Improvement of oil absorption and quality of potato chips based on pre‐drying and post‐frying heating treatments

BACKGROUND: Excessive oil absorption in fried potato chips remains a major concern for both health-conscious consumers and the food industry. This study investigated the effects of pre-drying and post-frying insulation method by hot air and microwave drying on oil absorption, texture and microstructure characteristics of potato chips. RESULTS: Both pre-drying and post-frying heating significantly reduced oil absorption, with the lowest oil content reaching 239.7 and 245.9 g/kg, respectively. Compared with the control group, the oil content can be reduced by up to 41.63%. Scanning electron microscopy (SEM) revealed that pre-drying preserved cellular integrity, reducing large pores and limiting oil penetration. In contrast, post-frying heating kept surface pores open, facilitating oil release and enhancing crispness. The changes in the L*, a* and b* value indicate a significant improvement in the color of potato chips after pre-drying and post-frying heating. CONCLUSION: Microwave pre-drying exhibited superior oil reduction efficiency, while post-frying hot air treatment contributed to better textural and color properties. These findings provide valuable insights for developing low-fat fried potato products while maintaining desirable texture attributes, offering a practical solution for healthier snack production. © 2025 Society of Chemical Industry.