End-to-End Potato Processing Solutions

End-to-End Potato Processing Solutions

  1. Raw Receiving

  2. Pulsed Electric Field (PEF)

  3. Hydrocutting Solutions

  4. Blanching

  5. SAPP

  6. Drying

  7. Batter Systems

  8. Frying

  9. Freezing

  10. Packaging

A Global Leader in Turn-Key Food Processing

FPS Food Process Solutions is a global leader in turn‑key food processing technologies. With the additions of CMP (Prince Edward Island), GEM Equipment (Oregon), Southern Fabrication Works (Idaho), and OptiCept Technologies (Sweden), the FPS Global Family delivers a comprehensive portfolio—creating a true “one‑stop shop” for complete End‑to‑End potato processing line solutions.

Across the FPS Group of Companies, we design and manufacture a broad range of equipment in‑house from our global manufacturing locations, covering the key stages of today’s modern French fry plant. With decades of collaboration alongside potato processors worldwide, FPS supports every step of the process—from raw receiving to final packaging. This experience allows FPS to seamlessly integrate and create your full potato processing line.

End-to-End Potato Processing Line Raw Receiving
Industrial food processing machine with stainless steel surfaces, pipes, slide, and conveyor belt system.

1.Raw Receiving

Raw potato receiving is the first step in potato processing, where truckloads of potatoes from the field or long‑term storage facilities are unloaded. During this stage, dirt, vines, rocks, and other foreign materials are removed, and the potatoes are sorted into various sizes for French fry and specialty/flake processing. Samples from each load are taken for quality analysis in the raw receiving lab. Once sized, potatoes are held in temporary storage before being delivered to the processing line.

    • Truck Offloading Equipment
      (Bags, SuperSacs, truck tippers, dump truck systems, bottom‑belt live load, and other delivery methods)

    • Dry Dirt Eliminators & Vine Removal Systems

    • Rock Traps, Barrel Washers & Combined Rock Removal + Wash Systems

    • Soil Extractor Mud Removal, Water Recycling & Water Polishing Systems

    • Taper Roll Sizers & Chain Sizers

    • Waste Hoppers
      (Dirt, stone, and waste elimination and removal)

    • Even‑Flow Storage Bins
      (Tilt belt feed with Jacobs Ladder or sloped inlet, Turkey Roost options)

    • Robust Raw Receiving Conveyors

End-to-End Potato Processing Line Pulsed Electric Field

3. hydrocutting Solutions

Cutting whole potatoes into various French fry diameters requires equipment capable of handling high volumes with precision to meet strict product quality specifications. Performance begins with accurate sizing using an adjustable taper roll sizer, ensuring potatoes are delivered to the correct hydrocutting line. From there, potatoes pass through alignment tubes and cutting blocks designed for specific diameters to maximize cut efficiency. This system enables the production of slices, wedges, and French fry sticks in a wide range of dimensions.

    • Hygienically Designed Adjustable Roll Sizer
      (Fully automated with precision controls)

    • Internal Electric Drive Motors

    • Manual or Automated Gates

    • Vertical Gap Adjustment

    • Laning Conveyor with Automated Directional Gates
      (Directs each potato to the correct hydrocutting line based on diameter)

    • Patented Fin Aligner
      (Centers each potato before entering the cutting block assembly to improve yield and consistency)

    • Precision‑Engineered Cutting Heads
      (Designed for accurate cuts with minimal product damage)

    • Complete Hydrocutting Loop
      (Includes stainless steel pump, cutter head, decelerator, dewatering conveyor, sliver remover, and water return tank)

2.Pulsed Electric Field

The FPS OPTICEPT® S-Solids Series is a state‑of‑the‑art PEF solution developed by FPS Food Process Solutions in collaboration with OptiCept Technologies. Designed specifically for the solid food processing industry, this advanced technology delivers significant benefits to the potato sector by softening potato tissue, reducing breakage, and minimizing feathering during cutting.

