Skip to content

Hongji Potato Flakes — Technical Datasheet

Product Overview

Hongji Agriculture's Potato Flakes (also known as Potato Granules or Instant Mashed Potato Flakes) are dehydrated potato products manufactured from premium processing potato varieties grown in the Zhangjiakou region of Hebei Province, China. The product is produced through a fully integrated supply chain spanning from proprietary seed breeding to controlled field cultivation and advanced processing, ensuring traceability, consistency, and food safety from farm to finished ingredient.

Potato Flakes serve as a critical ingredient in the global food manufacturing industry, valued for their superior water absorption, texture contribution, and clean-label appeal. They are widely used in bakery products, extruded snacks, instant mashed potatoes, soups, sauces, prepared meals, and meat products. The drum-drying process used to produce Hongji Potato Flakes preserves the natural potato cell structure, resulting in a product that reconstitutes into a mash with a texture closely resembling fresh-cooked potatoes.


1. Raw Material Specifications

1.1 Potato Varieties Utilized

Variety Characteristics Typical Starch Content Best Suited For
Atlantic High solids, low reducing sugars, light color 18–22% Flakes for frying batters, snacks
Shepody Long tuber shape, excellent fry color, uniform dry matter 19–23% Premium flakes for instant mash
Russet Burbank High starch, mealy texture, classic baking potato 20–24% Bakery-grade flakes, dough incorporation
Innovator Oval shape, high dry matter, low sugars 20–23% Dual-purpose flakes for mash and frying

Note: All varieties are sourced exclusively from contract farms within a 50 km radius of the processing facility, ensuring harvest-to-processing within 24 hours to minimize reducing sugar accumulation and enzymatic browning.

1.2 Growing Region — Zhangjiakou, Hebei

Parameter Value
Altitude 1,200–1,600 m
Climate Continental semi-arid
Annual precipitation 350–450 mm
Diurnal temperature variation 12–16°C (optimal for starch accumulation)
Growing season April–September
Soil type Sandy loam, well-drained, pH 6.0–7.5
GMO status Non-GMO, conventional breeding only

1.3 Raw Potato Quality Criteria for Acceptance

Parameter Acceptance Limit Method
Dry matter content ≥ 19.0% Underwater weight method
Reducing sugars ≤ 0.25% (fresh weight) DNS colorimetric
Defects (rot, green, mechanical damage) ≤ 5.0% by weight Visual inspection
Tuber size (minimum diameter) ≥ 40 mm Grading sieve
Soil & extraneous matter ≤ 2.0% by weight Weighing

2. Manufacturing Process

Seed Breeding → Field Cultivation → Harvest → Washing & Destoning → 
Steam Peeling → Inspection & Trimming → Slicing (8–12 mm) → 
Pre-Cooking (68–72°C) → Steam Cooking (98–100°C) → Mashing →
Drum Drying → Flaking → Milling (optional) → Screening → 
Metal Detection → Packaging → Storage (≤25°C, ≤65% RH)

2.1 Detailed Process Parameters

Process Step Parameters Purpose
Washing & destoning Water flow 20 m³/h, rotating drum washer Remove soil, stones, debris
Steam peeling 12–15 bar, 20–30 seconds Rapid skin removal, minimal cook loss
Pre-cooking 68–72°C, 15–20 minutes Starch gelatinization initiation, enzyme inactivation
Steam cooking 98–100°C, 25–35 minutes Complete gelatinization, cell wall softening
Mashing Rotary masher, ≤ 3 mm gap Break cooked potatoes into fine mash without cell rupture
Drum drying Single drum, 155–175°C surface, 15–25 sec residence Rapid dehydration, thin film formation
Flaking Doctor blade removal, flake breaker Separate dried sheet into flakes
Screening Vibrating sieve, 6 mesh (optional mill through 20 mesh) Remove oversize particles
Metal detection Fe ≥ 0.5 mm, SUS ≥ 1.0 mm, Non-Fe ≥ 0.8 mm Contaminant rejection

Critical Quality Step — Pre-cooking Temperature Control: The pre-cooking stage at 68–72°C is precisely controlled to initiate controlled starch gelatinization. This step is essential for modifying the rheological properties of the final mash. If pre-cooking temperature exceeds 75°C, excessive gelatinization causes sticky, pasty rehydrated mash. If below 65°C, insufficient gelatinization results in a gritty texture.

