Production Process
1. Harvesting:
Potatoes are harvested and either stored in temperature controlled stores or delivered to the factory in large bulker lorries.
2. Washing/ Sorting/ Slicing:
At the factory the fresh potatoes are washed thoroughly and filtered to remove any debris. They are then passed through an abrasive lined revolving drum in order to remove the peel completely. Following the peeling process the potatoes pass through an inspection conveyor belt where they are examined thoroughly to ensure that only the freshest and best potatoes are used to make Largo Food's crisps.
At this point the cleaned, peeled potatoes are ready to continue along the belt into a high-speed rotary slicing unit. They then enter the blancher, which helps to give the crisp its pale appearance by reducing any sugar content that may be in the potato slice.
3. Cooking of Potatoes:
On exiting the blancher the potato slices are then cooked in pure sunflower oil before being conveyed to the colour sorter where each cooked crisp is inspected to ensure that it meets the high quality levels set by Largo Foods.
4. Flavouring/ Weighing/ Packing of Crisps:
From here, the crisps are passed through the flavour drum where they receive a coating of flavour. The crisp slices are then transferred from the flavour drums to the packing machines where they are automatically weighed and filled into packets, which are then packed into cartons. The cartons are automatically sealed and packed before progressing through the warehouse and van distribution system to finally arrive in the retail outlet fresh and ready for the consumer.
Largo Foods Commitment to Quality:
Largo Foods is currently one of the biggest users of potatoes in Ireland. Largo Foods sources all of the Irish potatoes under contract by farmers/growers. Saturna, Lady Claire and Rosetta are the varieties predominantly used in the manufacturing of Largo Foods crisps.
The overall objective of the Quality System is to ensure that Largo Foods produces quality products and services and that each member of staff has an individual commitment to this quality.
The Quality System encompasses all aspects of the business from the purchasing of raw materials through to the transportation and selling of products. Quality control checks are in place, prior to production, during production and post production as follows:
Before Production:
Prior to unloading the sunflower oil, a sample is taken and four different chemical tests are carried out to ensure that the oil is of good quality and suitable for the production of crisps. Thereafter the oil in the tanks is tested on a daily basis to ensure there is no deterioration. Flavours are checked for salt and moisture and must be within agreed standards.
During Production:
The oil is checked at regular intervals to ensure that its quality is being maintained. There is an automatic moisture system whereby the crisp moisture is continuously being monitored. Laboratory staff carrying out ingredient moisture checks at regular intervals follows this up. It is critical that the moisture level of the crisps be maintained below a particular level to ensure product quality and freshness.
Laboratory staff carrying out checks continuously monitors the level of flavour applied to the product. There is a standard set for each flavour and levels must be within these agreed limits.
Post Production:
Quality checks also occur throughout the sales depots and vans to ensure that staff are rotating stock correctly, ultimately ensuring that the consumer receives the freshest product at all times. Supermarket shelves are also monitored to ensure that stock is rotated.