  • Dual Conveyor Belt Transport System

    • Maximizes potato fill rate for optimal energy efficiency in the treatment chamber

    • Built‑in lift mechanism separates the unit for maintenance and sanitation—unique in the industry

    • Available in variable sizes with capacities up to 80,000 kg/hr

    PEF Generator

    • Precise high‑kV wave generator for controlled electric‑field treatment

    • Optimized unit sizes provide cost‑effective redundancy

    • Compact footprint, energy‑efficient, and low water consumption

End-to-End Potato Processing Line Blanching

4.Blanching

After cutting and wet grading, French fries are blanched in hot water to reduce enzymatic activity and remove surface sugars. FPS offers both screw auger blanchers and belt blanchers, depending on line capacity and product requirements. Our industry‑leading belt blancher design provides exceptional control over the blanching process, ensuring consistent quality across a wide range of raw potato conditions. Featuring both immersion and deluge stages, the system allows operators to fine‑tune blanch water conditions in each zone. This ensures optimal treatment levels while minimizing overall water usage.

    • Multi‑Zone Belt Blancher

      • Zone 1 – Immersion Blanch

      • Zone 2 – Deluge Blanch

    • Precision Blanching Control
      (Belt blanchers deliver superior control over product colour and texture with minimal breakage due to optimized belt design.)

    • Custom Stainless Steel Perforated Circular Hump Belt
      (Wear‑resistant, easy to clean, no carry‑over design; ensures continuous, uniform product flow at discharge.)

Stainless steel industrial processing machine with conveyor belts, tanks, pipes, and valves on a black background.

5.SAPP Mix System and Dosing

Sodium Acid Pyrophosphate (SAPP)—and in some cases dextrose and salt—is applied to French fries or diced potatoes to help control colour, texture, and other quality attributes of the finished product. These ingredients are added after blanching and before drying, using methods such as flume dosing, dip conveyors, or spray/waterfall application, depending on plant capacity and preference.

To ensure consistent treatment, dry ingredients must be dissolved into precise solution concentrations. FPS provides mix systems ranging from manual to fully automated, designed for accuracy, hygiene, and ease of operation.

    • SAPP Mixing Systems and Dosing Tanks
      (Includes dry ingredient bag handling; available in manual, automated batch, or automated continuous configurations)

    • Hygienic Flume and Pipe Delivery Systems
      (Designed with optimized geometry for effective mixing and sanitation access)

    • Ingredient Application Systems
      (SAPP and ingredient dip conveyors, incline spray augers, and dosing spray systems)

    • Hygienic Process Conveyors

    • Cobra Head Decelerators

    • Dewater Vibratory Shakers & Bias Shakers

    • Screening Reels, Return Tanks & Pump Skids

A large industrial dryer and retrograder with a metal framework and multiple white rectangular modules, blue components, and a conveyor belt.

6.Drying

After the blanching and ingredient‑addition stages, French fries are dewatered and evenly distributed onto the dryer belt to ensure a uniform bed depth across the full width. Achieving the required finished dry‑solids content relies on precise control of temperature, humidity, air velocity, and retention time. Circulating hot air first removes surface moisture, then draws out internal moisture as the product moves through the dryer.

Humidity is automatically regulated through controlled exhaust and refresh‑air ratios, ensuring consistent performance. For specialty potato products, FPS also manufactures a combination dryer/retrograder, which uses colder air to retrograde starches prior to shredding.

    • Fully Welded Stainless‑Steel Enclosure
      (Vertically mounted coils for easy sanitation and enhanced food safety)

    • Externally Mounted Motors
      (Eliminates interior conduit and wiring for improved hygiene and easier cleaning)

    • Hygienic Plastic Belting
      (Minimizes product sticking and reduces product damage with lower drop heights between zones)

    • Best‑in‑Class Recirculating Equipment Cleaning System
      (Robust high‑flow, dishwasher‑style cleaning of all interior surfaces)

    • Optimized Airflow, Humidity & Temperature Control
      (Enables gentle, uniform drying for maximum final product quality)

End-to-End Potato Processing Line Batter Mixing System

7.Batter Mixing System / Batter Application System

FPS manufactures a complete batter mixing and application system designed for the demands of today’s modern French fry processing plants. The system includes dry batter handling (from superbag unloading to the dry hopper), filtration, weigh feeders, mixing systems, hydration tanks, Crylolators, and both drum and weir‑style dosing conveyors with full batter capture and recirculation.

The FPS Batter Mixing System is engineered to handle, dispense, mix, and store batter solutions to the desired consistency and temperature, ensuring reliable and uniform application.

Key Features:

  • Turnkey Hygienic Stainless‑Steel Design

  • Wide range of batter rates, temperatures, and viscosities

  • Optional ingredient‑addition capabilities

After drying, potato strips are immersed in the prepared batter mixture through conveyors or dipping systems to ensure even coating and complete coverage before frying. With increasing production rates, FPS provides robust, wider batter applicator belts designed to withstand higher loads and demanding operating conditions.

