Post-frying oil drainage from potato chips and french fries: a comparative study of atmospheric and vacuum drainage

This paper represents a study of the transient changes occurring in temperature, and moisture and oil contents during the so called “post-frying drainage”—which is the duration for which a product is held in the head space of the fryer after it is removed from the oil. Since most of the oil adhering to the product penetrates into the structure during this period, this paper examines the effects of applying vacuum during drainage (1.33 kPa) to maintain the product temperature consistently above the water saturation temperature corresponding to the prevailing pressure (11 °C), which potentially eliminates water condensation and prevents the occluded surface oil from penetrating into the product structure. Draining under vacuum significantly lowers the oil content of potato chips by 38% compared to atmospheric drainage. This phenomenon can be further confirmed by confocal laser scanning microscopy (CLSM) images, which show that the boundary between the core and the crust regions is clearly visible in the case of vacuum drainage, whereas in the case of atmospheric drainage, the oil is distributed throughout the structure. Unfortunately, the same approach did not reduce the oil content of French fries—the oil content of vacuum-drained product was found similar to the product obtained by draining under atmospheric pressure. This is because the reduction in oil content only occurs when there is net moisture evaporation from the product and the evaporation rate is sufficient to force out the oil from the product; this was clearly not the case with French fries. The CLSM images show that the oil distribution in the products drained under atmospheric pressure and vacuum was similar.

Provenance of the oil in par-fried french fries after finish frying

Frozen par-fried French fries are finish-fried either by using the same type of oil used for par frying, or a different type. The nutritive quality of the final oil contained in the product depends on the relative amounts and the fatty acid (FA) composition of the oils used for par frying and finish frying. With the aim of understanding the provenance of the oil in the final product, par-fried French fries—either purchased ready or prepared in the laboratory—were finish fried in oils different from the ones used for par frying. The moisture content, oil content, and FA compositions of the par-fried and finish-fried products were experimentally determined, and the relative amounts of each of the oils present in the final product were calculated using the FAs as markers and undertaking a mass balance on each component FA. The results demonstrate that 89% to 93% of the total oil in the final product originates from the finish-frying step. The study also shows that a significant proportion of the oil absorbed during par frying is expelled from the product during finish frying. Further, the expulsion of par-frying oil was found to occur in the early stages of the finish-frying step. Experiments involving different combinations of par-frying and finish-frying oils showed that the relative proportions of the 2 oils did not depend on the individual fatty acid profiles. This study concludes that any positive health benefits of using an oil having a favorable FA profile for par frying, can potentially be lost, if the oil used for finish frying has a less favorable composition.

On the possibility of non-fat frying using molten glucose

Fried products impose a health concerns due to considerable amount of oil they contain. Production of snack foods with minimal oil content and good management of oil during frying to minimise the production of toxic compounds continue to be challenging aims. This paper aims to investigate the possibility of producing a fat-free food snack by replacing frying oil with a non-fat medium. Glucose was melted and its temperature was then brought to 185°C and used to fry potato strips, to obtain a product referred here as glucose fries. The resulting product was compared with French fries prepared conventionally under conditions that resulted in similar final moisture content. The resulting products were also examined for crust formation, texture parameters, colour development and glucose content. Stereo microscope images showed that similar crusts were formed in the glucose fries and French fries. Texture parameters were found to be similar for both products at 5mm and 2 mm penetration depth. The maximum hardness at 2mm penetration depth was also similar for both products, but different from cooked potato. The colour development which characterised French fries was also observed in glucose fries. The glucose content in glucose fries was found to be twice the content of French fries, which is to be expected since glucose absorbed or adhered to the surface. In conclusion, glucose fries, with similar texture and colour characteristics to that of French fries, can be prepared by using a non-fat frying medium.

Changes in phenolic composition and antioxidant activity of virgin olive oil during frying

The concentration of hydroxytyrosol (3,4-DHPEA) and its secoiridoid derivatives (3,4-DHPEA-EDA and 3,4-DHPEA-EA) in virgin olive oil decreased rapidly when the oil was repeatedly used for preparing french fries in deep-fat frying operations. At the end of the first frying process (10 min at 180 degreesC), the concentration of the dihydroxyphenol components was reduced to 50-60% of the original value, and after six frying operations only about 10% of the initial components remained. However, tyrosol (p-HPEA) and its derivatives (p-HPEA-EDA and p-HPEA-EA) in the oil were much more stable during 12 frying operations. The reduction in their original concentration was much smaller than that for hydroxytyrosol and its derivatives and showed a roughly linear relationship with the number of frying operations. The antioxidant activity of the phenolic extract measured using the DPPH test rapidly diminished during the first six frying processes, from a total antioxidant activity higher than 740,mumol of Trolox/kg down to less than 250 mumol/kg. On the other hand, the concentration of polar compounds, oxidized triacylglycerol monomers (oxTGs), dimeric TGs, and polymerized TGs rapidly increased from the sixth frying operation onward, when the antioxidant activity of the phenolic extract was very low, and as a consequence the oil was much more susceptible to oxidation. The loss of antioxidant activity in the phenolic fraction due to deep-fat frying was confirmed by the storage oil and oil-in-water emulsions containing added extracts from olive oil used for 12 frying operations.