2.2 Drum Drying Specifications

Parameter Specification
Drum type Single-drum, atmospheric
Drum material Cast iron, chrome-plated surface
Drum diameter 1,200–2,000 mm
Drum speed 3–8 RPM (adjustable)
Steam pressure 5–8 bar
Surface temperature 155–175°C
Feed method Applicator roll or dip feed
Dried film thickness 0.15–0.35 mm
Residence time 15–25 seconds
Final moisture ≤ 6.0%

3. Physical & Chemical Specifications

3.1 Standard Grade — Potato Flakes

Parameter Unit Specification Test Method
Moisture % (w/w) ≤ 6.0 AOAC 925.10
Starch % (w/w) ≥ 75.0 (dwb) AOAC 996.11 (enzyme assay)
Protein % (w/w) 6.0 – 9.0 (dwb) AOAC 984.13 (N×6.25)
Ash % (w/w) ≤ 4.0 (dwb) AOAC 923.03
Fat (crude) % (w/w) ≤ 0.5 (dwb) AOAC 922.06 (Soxhlet)
Crude Fiber % (w/w) ≤ 1.5 (dwb) AOAC 962.09
Reducing Sugars % (w/w) ≤ 1.5 (dwb) DNS colorimetric method
Total Sugars % (w/w) ≤ 3.0 (dwb) DNS colorimetric method
pH (10% w/w slurry in distilled H₂O) 5.3 – 6.3 AOAC 981.12
SO₂ (residual, naturally occurring) mg/kg ≤ 10 Monier-Williams distillation
Bulk Density (loose) g/L 350 – 500 AOAC 975.15
Bulk Density (tapped) g/L 450 – 600 AOAC 975.15 (100 taps)
Water Absorption Index (WAI) g/g 5.5 – 7.5 Anderson method (80°C, 30 min)
Water Solubility Index (WSI) % 20 – 35 Anderson method (80°C, 30 min)
Swelling Power (85°C) g/g 14 – 20 Gravimetric, 30 min
Cold Water Solubility (25°C) % 15 – 25 Gravimetric, 30 min stirring
Whiteness Index ≥ 82.0 HunterLab, illuminant D65

dwb = dry weight basis

3.2 Color Specifications

Parameter Specification Instrument / Conditions
L* (lightness) ≥ 88.0 HunterLab ColorQuest XE, D65/10°
a* (red-green) −1.5 to +1.5 HunterLab ColorQuest XE, D65/10°
b* (yellow-blue) 8.0 – 18.0 HunterLab ColorQuest XE, D65/10°
Visual appearance Uniform cream to light yellow flakes Visual inspection under standard lighting
Discolored particles ≤ 2.0% by count Visual sorting

4. Microbiological Specifications

Parameter Specification Test Method Reference Standard
Total Plate Count (TPC) ≤ 10,000 CFU/g ISO 4833-1:2013 ICMSF
Yeast & Mould ≤ 100 CFU/g ISO 21527-2:2008 ICMSF
Enterobacteriaceae ≤ 100 CFU/g ISO 21528-2:2017 EU Reg 2073/2005
Salmonella Negative / 25 g ISO 6579-1:2017 EU Reg 2073/2005
Staphylococcus aureus ≤ 10 CFU/g ISO 6888-1:2021 ICMSF
Bacillus cereus ≤ 100 CFU/g ISO 7932:2004 ICMSF
Listeria monocytogenes Negative / 25 g ISO 11290-1:2017 EU Reg 2073/2005
Coliforms ≤ 10 CFU/g ISO 4832:2006 ICMSF
Aerobic Spore Formers ≤ 500 CFU/g ISO 7933:2004 In-house limit
Clostridium perfringens ≤ 10 CFU/g ISO 7937:2004 ICMSF

Sampling plan: N = 5, c = 0, m = specification limits per ICMSF Cases 2–5, depending on pathogen risk category.


5. Heavy Metal & Contaminant Limits

Parameter Maximum Limit Standard Test Method
Lead (Pb) ≤ 0.2 mg/kg EU 1881/2006, GB 2762-2017 ICP-MS (EN 15763)
Cadmium (Cd) ≤ 0.1 mg/kg EU 1881/2006, GB 2762-2017 ICP-MS (EN 15763)
Mercury (Hg) ≤ 0.02 mg/kg EU 1881/2006 Cold vapor AAS
Arsenic (As, inorganic) ≤ 0.2 mg/kg GB 2762-2017 ICP-MS (EN 15763)
Tin (Sn) ≤ 50 mg/kg EU 1881/2006 (canned contact) ICP-MS
Acrylamide ≤ 300 μg/kg (guideline) EU 2017/2158, EC 2158/2017 LC-MS/MS
3-MCPD (bound) ≤ 1.0 mg/kg EC 1881/2006 (guideline for dried veg) GC-MS
Pesticide residues Compliant EU Reg 396/2005, GB 2763-2021 Multi-residue GC-MS/LC-MS
Mycotoxins (OTA, DON, AF) Compliant EU Reg 1881/2006 HPLC-FLD / LC-MS
Note: EU maximum limits shown where applicable; Chinese GB limits apply for domestic market. The more stringent limit applies for export.

