French Fry Processing Line Design and Solutions- Italian Customer Specially Customized
August 28, 2025Admin
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French fries have long been a beloved staple across cultures worldwide, their crispy exterior and tender interior universally appreciated. As these golden, crunchy treats evolved from a local snack into a global icon of fast food, their widespread popularity not only transformed the culinary landscape but also ignited a quiet mechanical revolution. Traditionally, hand-cut fries resulted in inconsistent widths, lengths, and textures, leading to variations in taste and quality. This manual process also significantly increased production costs due to its unpredictability.
However, creating delicious fries involves more than just cutting and frying. To meet the rising demand for standardized, efficient, and cost-effective production of hundreds of millions of servings—while ensuring a rich, flavorful experience—we offer a range of specialized French fry production line solutions designed to cater to diverse customer needs.
Recently, an Italian client—who had previously purchased our dumpling machine—approached us with a new project. They required a production line capable of processing 500 to 1500 kilograms per hour, incorporating steps such as washing and peeling, cutting and dicing, lifting, blanching, water cooling, and air cooling. We tailored a comprehensive solution specifically to meet these requirements. Follow us to discover more about this customized production line.
Considering the customer’s production volume and space limitations, we recommend a 1-meter automatic potato root vegetable brush washing machine. Typically, the infeed area is located on the left side of the machine, while the outfeed area is on the right. However, at the customer’s request, we reversed these arrangements—placing the outfeed area on the left and the infeed area on the right—to better suit their operational setup.
1. Washing Area Control Panel
The control panel for the washing area of the potato root vegetable brush washing machine is designed to be simple and intuitive. To start the washing process, simply turn the forward knob. If the desired cleaning effect is not achieved after some time, you can turn the reverse knob to reverse the brush rollers for additional cleaning, ensuring thorough results.
2. Discharge Area Control Panel
The discharge area of the potato root vegetable brush washing machine is managed by a frequency converter, eliminating the need for manual discharging and greatly saving time and effort.
The discharge outlet operates independently with its own motor. The speed of the auger at the discharge outlet can be adjusted using the nearby frequency converter button. By varying the speed, different cleaning and peeling effects can be achieved, ensuring thorough and efficient processing.
3. Hard-bristle Brush
At the customer’s request, the first step involves both washing and peeling. To enhance water rinsing efficiency, we installed a spray head on the spray bar of the potato root vegetable brush washing machine. Additionally, a hard-bristle brush is used to remove skins while scrubbing, effectively preparing the vegetables for subsequent processing.
4. Foot and Universal Wheels
The potato root vegetable brush washing machine is equipped with circular feet that offer an adjustable height of up to 10 cm. This design maximizes ground contact, ensuring stability and adaptability to various surfaces. For uneven floors, simply adjust the foot bolts to level the machine, stabilize it, and tighten the retaining nuts. Additionally, four universal wheels are installed to facilitate easy movement and repositioning.
After the initial washing and peeling, the customer requested the ability to cut potatoes into both strips and dices. We recommended a versatile vegetable cube dicing machine capable of producing both shapes efficiently.
1. Large Feeding Port
The vegetable cube dicing machine is equipped with a large, funnel-shaped open feeding port, which facilitates easy loading of materials while preventing spillage. This design ensures a smooth flow of materials and enhances cutting efficiency.
2. Versatility
The vegetable cube dicing machine offers the flexibility to cut cubes or strips in sizes ranging from 3 mm to 20 mm, including 4, 5, 6, 8, 10, 12, 15, and 20 mm, simply by replacing the cutting blade. This versatility caters to a wide range of customer requirements and sets it apart from single-function machines.
3. Composite Cutting Tool
The vegetable cube dicing machine employs a composite cutting system that utilizes centrifugal force to slice the material with a vertical cutter. The disc cutter then transforms the slices into strips. Subsequently, the material is fed into a crosscutting blade, which cuts it into the desired cubes or cuboids. This integrated system enables a single-step process, producing uniform shapes, smooth cut surfaces, a high yield rate, and precise cutting dimensions.
4. Heightening the Machine
As part of the French fries production line, the vegetable cube dicing machine was specially elevated from its original height of 95 cm to 125 cm. This adjustment facilitates better integration with the vegetable brush washing machine and blanching machine, ensuring seamless operation, minimizing material spillage during production, and reducing manual labor.
After the vegetable cube dicing machine completes cutting, the cut material is discharged from the bottom outlet. To facilitate direct feeding into the blanching machine, a lifting machine is installed between the two units.
1. Material Pool
The lifting machine features a material pool designed to catch and hold the material, preventing it from falling to the ground and ensuring smooth transfer.
