Why are potato chips considered ultra-processed?

January 14, 2026 •

4 min read

According to the NOVA classification system developed by Brazilian researchers, ultra-processed foods are industrial formulations containing substances that would not typically be used in home cooking. This framework helps explain why are potato chips considered ultra-processed, highlighting extensive manufacturing techniques and a complex list of non-culinary ingredients that profoundly alter the original potato.

Quick Summary

Potato chips are classified as ultra-processed due to industrial processing methods that transform raw potatoes using multiple, non-culinary ingredients like flavor enhancers, emulsifiers, and modified starches. These processes and additives extend shelf life and create a highly palatable, addictive product, but strip away most of the original nutrients, resulting in a low-quality, high-fat, high-sodium snack.

Key Points

Industrial Formulation: Potato chips are formulated in factories using ingredients not typically found in a home kitchen, such as modified starches and emulsifiers.
Intensive Processing: Production involves multiple industrial techniques beyond simple cooking, including high-temperature frying, resulting in a product structurally and chemically different from a potato.
Non-Culinary Additives: They contain additives like monosodium glutamate (MSG) and artificial colors, which enhance flavor and appearance for commercial purposes.
Nutrient Depletion: The extensive processing strips the potato of most of its natural nutrients and fiber, creating an energy-dense but nutrient-poor food.
High Palatability: Additives and processing techniques are engineered to create a highly palatable, or 'hyper-palatable,' food that encourages overconsumption.
Extended Shelf Life: Preservatives, specific packaging, and industrial processing methods are designed to give potato chips a long shelf life, far exceeding that of a minimally processed food.
High in Unhealthy Components: Commercial chips are typically high in unhealthy fats (including trans fats from hydrogenated oils) and excessive sodium.

Understanding the NOVA Classification

To understand why potato chips fall into the ultra-processed category, it is essential to first grasp the NOVA food classification system. Developed in 2009, NOVA categorizes foods based on the extent and purpose of their industrial processing, not just their nutritional content.

Group 1: Unprocessed or Minimally Processed Foods. These are whole foods altered very little from their natural state, such as fresh vegetables, fruits, and meats. They might be washed, dried, or frozen but have no added ingredients.
Group 2: Processed Culinary Ingredients. These are substances like oil, salt, and sugar, extracted from Group 1 foods to be used in cooking.
Group 3: Processed Foods. Simple products made by combining Group 1 and 2 ingredients, like cheese or canned vegetables, using processes like cooking or preserving.
Group 4: Ultra-Processed Foods (UPF). These are industrial formulations made mostly from Group 2 substances and additives. They contain ingredients and additives not found in a regular kitchen, such as emulsifiers, flavor enhancers, and hydrogenated oils.

Commercial potato chips fit perfectly into Group 4. While they start with a potato (Group 1) and are fried in oil (Group 2) and seasoned with salt (Group 2), the final product is an industrial formulation containing numerous other additives and created through a series of specific industrial processes.

Industrial Processing and Formulation

The transformation from a humble potato to a packaged snack chip involves multiple industrial steps far beyond simple cooking. These steps and ingredients fundamentally alter the food's matrix and nutritional profile.

Multiple Intensive Manufacturing Steps

The production process involves several stages, each designed for efficiency, consistency, and a specific texture and flavor profile:

Potatoes are machine-peeled, sliced with high-speed blades, and often washed in cold water to remove starch, which affects texture and color.
Slices are then fried in industrial-grade oils at high temperatures. This intense heat can degrade the oil and create harmful compounds, like acrylamide, a known carcinogen.
After frying, the chips are seasoned in large rotating drums with a finely powdered mixture of salt and other additives to ensure uniform, intense flavor.
The chips are finally packaged using specialized machinery, often with nitrogen gas to prevent oxidation and extend their shelf life significantly.

