every year thousands of tons of Doritos are consumed worldwide to meet this enormous demand giant Harvesters are used to harvest tons of corn but how are 70,000 bags of Doritos produced every day we visited The Fray Factory to discover how one of the world's most popular snacks is made Doritos were created by Arch West a freay marketing executive in the 1960s he discovered crispy tortillas in a local restaurant in San Diego California taking advantage of leftover corn tortillas that would not be used due to being broken or not meeting sale standards he came up with
the idea to cut them into triangles fry them and season them thus creating the first Doritos the term Dorito is derived from the Spanish word Dorado which translates to small pieces of gold by 1988 Doritos had become the bestselling chips globally a trend that continues today with a diverse range of 10 different flavors unlike ordinary chips made from potatoes Doritos have corn flour as a basic ingredient corn are carefully cut from the plants ensuring not to damage the grains the harvesting capacity reaches 140 tons per day ensuring a steady supply to the plant the corn
are cut just above the ground and are then removed and transported to the factory the supplier takes care to clean and dry the grains this is accomplished using vibrating machines that effectively eliminate dust Stones sand and other residues while ensuring an increase in the moisture cont content to 14% a crucial factor for the production process next the prepared corn is sent to the nacho Factory the factory receives a daily shipment of 45,000 kg of corn the dry corn is moved from extensive storage bins to vessels where it undergos cooking in water this results in a
yearly production exceeding 6,500,000 kg of finished product Frito L's Factory stands as one of the world's largest chip factories iies capable of producing over 100,000 packs of nachos daily which are then distributed to the market the factory is organized into four main areas the corn area is dedicated to the production of tortilla type products like Doritos in the center there is a distribution center spanning 65,000 square m the factory has the capacity to produce 70 to 100,000 bags of Doritos daily which is approximately 18 million bags per year the first notable feature upon arrival is
the presence of two enormous silos each capable of storing 120 tons of corn grains with the contents of these silos the factory can produce 20,000 kg of Doritos this marks the initial phase in creating a Dorito the corn must undergo cooking before entering the soaking tank initially the corn is boiled in kettles close to Boiling Point later it is transferred to open tanks where it soaks for approximately half a day each cooking pot accom accomodates around 300 kg of corn and 90 L of water the corn is cooked at 93° C for about 4 minutes
before being left to soak for 12 hours after the initial cooking the corn is moved to large tanks for an overnight soaking facilitating the softening of the grains this soaking process enables the corn to absorb moisture aiding in the removal of the corn husk the outer husk of the grain is filtered out leaving behind only soft and hydrated corn when the moisture content reaches 45% the husks become soft and can be easily removed following the soaking process a pumping system transports the corn to the washer where the removed husks are separated the corn then moves
on a conveyor belt from the drum to the mill following the cleaning process it proceeds to a grinding machine equipped with rotating millstones that grind the corn into a dough this process involves pulverizing the corn grains between the two stones resulting in the production of a soft corn dough as the grinding process continues water is added into the flour to achieve the desired consistency of the Corn dough the resulting dough under go inspection for three crucial factors moisture content temperature and the texture of the grind the dough comes out of the mill through a narrow
nozzle that shapes it into a thin sheet this sheet is then passed between two metal rollers that shape it into a ribbon the third roller is equipped with triangular dyes cutting individual triangular nachos the dough moves between these rollers and through the cutter creating the distinctive Doritos shape similar to a cookie cutter the sharp edges of the roller pierce the dough producing perfect triangular pieces this machine has a capacity to cut 6,000 individual chips per minute amounting to over 8 million chips every 24 hours the freshly cut Doritos move along a conveyor belt to the
next stage which involves baking in the oven despite the seemingly organized process any leftover dough is not wasted in instead it is recycled and sent back to the Doats to be reused now it's time to toast those tortillas the Triangular nachos enter an extraordinary oven operating at 340° C with three levels and high temperatures the nachos spend just a few seconds in this specialized oven achieving the desired texture preventing them from drying out and preserving moisture this process also contributes to the formation of the characteristic bubbles found in Doritos the industrial oven effectively seals the
outer surface preserving moisture and creating bubbles in the dough this process is crucial for giving Doritos their distinctive crunch despite spending only 16 seconds inside it is sufficient to dry the dough to a point where it remains intact when handled the heat entrapment results in tiny moisture Pockets within the dough this gives Doritos their characteristic irregular texture later the team allows the tortillas to cool on a series of conveyor belts before proceeding to the fryer this short break also provides inspectors with an opportunity to ensure that none of the triangles have burned during their time
in the oven next a mesh conveyor belt takes the triangles to the fryer where the oil is maintained at a temperature of 182° c and nachos require only 55 seconds to fry at this stage the nachos attain the perfect color and crispy texture the bubbles present in a completed Dorito are essentially air pockets trapped in the chip during the frying process after this step a mesh conveyor belt removes the nachos and the excess oil returns to the fryer using vibrating conveyors the Doritos are now transported to a special drum where they are mixed with the
appropriate spices and ingredients at the following station a screw augur dispenses nacho seasoning into the drum large bags of the blend containing a secret combination of cheddar cheese parmesan cheese and spices are added to the machine's top funneling the mix into the drum the primary ingredients include various cheeses spices flavor enhancers like monosodium glutamate and preservatives to prolong the product's shelf life nozzles spray the nachos with canola oil enhancing the surface's adhesiveness and ensuring the seasoning sticks this massive drum effectively and evenly distributes the seasoning as the delicate chips move through the drum they serve
as buffers preventing breakage against each other the seasoned Doritos embark on a lengthy Journey along a 30m conveyor belt to ensure thorough cooling before undergoing Packaging with an annual value of $4 billion this high demand product under go careful handling once out of the seasoning drum the nachos are directed to various packaging machines by Hoppers the packaging device represents a technical choreography at its finest with each machine equipped with 14 cube-shaped scales Doritos are carefully positioned and Dro through the measuring machine where a series of spoons precisely weigh a bag of Doritos when there's enough
for a package a trap door opens the nachos fall and simultaneously a machine shapes an aluminum and plastic strip into a bag the nachos drop into the bag which is promptly closed and cut by heat sealing simultaneously sealing the bottom of the next bag the bagging machine introduces nitrogen and packs it with an airtight seal this process removes oxygen to prevent spoilage ensuring that Doritos stay fresh for an extended period additionally it creates an air cushion inside the bag preventing the chips from breaking each large bag of Doritos contains approximately one 100 chips a worker
verifies that there are eight bags in each box this plant has the capacity to manufacture and package 70,000 bags of Doritos every day totaling over 18 million bags per year next they are distributed to the retailers and made available for consumers to enjoy if you want to know how chocolate is made watch the video on your screen and please like the video If you enjoyed it and share it with someone who might be interested also subscribe to this channel by activating the notifications to continue learning thanks for watching
