Are Chips Considered a Processed Food? A Deep Dive into Food Classifications

November 22, 2025 •

4 min read

According to researchers, a staggering 58% of calories consumed in the U.S. come from ultra-processed foods. This statistic raises important questions about the foods we eat daily, such as chips. So, are chips considered a processed food? The answer is more nuanced than a simple yes or no.

Quick Summary

Chips are classified as ultra-processed foods under the NOVA system because they are industrial formulations containing added salt, fat, and other additives not typically found in a home kitchen.

Key Points

Chips are Ultra-Processed: Commercially made potato chips are categorized as ultra-processed due to significant industrial alteration and the use of additives.
NOVA System Explained: The NOVA classification divides foods into four groups based on processing level, with chips fitting into the fourth, most heavily processed category.
Industrial Process Matters: Unlike home-cooked food, commercial chips involve machine peeling, rinsing, and continuous vat frying, plus added flavorings and preservatives.
High in Salt and Fat: Ultra-processed chips are typically low in nutrients and high in sodium, added fat, and calories, contributing to potential health issues.
Read the Label: Check ingredient lists for additives like emulsifiers, flavor enhancers, and various preservatives to identify ultra-processed items.
Moderation is Key: While not all processed food is bad, ultra-processed items should be consumed sparingly and not replace whole, nutrient-dense foods.

What Defines a Processed Food?

Before we can answer whether chips are considered a processed food, we must understand the definition of processing. The USDA defines processed food as any raw agricultural commodity that has been altered from its natural state. This broad definition covers a wide range of products, from minimally processed items like pre-cut vegetables to heavily processed items like frozen dinners. The key lies in the degree of processing.

The NOVA Classification System

To provide clarity, many nutritionists and health organizations use the NOVA classification system, which groups foods into four distinct categories based on their level of processing.

Group 1: Unprocessed or Minimally Processed Foods. These are foods in their natural or near-natural state. Examples include fresh fruits, vegetables, eggs, and plain nuts.
Group 2: Processed Culinary Ingredients. These are substances derived from Group 1 foods through simple processing, such as pressing, grinding, or refining. Think of items like vegetable oils, sugar, and salt.
Group 3: Processed Foods. These are relatively simple products made by adding Group 2 ingredients to Group 1 foods. Examples include cheeses, canned fish, and fresh bread.
Group 4: Ultra-Processed Foods. This category consists of industrial formulations made predominantly from substances extracted from foods, often with numerous additives not used in home cooking. This is where most commercially produced chips fall.

Why Chips Are Considered Ultra-Processed

While a simple chip might seem like it only contains potato, oil, and salt, the manufacturing process goes far beyond what happens in a home kitchen. Commercial chip production involves multiple industrial steps and additives that firmly place them in the ultra-processed category.

A Chip's Journey from Potato to Bag

Here is an overview of the industrial process:

Selection and Storage: Specific potato varieties with the right starch and sugar content are chosen to ensure proper color and crispness. They are stored in climate-controlled environments.
Washing and Peeling: Machines wash and peel the potatoes efficiently.
Slicing: Potatoes are machine-sliced into thin, uniform pieces for consistent frying.
Washing Again: Sliced potatoes are washed once more to remove excess starch, which affects texture.
Frying: The potato slices are cooked in large, continuous vats of vegetable oil at high temperatures. The oil replaces the water in the potato slices, making them crispy. The oils used are often refined and may be a blend of different types.
Flavoring: A rotating drum tumbles the chips while oil is sprayed on, followed by the application of powdered seasonings and flavor enhancers.
Packaging: The finished chips are rapidly weighed and packaged for transport, ensuring a long shelf life.

Comparison: Ultra-Processed Chips vs. Minimally Processed Snacks


Feature	Ultra-Processed Chips	Minimally Processed Snack Alternatives
Ingredients	Potatoes, refined vegetable oils, salt, plus potentially emulsifiers, flavor enhancers (e.g., MSG), and artificial colors depending on the flavor.	Fresh fruit, plain nuts, seeds, air-popped popcorn with a minimal amount of oil and salt.
Manufacturing	Industrial processes including high-heat frying, chemical additives for flavoring and preservation, and rapid packaging.	Washing, cutting, drying, roasting, or simple cooking methods that are achievable in a home kitchen.
Nutritional Profile	High in calories, sodium, and unhealthy fats. Typically low in fiber, vitamins, and minerals due to processing.	Nutrient-dense, high in fiber, vitamins, and minerals. Naturally lower in sodium and unhealthy fats.
Energy Release	Engineered to be hyper-palatable, which can lead to overconsumption and rapid blood sugar spikes.	Provides sustained energy due to higher fiber content and lower caloric density.

The Health Implications of Ultra-Processed Foods

Research links high consumption of ultra-processed foods, including chips, to increased risks of chronic health issues like obesity, type 2 diabetes, and heart disease. While the specific health impacts can be debated—is it the processing itself or the unhealthy ingredient profile?—the consensus is that a diet rich in these items is detrimental to long-term health. Their low nutrient-to-calorie ratio and high levels of sodium, sugar, and unhealthy fats mean they displace more nutritious whole foods in a diet.

It is important to remember that not all processed foods are bad. Minimally processed items like frozen vegetables or pasteurized milk can be valuable parts of a balanced diet. However, the industrial formulations of ultra-processed foods like chips are specifically designed to be highly profitable, convenient, and addictive, prioritizing taste and shelf life over nutritional value. Consumers should be aware of these distinctions to make healthier choices.

Conclusion

In conclusion, chips are definitively considered a processed food, and more specifically, an ultra-processed food, according to widely accepted classification systems like NOVA. The industrial processes involved in their creation, along with the high levels of added salt, refined oils, and other additives, place them in this category. While they can be enjoyed in moderation as an occasional treat, they are not a substitute for nutrient-dense, minimally processed whole foods. Understanding the differences between levels of food processing empowers consumers to make more informed dietary decisions and promote better overall health.

For more information on differentiating between different levels of processing, you can consult the Mayo Clinic Health System on Processed Foods.

Frequently Asked Questions

A processed food is simply any food that has been altered from its natural state, such as canned beans or cheese. An ultra-processed food, however, is a more heavily manufactured formulation that includes ingredients not typically used in home cooking, like specific additives, emulsifiers, and flavor enhancers.

Chips are considered ultra-processed because of the extensive industrial process they undergo, including high-heat frying in refined oils and the addition of specific flavorings and preservatives, which goes beyond what's done in a typical home kitchen.

Most commercially available potato chips, especially flavored ones, are considered ultra-processed. Even some 'ready salted' varieties that list few ingredients are made using industrial processes that qualify them for this category.

Ultra-processed chips are typically low in nutritional value, containing minimal fiber, vitamins, and minerals. Their caloric density comes from added fat and salt, providing 'empty calories' rather than essential nutrients.

Healthier alternatives include minimally processed snacks like plain nuts, seeds, fresh fruit, or homemade air-popped popcorn seasoned with a small amount of salt and oil.

A good indicator is a long ingredient list with many unfamiliar names, especially near the end. Ingredients like emulsifiers, added sugars (e.g., high-fructose corn syrup), and artificial flavors or colors are common in ultra-processed products.

Consuming ultra-processed foods occasionally is generally not a major concern. The key is moderation and ensuring they don't replace the majority of a diet built on nutrient-dense, whole foods.