Watch – A behind the scenes look at how Kettle chips are made in Norfolk

Kettle Foods factory.
Picture: ANTONY KELLY

Kettle Foods factory. Picture: ANTONY KELLY - Credit: Archant

Kettle Foods has been established in Norwich since 1988 and has gone from a handful of staff and one fryer to 443 staff and 22 fryers.

Kettle Foods factory.
Picture: ANTONY KELLY

Kettle Foods factory. Picture: ANTONY KELLY - Credit: Archant

On average 3.6 million bags off crisps are produced at the Bowthorpe factory each week and are distributed across 23 countries.

This growth means the factory has gone from using three tonnes of potatoes a week to processing more than 50,000 tonnes per year – most of which are grown within a 30 mile radius of the site.

Kettle uses six varieties of potato to make sure there are enough throughout the year.

One in three UK households buys a Kettle Chips product each year with 92 million bags sold in the UK in 2016.

Kettle Foods factory.
Picture: ANTONY KELLY

Kettle Foods factory. Picture: ANTONY KELLY - Credit: Archant

Each lorry delivering to Kettle carries around 175,000 potatoes and it takes 30 minutes for the spuds to go from delivery to bag.

There are 43 Kettle products made in Norwich with other lines made at sister factories including vegetable crisps made in the Netherlands and popcorn near Birmingham.

Kettle Foods factory.
Picture: ANTONY KELLY

Kettle Foods factory. Picture: ANTONY KELLY - Credit: Archant

Kettle Foods factory.
Picture: ANTONY KELLY

Kettle Foods factory. Picture: ANTONY KELLY - Credit: Archant