2. Baffles
The conveyor belt of the lifting machine is equipped with baffles. These baffles help to separate the material during conveyance, prevent piling or clogging, and reduce sliding, ensuring a consistent flow into the next process.
After dicing and slicing the potatoes, the customer requested a blanching time of 2-4 minutes and a transmission speed of 2-10 m/min. We customized the machine to meet these specifications, ensuring optimal blanching performance.
1. Control System
The blanching machine is equipped with a user-friendly control box featuring clear and straightforward buttons, making operation accessible even to beginners. We also offer customizable language options upon request.
The customer ordered a 5-meter blanching machine with five heating zones, allowing them to adjust the blanching effect by turning each zone on or off independently.
In addition to the main control panel, there are two smaller control panels positioned above it, each serving distinct functions. On the left is the frequency converter, which sets the mesh belt’s speed, while on the right is the temperature controller. Once the desired temperature is set, the system automatically maintains it through multi-zone monitoring and control. Heating stops automatically when the set temperature is reached, preventing energy waste and ensuring consistent sterilization temperatures.
2. Insulation System
The blanching machine is enclosed with a double layer of stainless steel rock wool insulation, effectively reducing heat loss. Additionally, it features a watertight cover to prevent steam from escaping, which helps protect personnel from scalding and enhances the machine’s insulation performance, maintaining a consistent sterilization temperature. A dehumidification port is positioned at the top of the watertight cover, allowing for uniform discharge of steam and heat flow.
3. Mesh Belt
The blanching machine uses a 304 stainless steel mesh belt, known for its heat resistance and corrosion resistance. Baffles are mounted on the belt to guide the material through the blanching tank and prevent it from settling. The spacing between the baffles and the mesh belt can be customized to accommodate the size of the customer’s materials.
4. Elevated Discharge Port
The blanching machine‘s conveyor belt is equipped with a built-in elevator at the discharge end, allowing the blanched material to be directly transferred to the cooling pool. This design facilitates continuous production and improves operational efficiency.
The customer requested a -5 ℃ salted cold water cooling 10-15 minutes after blanching to improve taste, optimize subsequent processing, and extend shelf life. Immediate immersion in cold water rapidly halts the heating process, preserving the characteristic “crisp on the outside, soft on the inside” texture of French fries. It also helps remove residual surface starch, preventing sticking during further processing, reducing oxidative browning, and maintaining a golden color.
1. Water Cooling Part
For water cooling, we provided the customer with a 5-meter-long cooling machine featuring a large water tank to enhance cooling efficiency. Additionally, the cooling machine is equipped with a filtration system to remove any residual waste from the material, ensuring cleaner and more effective cooling.
2. Bitzer Compressor Unit
To ensure the water temperature remains at -5°C, we connect a chiller to the cooling machine. This setup not only facilitates internal water circulation but also effectively reduces and maintains the water temperature at -5°C, guaranteeing a consistent and reliable cooling effect.
Due to space constraints, there was insufficient room between the cooling machine and the air drying machine to install a belt conveyor. As a result, the product flows directly from the cooling machine into the air drying machine. However, the mismatch in operational speeds could cause product accumulation at the inlet of the air drying machine, hindering the drying process. To address this, we inserted a vibration machine between the two units. The vibration helps to evenly separate the product before it enters the air drying machine, ensuring smooth and efficient drying.
Following the previous processing steps, the surface of the fries retains moisture. As a final step, we recommended connecting a 5-meter parallel air drying machine. This machine uses fans to de-water the surface of the product, effectively removing moisture and preparing the fries for subsequent processing.
1. Fan
Knife-type fan: Provides a focused, targeted airflow that effectively removes moisture from the product.
Disc-type fan: Features a large air outlet, increasing the contact area between the air and the product, which enhances drying speed and efficiency.
2. Stainless Steel Belt
We equip the parallel air drying machine with a stainless steel chain belt to ensure that the moisture on the surface of the material is fully dropped.
Ⅷ. Free Customized Drawing Provided
Due to site constraints, our Italian customer opted to install the production line outdoors. We designed a new layout based on their site, transforming the original linear production line into a U-shaped configuration. This design maximizes the utilization of the available space while facilitating smoother worker movement.
We offer free custom design drawings upon inquiry.
In summary, this customized processing line is thoughtfully designed to optimize efficiency, space utilization, and product quality, tailored specifically to the customer’s site and operational requirements. From advanced control systems and effective insulation to innovative drying solutions and flexible layout design, each component works synergistically to ensure a smooth, reliable, and efficient production process. We are committed to providing comprehensive support and customized solutions to help our customers achieve their production goals seamlessly.
Contact us today to learn more about how we can customize a solution that perfectly fits your needs and elevates your production line!
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