Horticulture Case Study - Tyrrells Crisps

When your philosophy is "fresh is best," there’s no room for compromise. That’s why Calor is relied upon to power a rural business which has grown from a farmer’s diversification into the gourmet foods market.

Tyrrells Chips, based near Leominster in Herefordshire, has a growing reputation among discerning food fans, with its products hailed by celebrity chefs and gourmets alike.

Begun by potato farmer Will Chase in 2001, the company now produces nearly 7,000 boxes of top quality gourmet potato chips each week, supplying stores such as Selfridges, Harrods, Harvey Nicholls and Fortnum & Mason, as well as farm shops, delicatessens and ‘gastropubs’ across the UK.

The business was born, says production director Ian Parkinson, from a need to add value to the farm’s existing potato crop. "Tyrrells had been a major supermarket table potato grower for over 15 years, farming 800 acres," he says. "But we were coming under increasing price pressure. As a potato producer, your costs remain fixed but crop prices fluctuate. The challenge we faced was how to address that price uncertainty but remain in the same business. "

The answer was to diversify into potato chip production and add value to what had become a commodity product. "Supermarkets believe that customers only shop with their eyes and don’t care about flavour," says Ian. "Developing our own gourmet chip business allowed us to meet the challenges of price pressure and to keep growing top quality, established potato varieties."

Farmer Will Chase bought a second hand fish and chip fryer and tried his hand at slicing and cooking his own potato chips. To his surprise, the results were delicious, and Tyrrells Chips was born.

Now, 200 acres of Duke of York and Golden Wonder potatoes are grown for processing into chips and the £3 million business employs 25 staff. A key element in the production of a quality food product, say Ian Parkinson, is the fact that the potatoes are grown on Tyrrells own farm next to the factory, eliminating lengthy journeys.

"Reducing the handling of the crop minimises bruising but also ensures freshness," he says. "It’s not unknown for our potatoes to be growing in the fields in the morning and be turned into chips by lunch time.

"We can also provide complete traceability, from each bag of chips right back to the potato," he adds.

Tyrrells chips have a twelve week shelf life, but the company’s approach is that ‘fresh is best’ and the aim is to achieve a 24 hour turnaround, from lifting the potatoes to delivery at the retailer’s premises. The product is a light coloured chip, in contrast to the darker, harder chips available in the gourmet market.

This is a unique difference, where the cooking process is integral to achieving the right result – and it’s here that Calor plays a key role.

Tyrrells uses a batch frying method in contrast to the ‘continuous frying’ method used by the mass producers. Potatoes are washed and peeled, before being sliced in batches into kettles, each containing 1,300 litres of hot sunflower oil.

The slice size determines the ‘curl’ of the chip and the required cooking time. This, along with the oil
temperature, is a closely guarded secret and is monitored for each individual batch. The chips float on the surface of the oil and are stirred using hand held paddles before being seasoned and bagged within seconds of being cooked.

"There is no substitute for cooking on gas, and that’s why we turned to Calor," says Ian Parkinson. "When the sliced potatoes enter the kettle, the oil temperature dips and it has to be recovered quickly to achieve the right curl and texture, and ensure consistent quality," he adds."In an off-mains gas area, only Calor LPG allows us to achieve this."

Calor LPG was identified as the fuel of choice and was specified well in advance of the new factory’s design. Specialised burners, powered by Calor LPG, bring the oil in the kettles up to the required temperature and provide precise control and flexibility.

"We were determined to learn from the experts and carried out our research in the US, home of the gourmet chip," adds Ian. "That’s where the production technology was developed and we knew that the best methods and equipment would produce the best product. That’s why we specified LPG powered equipment." Demand for Tyrrells Chips has grown significantly, to the point where three new Calor LPG tanks were installed last year to power the factory’s increased production. "Calor was approachable and on the ball – we knew we were dealing with the experts," says Ian. "We’ve worked with them over many years and they’ve always given us a competitive price, and excellent service.

"Calor’s engineers gave us technical guidance in the design of the new factory area and specified the fuel supply according to our predicted requirements. They even included the potential drop in outside air temperature, which would affect our fuel demands and influence our production levels," he adds. "All our deadlines were met without a hitch."

Also integral to the operation is the knowledge that Calor’s delivery network is second to none. "We have a predicted top up which is essential for our business as we fry week to week, according to demand," says Ian Parkinson. "Running out of gas would mean letting down our customers, so that peace of mind is essential."

Tyrrells typically fries its chips in different flavours through the week. Monday’s production is mainly Ready Salted or Cider Vinegar and Sea Salt, with Tuesday dedicated to Cheddar Cheese and Chives. Wednesday sees Thai Curry or Chilli and Lemon as its main flavours, while the remainder of the week is given over to production of the company’s new root chips range – which includes parsnip, celeriac, beetroot and carrot chips.

Calor’s Paul Madge, who oversaw the project, points out that LPG is the fuel of choice for off mains businesses looking for efficient, flexible heating and power. "The applications for cleaner burning LPG are growing all the time," he says. "It’s clear that, with tightening fuel storage regulations, environmental pressures and the need for reliable, controllable energy, LPG delivers – you can have gas even where you don’t have gas."

Tyrrells has received a string of accolades including Food Chain Supplier of the Year, Outstanding Small Business of the Year and, most recently, the Great British Food Award. The company has also recently broken into the European market and may install further tanks and burners in the next year to meet demand.

"Calor LPG is extremely safe and easy to use," adds Ian Parkinson. "We’re very pleased with the technical support and service which provides the energy to cook our quality product."