This content details the comprehensive journey of a potato from farm to crisp, highlighting the agricultural practices, technological advancements, and commitment to quality and sustainability involved in producing a popular snack food.
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at this potato farm in the new south
wales riverina it takes 120 days from
planting to harvesting to create a
product that can be consumed within minutes
minutes
but the journey of these spuds stretches
jason menegazo's family has been growing
potatoes for over half a century
eight or ten tubers for the last two
decades they've concentrated on one
major client oh yeah look at that
in the last 20 years we've been solely
supplying to smith's
in the crisping industry
and before that my family we started
basically as migrant europeans coming to
australia to the small blocks
in werribee south and that was 80 years
ago now
so yeah it's a long history it didn't
look at that
perfect agronomist jp smith is
inspecting the quality of the potatoes
that will soon be turned into snack chips
chips
yeah this looks really good it can take
20 years to fully develop a potato
variety and he says consistency is everything
everything
so we're looking at
size color texture
texture
dry matter so solid content of the potato
potato and
and
we look at all these things because when
we produce them our consumers want to have
have
that beautiful potato in their packet
when they're eating it so it gives them
the experience of that excellent quality
in every body in every bag
pepsico which owns smith snack foods has
developed its seven potato varieties to
ensure year-round supply
we have a variety now that we grow in
australia that we grow it in the spring
and summer and when the crop dies we can
leave it in the ground for up to four
months using mother nature as a as the
refrigerator allowing us to have the
same great quality in the middle of the
winter as we have during the summer and spring
the company contracts a staggering 120
annually they're grown by farmers across
47 sites around australia ranging from
northern queensland to southern victoria [Music]
at the processing shed the potatoes are
green ones don't make the cut [Music]
[Music]
today jason's wife claudine and their
daughter matisse are helping out on the
and his father gerald who has retired
from the farm occasionally drops by to
check on operations and offer advice [Music]
[Music]
these potatoes are heading on a 1300
kilometer trip where they'll be turned
into crinkle-cut chips within 48 hours [Music]
introduced from england in 1931 this
year smith's ship celebrates 90 years of
manufacturing in australia
in sydney surry hills frank smith and
george ensor established the first of
several factories around the country
over the decades the manufacturing
methods and technology have evolved dramatically
dramatically [Music]
[Music]
i've traveled up to the smith's chips
factory here in brisbane where millions
of potatoes are turned into packets of
chips each year i'm heading in to see
this is one of two factories where the
chips are still made the other is in adelaide
in one day 320 tonnes of potatoes roll
through the site around
[Music]
a water flume shoots the potatoes across
to the factory where they are peeled
[Music]
the slices are then fried for 3 minutes
to cook these chips 14 tonnes of
australian sourced canola oil is used
infrared cameras monitor the moisture
and oil content as they move along the
[Music]
an optical sorting machine discards any
while the process is largely automated around
around
employees work here
long gone are the days when consumers
seasoned their chips using a satchel of
salt included in each packet
chicken was the first flavor variety
released in 1961.
from there the classic staples including
original salt and vinegar and barbecue
continue to this day
and the company is constantly searching
for the next big flavor
so we've got a research and development department
department
that work really closely with our
consumers um they look at what's
happening on social media what
restaurants are doing what different
food trends are out there in the market
um and they also will uh
look to you know overseas so look at
europe the us japan because they're
quite innovative in terms of their
you know their food flavors
the chips go through a quality control
process which includes taste testers
we have people here who will taste the
chip and they will say oh i think it's
from this area or another area or a
certain grower some of our team are
are super well trained and so familiar
with the products that they actually can
detect a minor difference in the in the
product texture or flavor
manufacturing manager jason webster says
95 of production waste is recycled much
of it going to compost and animal feed
and it's in the company's interest to
minimize waste where possible we're
really passionate about you know
ensuring we maximize you know what we
recycle but more importantly we don't
want to create the waste in the first
place so when you look at things like
peel we have stringent measures in terms
of what our peel levels should be
for over peeling we're creating more
waste and also we're then having to use
more potatoes to make to make our
finished products so it's not just the
emphasis on where that waste goes it's
the emphasis is on let's not have that
waste in the first place and minimize it
as much as much as we can
in addition to potato snacks the factory
produces corn chips and other
grain-based products
i'm learning about ceo danny celloni
says the company is continually
addressing sustainability in its manufacturing
manufacturing
he says this facility has reduced its
use of water by 40 percent and
electricity by 16
over the past five years
we need to continue to improve sharpen
our tools understand the latest
technology to
ensure that we leave a better footprint
in the community and the environment we
operate in so that's an integral part of
the way we work
right as we speak now our snacks
packaging 100 of it is recyclable we're
also working on biodegradable or
compostable we want to get there by
2025. by the end of this year we'll have
100 renewable electricity from our
manufacturing plants
that's a long way from potatoes in the
panic but this is where it all begins
farmer jason menegazo says he is honored
to follow in his father's footsteps
i'm proud and i'm lucky too because i've
been given that opportunity to farm
and it's something that i've learned
from my father
and then obviously evolved on with new
skills and new
practices that we we are doing on the farm
farm
you always keep learning from your
elders even though technology changes
it's just
the culture and principles remain the same
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