French fries are a highly sought after commodity in food service and retail. India has become a major exporter of frozen french fries, targeting regions like the Middle East, South East Asia, USA and EU.
The increasing global consumption of frozen fries has primarily been driven by the QSR (quick service restaurant) and convenience foods segments. It is creating a strong ongoing export opportunity for suppliers with experience in maintaining volumes and compliance.
The growth in the USA and EU is a result of an increasing number of wholesale french fry suppliers who are meeting the high quality standards as expected. Processing quality and export ready criteria are critical to successfully enter international markets.
Product and Market Needs
Frozen French fries can be exported as per the below specified varieties:
- Straight cut fries using potatoes cut to 6mm, 9mm or 11mm thick,
- Crinkle cut frozen French fries for texture.
- Waffle, shoestring (3-4mm), and wedge cuts serve specialized menu applications
- Steak cut (12-15mm) meets premium foodservice needs
Every single country has their own preference and accordingly they consider suppliers.
- In the EU, straight-cut frozen French fries with an even golden colour and few defects according to USDA Grade A classification are preferred.
- Buyers in the USA prefer to have straight cut frozen French fries that have uniform size and flavour.
- In the Middle East, there is a demand for Halal certified French fries, which are supplied to bulk users for fast food chains.
- In Asia, crinkle-cut frozen French fries are being sought after because of their visual appeal in retail packs.
Primary end-use segments consist of quick-service restaurants that require large quantities of consistent quality fries, retail for consumer packaging, HORECA for plated meals, and food processing for future use. The wholesaler’s role is to service these needs by supplying either straight cut or crinkle cut frozen French fries according to regional preferences.
Raw Material Sourcing
Low sugar content and dry matter will ensure frozen French fries to be consistent in texture, color, and oil uptake. The varieties of potato best suited for this are Kufri Frysona and Santana. These are primarily known for:
- High dry matter content (20-23%)
- Low reducing sugars (<0.2%)
- 60mm+ uniform sizing
- Minimal external defects
Through contract farming and the establishment of clusters in Gujarat, there will be a continuous supply of raw material available to processing plants. This will help them support the expected total export volumes of more than 1 lakh tonne.
Processing Stages
It is important to prepare frozen french fries in proper steps to meet the export-grade criteria globally.
- Cleaning and Sortation
In order to eliminate contamination, the first step is to wash the potatoes. The potatoes are washed to eliminate stones, dirt, and bad tubers.
- Peeling and Cutting
Potatoes are peeled with the use of automated steam or abrasive peeling methods as per the below attributes:
- 6mm shoestring cuts
- 9-11mm standard French fries
- 12-15mm steak cuts
- Crinkle/waffle patterns
- Blanching and Dewatering
Blanching potatoes is executed with heat at a temperature of 70-90°C. This will deactivate enzymes, enhance the color of the potatoes, and reduce sugars in the potatoes. Following blanching, dewatering is performed via centrifuge to surface dryness.
- Individual Quick Freezing (IQF)
Individual Quick Freezing (IQF) preserves product quality by forming small ice crystals. This process maintains the texture of the frozen product. It also prevents clumps during the transportation of French fries in Bulk.
- Packing & Labeling
The food-grade cartons weighing between 20-25 kg contain vacuum or Modified Atmosphere Packed (MAP) sealed bags with labels providing nutritional information, origin and allergen details, traceability codes ensure regulatory compliance for entry into global markets.
- Cold Chain & Storage
The temperature of products is maintained at a minimum of -18°C by using temperature loggers, and protocols in place to minimise the thaw cycle as much as possible. Maintaining this temperature is essential for maintaining product quality from the plant to port for exporters of bulk french fries.
Quality Standards and Certifications
Certifications provide reassurance to buyers about the quality and consistency of frozen french fries.
- ISO 22000 / FSSC 22000
ISO 22000 , and FSSC 22000 are two global certification programs that assist in managing food safety hazards throughout the supply chain. These certifications are required for suppliers of French fries to EU and US Markets.
- HACCP
Using HACCP provides methods to identify any potential hazards that may arise during the production of french fries and are also required to guarantee defect-free straight cut french fries and minimize food contamination.
- BRCGS / IFS
BRCGS and IFS are two main standards for retailers, which create a level of assurance for suppliers of wholesale frozen French fries that their operations are reviewed for compliance. It will help them establish credibility with distributors across Europe.
- FDA Registration & USDA Compliance
Both FDA Registration and USDA Compliance are necessary certifications for frozen french fries distributed within the USA. It must align with their respective Grade A standards for color, defect, and texture classifications.
- Halal / Kosher
Halal and Kosher certifications are essential for suppliers of frozen french fries exporting to the Middle East, as these certifications would allow suppliers to service QSR segments within the region.
- FSSAI Compliance
FSSAI compliance is India’s basic export requirement for frozen french fries, and other similar initiatives. .
Meeting traceability and laboratory testing are also critical requirements for suppliers.
Packaging and Logistics
Frozen french fries need to be kept secure while transported and below are the aspects that need to be maintained for quality approval.
- Packaging Before Export
French fry bulk packaging using standard bulk carton will safely ship in all conditions. Customers can also have their own unique packaging created.
- The Cold Chain
Through continual monitoring within the Reefer container at a consistent -18C, frozen/thawed issues are prevented through the use of loggers.
- Applicable documentation
It is important to have documentation ready like Certificate of Origin, Health Certificates, and Permits for targeted market(s) for seamless delivery.
Challenges and Best Practices
Exporters experience several roadblocks, but they develop techniques for sustained success.
Challenges
Exporters are impacted by cold chain failures, causing deterioration in product quality and loss of texture. They are also affected by moisture-related issues and receiving rejection of their products due to non-compliance issues.
Best Practices
Automation in the production and sizing of French Fries allows for greater accuracy and efficiency in production. The utilization of real-time tracking methods ensures that the transportation process is secure and that products are properly monitored during transport. The continuation of three-party system audits helps in maintaining the certifications of all parties. It is crucial for improving the quality and reliability of bulk French fries for global partners.
Conclusion
The success of Indian frozen French fries exporters on a global scale begins with their high-quality processing and strict quality control standards.
Among the emerging trends in frozen French fries exports are premium, lower-oil French fries options. A number of wholesale French fries suppliers are investing in these types of products for the QSR and retail marketplaces across the Middle East, Asia, USA and EU.
To maintain a consistently available supply of bulk French fries, have competitive prices and provide full compliance assistance when importing French fries into your markets, we recommend partnering with a reputable Indian exporter.