End-to-End Potato Processing Line Batter Application System

    • Fully Welded Stainless‑Steel Enclosure
      (With controlled air circulation for efficient heat exchange)

    • External Drive System
      (The only system of its kind, maximizing energy efficiency and extending equipment lifespan)

    • Hygienic Plastic Belting
      (Eliminates chains, reducing lubrication contamination and improving sanitation)

    • Clean‑in‑Place (CIP) Hood Construction for Batter Applicator (Optimizes cleaning times for better efficiency)

End-to-End Potato Processing Line Frying

8.Frying

FPS designs and manufactures custom Single‑Stage Conventional Fryers and Two‑Stage Fryers for modern French fry production. The Two‑Stage Fryer is essential for achieving optimal quality in coated potato products.

Stage A ensures proper singulation as the batter sets, reducing the risk of clumping or “marriages” that negatively affect product quality.

Stage B provides even, controlled cooking, allowing partially cooked fries to be processed at higher bed depths. Increased oil flow moves through the product to create the signature crispy, golden exterior while maintaining a moist, fluffy interior.

FPS engineers use Computational Fluid Dynamics (CFD) to custom‑design oil inlet and outlet geometry, optimizing oil distribution, temperature control (ΔT), and overall product quality. The system incorporates four stages of oil filtration to ensure clean return oil and superior finished product consistency.

    • Complete French Fry Frying Systems
      (Including Two‑Stage Fryers, multi‑stage oil filtration, circulation pumps, heat exchangers, piping with valves, support structures, and catwalks)

    • Four‑Stage Oil Filtration
      (Chip box, hydrocyclone, Sweco vibration filter, and paper filter for exceptional oil clarity)

    • Largest Throughput Fryers in the World
      (Including 10’ and 12’ wide fryer systems)

    • Protected CIP System Nozzles
      (Ensures reliable, effective cleaning during CIP operations)

End-to-End Potato Processing Line IQF Freezer
End-to-End Potato Processing Line Spiral Freezer

9.Freezing

FPS manufactures robust turn‑key freezing and chilling solutions for French fry and specialty potato production. Our freezer tunnels use advanced product separation and fluidization technologies to ensure gentle, efficient handling. With PulseFlow™ IQF technology, mechanical components are eliminated inside the freezer, allowing product to be continuously lifted, separated, and fluidized through the tunnel. This rapid freezing minimizes ice‑crystal formation, preserving texture, flavour, and maintaining individual product separation prior to the next processing stage.

For specialty potato lines, our Spiral Freezer leads the industry in hygienic design. Continuous TIG welding and tri‑flex flashing joints create smooth, food‑safe surfaces while accommodating thermal expansion and contraction. FPS is also the only OEM offering the 72” DDS Direct Drive belting option with Intralox, enabling greater production capacity for products such as hash browns, patties, and other formed items.

    • Fully Welded Enclosure and Floor
      (With tri‑flex flashing to eliminate bacterial harbourage points)

    • SynchroSD™ Defrost System
      Ensures seamless operation without interrupting production

    • Externally Mounted Motors
      Removes interior wiring and junction boxes for improved sanitation and product safety

    • Best‑in‑Class Recirculating Equipment Cleaning System
      Provides robust high‑volume, “dishwasher‑style” cleaning of all interior surfaces

    • Precision Airflow Control
      Individually controlled centrifugal fans deliver gentle, mechanically assisted fluidization

End-to-End Potato Processing Line Packaging

10.Packaging

Our end-to-end solution extends seamlessly from freezer discharge through frozen grading and all the way to final packaging. Beyond supplying hygienic conveyors, we provide customers with the benefit of our deep experience integrating weigh-scale, bagging, inspection, and other end-of-line packaging systems. Fully synchronized with the FPS freezer, we manage every step—from frozen product discharge to finished bags ready for case packing and palletizing.

    • Complete frozen product handling systems downstream of the freezer

    • Product accumulation, abort, and smooth transfer solutions to scale systems

    • Turnkey add‑back equipment, including spiral abort chutes, tote‑off systems, accumulators, tote dumpers, and hopper/elevating conveyors.

    • Sanitary-design scale decks and mezzanines, built for durability, cleanliness, and ease of maintenance

Explore Our End-to-End Potato Processing Solutions

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