A conversation with Lutosa’s R&D Engineer on consistency, coating technology and what really happens between the fryer and the table.
When foodservice operators talk about consistency, they mean it across thousands of covers, dozens of staff, and supply chains that span continents. Delivering a fry that performs reliably — same colour, same crunch, same yield — batch after batch, year after year, is not an accident. It’s the result of continuous R&D work that most operators will never see, but immediately notice when it’s missing.
We spoke with one of Lutosa’s R&D engineers to understand what goes into a frozen fry that actually holds up in a professional kitchen.
More than a cut potato: the case for process complexity
Q. How would you describe what R&D actually does on a product like frozen fries?
“Most people assume the fry is a basic product.
At Lutosa, we work well beyond the classic fry. We develop coated varieties engineered for specific textures and flavours, and entirely separate product families (mash, rösti, flakes) each with their own technological challenges. R&D spans from lab-scale experiments all the way to full industrial production, and we work alongside quality, production, marketing, and commercial teams throughout.”
For operators, this matters because it means the products arriving in their kitchen have been stress-tested far beyond what standard freezing and slicing would deliver. The engineering is in the details and the details determine whether a fry survives the gap between kitchen and guest.
The raw material problem: why potato variability is a professional kitchen issue
Q. What do operators need to understand about the potato as an ingredient?
“The potato is a living raw material. It evolves with the seasons and from one harvest to the next. Water content, sugar levels, dry matter, texture — these parameters all shift, and they have a direct impact on how a fry cooks, how it colours, and how it tastes.”
“We track these variables continuously. Key selection criteria include sugar content, dry matter, and calibre. Based on those measurements, we adjust the process to compensate for natural fluctuations and guarantee a consistent end product, regardless of the harvest.”
“The goal is something that sounds simple but is technically demanding: the same fry, every single time.”
Quality checkpoint: colour and crunch are assessed approximately every hour on the production line allowing real-time correction before deviations become a product issue.
Coating technology: the invisible answer to your delivery challenge
Q. How do you address crunch retention for delivery and take-away contexts?
“Coating is our primary answer to hold time. As a general rule, a thicker coating means the crunch holds longer. But the composition matters just as much as the thickness — small modifications in coating formulation can deliver a completely different eating experience.”
“Our Ultra-Crunchy range, launched in 2024, significantly improved crunch retention compared to standard coated fries. The result came from optimising the blend of starches and functional ingredients in the coating — changes that are invisible to the consumer, but immediately felt in the texture.”
For operators working in delivery, dark kitchens, or high-volume take-away, this is not a marginal improvement. A fry that holds its crunch for 15 to 20 minutes post-fryer is a fundamentally different product in terms of guest experience and complaint rates.
Adapting to market expectations: what your customers expect before they order
Q. Lutosa operates across many international markets. How does R&D adapt to different foodservice expectations?
“Cut dimensions, colour, texture, flesh colour — expectations vary significantly from one market to the next. The American market is known for its preference for white-fleshed fries. European markets tend to look for yellow flesh and a more pronounced potato flavour. After years of presence on these markets, we’ve built a catalogue broad enough to meet these demands precisely.”
For multi-market operators or distributors, this means specification accuracy is built into the product range — not something to negotiate on every order.
Sustainability and what's coming: air fryer optimisation, new varieties, and nutritional improvements
Q. What are the major R&D priorities for the coming years?
“Environmental impact is a central challenge. We’re actively working on reducing carbon-intensive energy use and improving waste management across production. We also maintain dedicated test plots to trial new potato varieties better adapted to variable climate conditions — one of which, Satis, has already been integrated into our product range.”
“On the nutritional side, we’ve replaced palm oil with sunflower oil. And with the rapid uptake of air fryers — both in homes and increasingly in professional settings — we’re developing fries specifically optimised for that cooking method: crispier results, less oil, built for how people are actually cooking today.”
“Our mission in R&D is to keep the tradition of the Belgian fry intact, while adapting it to today’s expectations — preserving its crunch and authentic taste, while responding to health, environmental, and operational challenges.”