A Long List of Non-Culinary Ingredients

Unlike homemade chips, which only require potatoes, oil, and salt, commercial chips feature a lengthy ingredient list. Many of these ingredients are extracted, modified, or synthetic substances not used in home cooking. Common examples found on chip labels include:

Flavor Enhancers: Monosodium glutamate (MSG) is frequently added to boost the savory "umami" flavor and can increase palatability, encouraging overconsumption.
Modified Starches and Sugars: Dextrose and other modified starches are used as fillers, binders, and flavor components that would be unfamiliar to a home cook.
Emulsifiers: Additives that help blend ingredients that don't typically mix, ensuring a consistent texture and seasoning.
Colorings and Anti-Caking Agents: Artificial colors and other processing aids ensure a consistent visual appeal and prevent seasoning from clumping.
Hydrogenated Oils: Some varieties may use partially hydrogenated oils to enhance texture and increase shelf life, which introduces harmful trans fats.

Impact on Palatability and Health

The industrial formulation and extensive processing make potato chips highly palatable and energy-dense, but nutritionally deficient. These characteristics contribute to overconsumption and have been linked to several negative health outcomes.

Comparison: Homemade vs. Store-Bought Potato Chips


Feature	Homemade Potato Chips	Store-Bought (Ultra-Processed) Chips
Ingredients	Whole potato, chosen oil, salt. Simple, recognizable components.	Long, complex list including additives, flavor enhancers, and modified ingredients.
Processing	Simple slicing, frying, or baking. Limited and controlled by the cook.	Multiple industrial steps (peeling, slicing, frying, seasoning, packaging) designed for mass production.
Nutrient Content	Retains more fiber and nutrients from the original potato. Minimal nutrient loss.	Stripped of most nutrients and fiber. Added nutrients, if any, are synthetic.
Additives	None, beyond basic salt.	Contains multiple non-culinary additives like MSG, emulsifiers, and colorings.
Fat and Sodium	Cook controls amount of oil and salt. Potential for lower fat/sodium.	High in industrial fats and excessive sodium to enhance flavor.
Shelf Life	Short shelf life, typically a few weeks at most.	Extended shelf life due to preservatives and packaging, often months or longer.

Conclusion

In summary, the reason why are potato chips considered ultra-processed is a combination of their extensive industrial manufacturing and the formulation with additives that are not used in home cooking. According to the NOVA classification, they are defined not by their base ingredient but by the chemical substances and intensive processes that result in a product far removed from its original state. This ultra-processing results in a food that is highly palatable, engineered for long shelf life, and often energy-dense yet nutrient-poor. The combination of these factors makes store-bought potato chips a clear example of an ultra-processed food, with documented associations to negative health outcomes like obesity, heart disease, and diabetes when consumed excessively. Opting for minimally processed snacks or making homemade alternatives offers a path toward controlling ingredients and improving diet quality.

For more information on the processing of ultra-processed foods, you can visit the Food Standards Agency's page on the topic.

Frequently Asked Questions

The main distinction lies in the extent and purpose of processing. Processed foods, like canned tuna or cheese, are made with simple ingredients using familiar methods. Ultra-processed foods, like chips, are industrial formulations made mostly from processed ingredients and additives not used in home cooking.

No. When you make chips at home, you are using simple, recognizable ingredients (potatoes, oil, salt) and employing basic cooking techniques. This is considered a minimally processed food, not ultra-processed.

Ingredients like MSG are added as flavor enhancers to increase the snack's palatability and appeal. This is a common tactic in ultra-processed foods to create a 'hyper-palatable' product that is difficult to stop eating.

Yes, high-temperature frying can create harmful chemical compounds, such as acrylamide. This, combined with the use of industrial oils, adds to the potential health risks associated with commercial potato chip consumption.

The intensive industrial processing involved in creating ultra-processed foods often strips the original food source of its natural nutrients and fiber. Any vitamins or minerals that are present are typically added back synthetically, known as fortification.

Studies have linked high consumption of ultra-processed foods to increased risks of chronic health conditions, including obesity, type 2 diabetes, heart disease, and some cancers.

You can often identify ultra-processed foods by their long ingredient list containing many unrecognizable or unfamiliar items, aggressive marketing, and their long shelf life. Look for ingredients rarely used in home cooking, like certain emulsifiers, modified starches, or flavorings.