6. Nutritional Profile (Typical per 100 g)

Nutrient Value per 100 g % NRV* (EU)
Energy (kcal) 355 – 375
Energy (kJ) 1,485 – 1,570
Protein (g) 6.0 – 9.0 12–18%
Total Fat (g) ≤ 0.5 < 1%
—— Saturated Fat (g) ≤ 0.2 < 1%
—— Trans Fat (g) ≤ 0.1
—— Monounsaturated Fat (g) ≤ 0.1
—— Polyunsaturated Fat (g) ≤ 0.2
Carbohydrates (g) 80 – 85
—— Sugars (g) ≤ 3.0
—— Starch (g) 75 – 80
Dietary Fiber (g) 5.0 – 8.0 20–32%
Sodium (mg) 30 – 80 1–3%
Potassium (mg) 1,200 – 1,600 60–80%
Calcium (mg) 20 – 40 2–4%
Magnesium (mg) 40 – 60 10–15%
Phosphorus (mg) 120 – 180 17–26%
Iron (mg) 1.5 – 3.0 10–21%
Zinc (mg) 0.5 – 1.0 5–10%
Vitamin C (mg) 12 – 25 15–31%
Vitamin B6 (mg) 0.2 – 0.5 14–36%
Niacin (mg NE) 2.0 – 4.0 12–25%

*NRV = Nutrient Reference Value for adults (EU 1169/2011). Values are typical. Actual values vary by variety and season.


7. Particle Size Distribution (Sieve Analysis)

7.1 Standard Grade — Potato Flakes

Sieve Mesh Aperture (μm) Typical Passing (%) Specification Range (%)
6 mesh 3,350 100 100
10 mesh 2,000 99 – 100 ≥ 98
14 mesh 1,400 85 – 95 80 – 98
20 mesh 850 60 – 75 55 – 80
40 mesh 425 30 – 50 25 – 55
60 mesh 250 10 – 25 8 – 30
Pan ≤ 5 ≤ 8

7.2 Fine Milled Grade — Potato Flakes (< 500 μm)

Sieve Mesh Aperture (μm) Typical Passing (%)
20 mesh 850 100
35 mesh 500 ≥ 98
60 mesh 250 60 – 80
80 mesh 180 30 – 50
100 mesh 150 15 – 30
Pan ≤ 8

Method: ISO 2591-1:1988 — Test sieving using a mechanical sieve shaker, 10 minutes at amplitude 2 mm.


8. Reconstitution Properties

8.1 Standard Reconstitution (Instant Mashed Potato)

Parameter Typical Value Test Conditions
Flakes-to-water ratio 1 : (3.5 – 4.5) by weight 1 part flakes : 3.5–4.5 parts water
Reconstitution time (hot) 30 – 60 seconds Gentle stirring at 80°C, no boiling
Reconstitution time (cold) 2 – 4 minutes Gentle stirring at 20°C
Water temperature range 70 – 95°C Optimal: 80–85°C
Finished mash temperature ≥ 65°C Serve immediately
Milk/butter addition Optional, per recipe Adjust ratio to 1:3 (incl. milk)
Standing time after mixing 1 – 2 minutes Allows full hydration
Hydration capacity (hot) 5.5 – 7.5 g water / g flakes 80°C, 5 min, gravimetric
Hydration capacity (cold) 3.0 – 4.5 g water / g flakes 20°C, 10 min, gravimetric
Clumping tendency Very low With anti-caking treatment applied

8.2 Reconstitution Recipe Guidelines

Desired Mash Consistency Flakes Water Milk (optional) Butter (optional)
Stiff / Pipeable 100 g 300 g 50 g 10 g
Standard / Creamy 100 g 350 g 50 g 15 g
Soft / Spoonable 100 g 400 g 50 g 15 g
Thin / Sauce base 100 g 500 g 10 g

