How to Make Professional Doritos Chip Corn Chip Snack
Doritos are also known as tortilla chips. Currently, there are two manufacturing processes: the traditional alkaline process and the twin-screw extrusion process.
The following is the production process and related equipment for making traditional Chips:
| Stone Removing System | 1. Cleaning and Feeding
-Remove Stone & magnetic. -Feed into alkali-resistant soaking tank. |
| Soaking& Cooking Tank | 2.Lime Water Preparation and Soaking
– Lime dosage: 1-2% (based on dry corn). – Maintain at 80-85°C. – Soak for 8-12 hours. – This softens the seed coat, gels the starch, and generates unique flavor precursors. |
| Washing Tank | 3. Discharge and Initial Washing
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| Peeling Machine | 4.Deep Peeling and Washing
Thoroughly removes the softened seed coat and germ. |
| Grinding Machine | 5. Grinding the dough
– Grind the dough into a wet dough (Masa). – This step requires strict control of the moisture content. – Moisture: about 50-55%). -Particle size: 30 mesh. |
| Pressing Machine | 6. Sheeting
– The Masa dough pass through a precision double-roller sheeter. – It is rolled into a continuous sheet of dough. – Target thickness: 1-2 mm. |
| Punching Machine | 7. Perforation
– The dough passes through a punching roller. – This prevents bulge during frying. |
| Triangle Forming Machine | 8. Cutting
– Pressed into shapes such as triangles by a rotary die cutting machine |
| Secadora | 9. Baking& Shape Keeping
– This evaporates some of the moisture, shapes the product, and produces a baked aroma. |
| Frying Machine | 10. Deep-frying and puffing
-Then it enters a continuous fryer. -Oil temperature: 170-190°C. -Frying time: 30-60 seconds
The residual moisture in the dough evaporates rapidly, causing it to puff up fully, resulting in Doritos’ signature light and crispy texture. |
| Seasoning Machine | 11. Seasoning
– The hot tortilla chips are evenly mixed with seasoning oil and flavor powder (such as cheese powder and barbecue powder) in a rotating seasoning drum. |
| Packaging Machine | 12. Cooling and Packaging
– After seasoning, the tortilla chips are cooled to room temperature via a cooling belt. – Then, they are packaged in nitrogen by an automatic packaging machine to ensure crispness. |
Summary
As a professional equipment manufacturer, we offer two mature complete production line solutions for corn tortilla chips:
1. Traditional Alkaline Process
• Advantages:
Rich and natural product flavor.
Crispy texture with multiple layers.
• Disadvantages:
Long process flow, requiring significant equipment investment and floor space.
Higher energy and water consumption.
Requires extensive production control experience.
2. Twin-Screw Extrusion Process
• Advantages:
Extremely high production efficiency.
Compact and integrated equipment.
Low unit cost.
Uniform product shape.
Suitable for rapid flavor innovation.
• Disadvantages:
Relatively simple product flavor,
Difficult to replicate the traditional baked aroma,
Texture is more hard and crispy.
Key recommendation:
Choosing traditional processes is for creating a unique flavor brand;
choosing twin-screw extrusion technology is for innovative tastes and styles.
We will provide you with the most suitable turnkey solution to meet your objectives.