Modelling oil absorption during post-frying cooling - I: model development

Several studies have highlighted the importance of the cooling period in oil absorption in deep-fat fried products. Specifically, it has been established that the largest proportion of oil which ends up into the food, is sucked into the porous crust region after the fried product is removed from the oil bath, stressing the importance of this time interval. The main objective of this paper was to develop a predictive mechanistic model that can be used to understand the principles behind post-frying cooling oil absorption kinetics, which can also help identifying the key parameters that affect the final oil intake by the fried product. The model was developed for two different geometries, an infinite slab and an infinite cylinder, and was divided into two main sub-models, one describing the immersion frying period itself and the other describing the post-frying cooling period. The immersion frying period was described by a transient moving-front model that considered the movement of the crust/core interface, whereas post-frying cooling oil absorption was considered to be a pressure driven flow mediated by capillary forces. A key element in the model was the hypothesis that oil suction would only begin once a positive pressure driving force had developed. The mechanistic model was based on measurable physical and thermal properties, and process parameters with no need of empirical data fitting, and can be used to study oil absorption in any deep-fat fried product that satisfies the assumptions made.

Modelling oil absorption during post-frying cooling - II: solution of the mathematical model, model testing and simulations

The mathematical models that describe the immersion-frying period and the post-frying cooling period of an infinite slab or an infinite cylinder were solved and tested. Results were successfully compared with those found in the literature or obtained experimentally, and were discussed in terms of the hypotheses and simplifications made. The models were used as the basis of a sensitivity analysis. Simulations showed that a decrease in slab thickness and core heat capacity resulted in faster crust development. On the other hand, an increase in oil temperature and boiling heat transfer coefficient between the oil and the surface of the food accelerated crust formation. The model for oil absorption during cooling was analysed using the tested post-frying cooling equation to determine the moment in which a positive pressure driving force, allowing oil suction within the pore, originated. It was found that as crust layer thickness, pore radius and ambient temperature decreased so did the time needed to start the absorption. On the other hand, as the effective convective heat transfer coefficient between the air and the surface of the slab increased the required cooling time decreased. In addition, it was found that the time needed to allow oil absorption during cooling was extremely sensitive to pore radius, indicating the importance of an accurate pore size determination in future studies.

Structure oil-absorption relationships during deep-fat frying

Analysis of the oil-absorption process in deep-fat fried potato cylinders (frying temperatures of 155degreesC, 170degreesC, and 185degreesC) allowed to distinguish 3 oil fractions: structural oil (absorbed during frying), penetrated surface oil (suctioned during cooling), and surface oil. Results showed that a small amount of oil penetrates during frying because most of the oil was picked up at the end of the process, suggesting that oil uptake and water removal are not synchronous phenomena. After cooling, oil was located either on the surface of the chip or suctioned into the porous crust microstructure, with an inverse relationship between them for increasing frying times.

The possibility of lowering oil content of potato chips by combining atmospheric frying with postfrying vacuum application

Four protocols involving the application of low pressures, either toward the end of frying or after frying, were investigated with the aim of lowering the oil content of potato chips. Protocol 1 involving frying at atmospheric pressure followed by a 3 min draining time constituted the control. Protocol 2 involved lowering of pressure to 13.33 kPa, 40 s before the end of frying, followed by draining for 3 min at the same pressure. Protocol 3 was the same as protocol 2, except that the pressure was lowered 3 s before the end of frying. Protocol 4 involved lowering the pressure to 13.33 kPa after the product was lifted from the oil and holding it at this value over the draining time of 3 min. Protocol 4 gave a product having the lowest oil content (37.12 g oil/100 g defatted dry matter), while protocol 2 gave the product with highest oil content (71.10 g oil/100 g defatted dry matter), followed by those obtained using protocols 1 and 3(68.48 g oil/100 g defatted dry matter and 52.50 g oil/100 g defatted dry matter, respectively). Protocol 4 was further evaluated to study the effects of draining times and vacuum applied, and compared with the control. It was noted that over the modest range of pressures investigated, there was no significant effect of the vacuum applied on the oil content of the product. This study demonstrates that the oil content of potato chips can be lowered significantly by combining atmospheric frying with draining under vacuum.

Frying of potato chips in a blend of canola oil and palm olein: changes in levels of individual fatty acids and tocols

The changes occurring in the levels of nutritionally relevant oil components were assessed during repeated frying of potato chips in a blend of palm olein and canola oil (1:1 w/w). The blend suffered minimal reductions in omega-3 and omega-6 polyunsaturated fatty acids. There was no significant difference between the fatty acid composition of the oil extracted from the product and that of the frying medium, in all three cases. The blend also contained a significant amount of tocols which add a nutritional value to the oil. The concentration of the tocols was satisfactorily retained over the period of oil usage, in contrast to the significant loses observed in the case of the individual oils. The blend also performed well when assessed by changes in total polar compounds, free fatty acids, p-anisidine value. When fried in used oil, the product oil content increased progressively with oil usage time. This study shows that blended frying oils can combine good stability and nutritional quality