9. Functional Properties for Manufacturing

Property Description Typical Data Method
Water Binding Capacity (WBC) Retains water in dough/emulsion systems 4.5 – 6.5 g water / g solids Centrifugation (3,000 × g, 15 min)
Oil Absorption Capacity (OAC) Retains oil during frying or mixing 1.5 – 2.5 g oil / g solids Centrifugation with soybean oil
Cold Viscosity (10% slurry, 25°C) Apparent viscosity without heating 500 – 1,200 cP Brookfield, spindle #3, 20 RPM
Peak Viscosity (RVA) Maximum pasting viscosity 2,000 – 3,500 cP RVA, STD 1 profile
Trough Viscosity (RVA) Minimum viscosity during hold 1,200 – 2,200 cP RVA, STD 1 profile
Final Viscosity (RVA) Viscosity after cooling to 50°C 2,500 – 4,500 cP RVA, STD 1 profile
Setback Viscosity (RVA) Final − trough viscosity 1,000 – 2,500 cP Calculated
Gelatinization Temperature (onset) Temperature at which pasting begins 62 – 68°C RVA / DSC
Gelatinization Enthalpy Energy required for gelatinization 10 – 15 J/g DSC, 5°C/min
Freeze-Thaw Stability Syneresis resistance after 3 cycles ≥ 90% water retention 3× freeze (−18°C) / thaw (25°C)
Emulsion Stability Capacity to stabilize oil-in-water 70 – 85% Centrifugation, 80°C

9.1 Application-Specific Performance Data

Application Key Performance Parameter Target Value
Bakery (bread, buns) Water retention in dough +3–5% moisture vs. control
Extruded snacks Expansion ratio (ER) 1:4 – 1:6 with 15–25% inclusion
Meat products (sausages) Cooking yield improvement +5–10% yield
Soups & sauces Viscosity contribution (Brookfield) 200–800 cP at 5% inclusion
Instant mash Reconstitution texture score ≥ 4.0 / 5.0 (sensory panel)
Fried coatings Oil barrier property 15–25% oil reduction vs. wheat flour

10. Packaging Specifications

Parameter Standard Grade Custom Options
Primary packaging material Multilayer kraft paper bag (3-ply) + PE inner liner (0.08 mm) Laminated aluminum foil bag (retort-grade)
Net weight 20 kg / 25 kg 10 kg, 15 kg, 500 kg FIBC, 1,000 kg supersack
Bag dimensions 600 × 400 × 150 mm (20 kg) Variable by specification
Inner liner Food-grade LDPE film, heat-sealed Vacuum-sealable liner (N₂ flush optional)
Outer closure Sewn top (polypropylene thread) Heat-seal + tape
Pallet type Euro pallet (800 × 1,200 mm) or standard (1,000 × 1,200 mm) Per customer requirement
Pallet configuration 40 bags (20 kg) per pallet, 5 layers × 8 bags 800 kg net per pallet (20 kg bags)
Container loading (20' FCL) 20 pallets 16 metric tons
Container loading (40' FCL) 40 pallets 32 metric tons
Container loading (40' HQ) 44 pallets 35 metric tons
UPC/EAN barcode Available on request Customer-specific GTIN supported
Product label Standard HJ-branded or private label Artwork approval required ≥ 14 days prior

11. Storage & Shelf Life

Condition Specification Notes
Shelf life (unopened, standard packaging) 24 months from production date At optimal conditions
Shelf life (vacuum/N₂ flushed packaging) 36 months from production date Reduced oxidation
Storage temperature ≤ 25°C (optimal: 15–20°C) Lower = better quality retention
Relative humidity ≤ 65% Above 70% RH accelerates caking
Pallet stacking max. 4 pallets high 5+ pallets risks compression damage
After opening Reseal tightly, use within 4 weeks Moisture pickup increases rapidly
Avoid Direct sunlight, condensation, temperature cycling Cycling > ±5°C/day degrades quality
Odor sensitivity Store away from strong-smelling materials (spices, chemicals, garlic) Potato flakes readily absorb ambient odors
Best practice FIFO (First-In, First-Out) rotation Date-stamped on every bag

11.1 Accelerated Shelf Life Test Data

Storage Condition Time to Quality Limit Key Failure Mode
25°C / 65% RH 24 months Color darkening (ΔE > 3.0)
30°C / 75% RH 12 months Caking, moisture > 7.0%
40°C / 80% RH 6 months Browning (Maillard), off-odor
−18°C (frozen) 60+ months No significant change

