and friendly participation
of waste discharge. Although manual of the plant personnel in providing
removal of solids reduces the waste much of the data contained herein are
load, the choice between manual and fully acknowledged.

References

1. Agricultural Economics Division, Statisti 6. Treadway, E. H., and

Coidon, T. C,
cal and Historical Research Branch, "The Chemicals Get We from Po
Service, U. S. tatoes." "Crops in Peace and War?
Agricultural Marketing ''
of Agriculture. Private The Yearbook of Agriculture. Pp.
Department
communication (Feb. 1958). 190-94, U. S. Department of Agri
" culture (1950).
2. Porges, R., Waste Loadings from Po
tato Plants.'* This 7. Gray, H. F., and Ludwig, H. F., "Char
Chip Journal,
acteristics and Treatment of Potato
24, 8, 1001 (Aug. 1952).
Esso Dehydration Wastes.'' Sewage Worles
3. Anon., "In the Chips.'' Oilways,
Jour., 15, 1, 71 (Jan. 1943).
1 (Jan. 1958).
8. Jones, E. E., "Disposal of Waste Waters
4. Wright, R. C, Davis, Martha E., and
from the Preparation of Vegetables
Hendel, C. E., "The Making of Po
for Drying.'' Jour. Soc. Chem. Ind.,
tato Chips.'' "Crops in Peace and
War?The Yearbook of Agriculture."
64, 80 (1945).
9. DeMartini, F. E., Moore, W. A., and
181-89, U. S. Department of Agri
Pp. Terhoven, G. E., "Food Dehydration
culture (1950). Wastes.'' 191 to the Pub.
Supplement
5. Heinze, P. H., Leader, Beltsville Horti Health Mepts. (1946).
cultural Crops Unit, Agricultural Mar 10. Brown, H. D., Eesearch The
Coordinator,
Service, U. S. Department of National Potato Cleve
keting Chip Institute,
Agriculture. Private communication land, Ohio. Private communication
(Feb. 1958). (July 1958).