Combination of moderate vacuum frying with high vacuum drainage: relationship between process conditions and oil uptake

This paper explores the possibility of combining moderate vacuum frying followed by post-frying high vacuum application during the oil drainage stage, with the aim to reduce oil content in potato chips. Potato slices were initially vacuum fried under two operating conditions (140 °C, 20 kPa and 162 °C, 50.67 kPa) until the moisture content reached 10 and 15 % (wet basis), prior to holding the samples in the head space under high vacuum level (1.33 kPa). This two-stage process was found to lower significantly the amount of oil taken up by potato chips by an amount as high as 48 %, compared to drainage at the same pressure as the frying pressure. Reducing the pressure value to 1.33 kPa reduced the water saturation temperature (11 °C), causing the product to continuously lose moisture during the course of drainage. Continuous release of water vapour prevented the occluded surface oil from penetrating into the product structure and released it from the surface of the product. When frying and drainage occurred at the same pressure, the temperature of the product fell below the water saturation temperature soon after it was lifted out of the oil, which resulted in the oil getting sucked into the product. Thus, lowering the pressure after frying to a value well below the frying pressure is a promising method to lower oil uptake by the product.

Physicochemical changes occuring in oil when atmospheric frying is combined with post-frying vacuum application

The aim of this study was to investigate the effect of atmospheric frying followed by drainage under vacuum on the stability of oil, compared to similar frying with drainage at atmospheric pressure. Changes in the oil were assessed by the free fatty acid (FFA) content, p-anisidine value (AnV), colour, viscosity, fatty acid profile and concentration of tocols. The rate of FFA formation in the case of vacuum drainage was found to be about half that of atmospheric drainage. Oil deterioration by oxidation and polymerisation was also reduced by the use of vacuum drainage. The AnV of the oil after vacuum drainage was lower by about 12%, the total colour difference was improved by 14% and viscosity was slightly reduced after 5 days of frying, compared to the values for oil that had been drained at atmospheric pressure. There was a reduction in the loss of polyunsaturated fatty acids in the case of vacuum drainage after 5 days of frying but differences in retention of tocols were only evident in the first two days of frying.

Studying oil absorption in restructured potato chips

The oil-absorption capacity of different restructured potato chips during deep-fat frying was investigated. Low-leach potato flake was chosen as the major ingredient, whereas native and pregelatinized potato starches were studied as complementary ingredients. Results showed that off absorption increased significantly when reducing product thickness in all products. Interestingly, it was found that the product containing native potato starch as an ingredient picked up the lowest amount of on when sheeted into a thick chip, whereas it absorbed the largest amount of oil when sheeted into a thin chip. Those findings were mainly attributed to crust microstructure development as revealed by electron microscopy and confocal microscopy.

The impact of blanching and high-pressure pretreatments on oil uptake of fried potato slices

The effect of high-pressure (HP) pretreatment on oil uptake of potato slices is examined in this paper. Potato slices were treated either by HP or thermal blanching, or a combination of thermal blanching followed by HP prior to frying. The effect of HP on starch gelatinization and potato microstructure was assessed by differential scanning calorimeter and environmental scanning electron microscope (ESEM), respectively. After treatments, the slices were fried in sunflower oil at 185 °C for a predetermined time. Frying time was either kept constant (4 min) or varied according to the time needed to reach a desired moisture content of ≈2%. The high pressure applied in this study was found not to be sufficient to cause a significant degree of starch gelatinization. Analysis of the ESEM images showed that blanching had a limited effect on cell wall integrity. HP pretreatment was found to increase the oil uptake marginally. When frying for a fixed time, the highest total oil content was found in slices treated at 200 MPa for 5 min. The oil content was found to increase significantly (p<0.05) to 41.23±1.82 compared to 29.03±0.21 in the control slices. The same effect of pressure on oil content was found when the time of frying varied. On the other hand, HP pretreatment was found to decrease the frying time required to achieve a given moisture content. Thus, high-pressure pretreatment may be used to reduce the frying time, but not oil uptake.

A comparative study of the characteristics of French Fries produced by deep fat frying and air frying

Air frying is being projected as an alternative to deep fat frying for producing snacks such as French Fries. In air frying, the raw potato sections are essentially heated in hot air containing fine oil droplets, which dehydrates the potato and attempts to impart the characteristics of traditionally produced French fries, but with a substantially lower level of fat absorbed in the product. The aim of this research is to compare: 1) the process dynamics of air frying with conventional deep fat frying under otherwise similar operating conditions, and 2) the products formed by the two processes in terms of color, texture, microstructure, calorimetric properties and sensory characteristics Although, air frying produced products with a substantially lower fat content but with similar moisture contents and color characteristics, it required much longer processing times, typically 21 minutes in relation to 9 minutes in the case of deep fat frying. The slower evolution of temperature also resulted in lower rates of moisture loss and color development reactions. DSC studies revealed that the extent of starch gelatinization was also lower in the case of air fried product. In addition, the two types of frying also resulted in products having significantly different texture and sensory characteristics.