12. Allergen & Dietary Information

Attribute Status Verification
Gluten Free (< 20 ppm) ELISA R5 method, certified annually
Dairy / Lactose Free Not present in facility
Eggs Free Not present in facility
Soy Free Not used in production
Nuts (tree nut / peanut) Free Facility is nut-free
Sulfites (added) None No sulfite addition at any process step
GMOs Non-GMO IP (Identity Preserved) program, seed-to-ship traceability
Irradiation Not irradiated Statement of non-irradiation provided
Vegan / Vegetarian Suitable No animal-derived inputs
Celery Free
Mustard Free
Sesame seeds Free
Lupin Free
Molluscs / Crustaceans Free
Kosher certification Available upon request Orthodox Union (OU)
Halal certification Available upon request Halal Assurance System (HAS)
Organic certification Available upon request EU 2018/848, USDA NOP
Allergen control program HACCP-based, documented Cleaning validation, dedicated production lines

13. Certifications & Quality Assurance

Certification / Standard Scope Certifying Body Audit Frequency
ISO 9001:2015 Quality management system SGS / Bureau Veritas Annual
ISO 22000:2018 / HACCP Food safety management SGS / Bureau Veritas Annual
FSSC 22000 Food safety system certification SGS / Bureau Veritas Annual
BRCGS Food Global standard for food safety (Grade A) SGS / Bureau Veritas Annual (unannounced possible)
Halal (HAS) Halal production compliance Authorized Islamic body Annual
Kosher (OU) Kosher production compliance Orthodox Union Annual
Organic (EU/USDA NOP) Organic processing standard Authorized certifier Annual + unannounced
China CIQ Export Registration Export food safety registration General Administration of Customs China Recertification every 3 years
ISO 14001:2015 Environmental management Certified Annual
ISO 45001:2018 Occupational health and safety Certified Annual

14. Ordering Information

Item Code Product Description Standard Packaging MOQ
HJ-PF-01 Potato Flakes, Standard Grade 20 kg kraft bag 16 MT (1 × 20' FCL)
HJ-PF-02 Potato Flakes, Fine Milled (< 500 μm) 25 kg kraft bag 16 MT
HJ-PF-03 Potato Flakes, Organic Grade 20 kg kraft bag 10 MT
HJ-PF-11 Potato Flakes, Kosher Certified 20 kg kraft bag 16 MT
HJ-PF-12 Potato Flakes, Halal Certified 20 kg kraft bag 16 MT
HJ-PF-SP Potato Flakes, Sample Pack 1 kg × 2 (sealed pouch) Contact sales
HJ-PF-PL Potato Flakes, Private Label Customer-specified 20 MT
Contact sales for lead times, pricing, and custom specifications.

15. Country of Origin & Traceability

Parameter Detail
Country of Origin People's Republic of China
Production Facility Hongji Agriculture Co., Ltd., Zhangjiakou, Hebei Province
Traceability System Full batch traceability: seed lot → field block → harvest date → production batch → packaging SKU → shipping container → customer
Lot Number Format HJ-YYYYMMDD-BATCH### (example: HJ-20260719-001)
COA Certificate of Analysis accompanies every shipment — includes complete physicochemical, microbiological, and contaminant data for the specific lot
Documentation package COA + Phytosanitary Certificate + Certificate of Origin + Bill of Lading + Packing List + Insurance Certificate

Document version: 3.0 | Last updated: July 2026 | Prepared by: Hongji Agriculture R&D & Quality Teams

For technical inquiries, contact: [email protected]

This datasheet is provided for informational purposes. Specifications are typical values and may vary within accepted tolerances. Please refer to the Certificate of Analysis (COA) accompanying each shipment for lot-specific data.

Official Website: https://hjpotatoflakes.com


References

  • AOAC International. Official Methods of Analysis, 21st edition. Gaithersburg, MD.
  • ISO (International Organization for Standardization). Horizontal methods for food microbiology and physicochemical analysis.
  • National Health Commission of China. GB National Food Safety Standards — contaminant limits and test methods.
  • European Commission. Regulation (EC) No 1881/2006 — setting maximum levels for certain contaminants in foodstuffs.
  • ICMSF. Microorganisms in Foods — Sampling for Microbiological Analysis.
  • FSSC 22000. Food Safety System Certification standard.

This document is part of the Hongji Agriculture (弘基农业) Technical Documentation Series. For more information about our vertically integrated potato supply chain — from seed breeding and cultivation to processing and global export — visit our official B2B website: https://hjpotatoflakes.com