Meet the scientist behind new potato chip varieties: 5 new types developed over 15 years

(SeaPRwire) –   There is a significant amount of scientific work behind every bag of potato chips.

For decades, scientists have been breeding potatoes for chip production that thrive in diverse climates, resist disease and pests, can be stored for long periods, and still provide a perfect crunch. They also monitor consumer preferences; for instance, the trend toward smaller snack portions has driven demand for potatoes that yield smaller chips.

“The potato sector is constantly evolving,” explained David Douches, a professor at Michigan State University who directs the Potato Breeding and Genetics Program. “The needs, costs, pressures, and markets all shift. We have to adapt our varieties accordingly.”

Over the past 15 years, Douches has created five new potato varieties specifically for chips. His most recent innovation is a bioengineered potato that retains the correct sugar balance even in colder storage, helping to prevent spoilage. He is currently cultivating seeds for commercial trials of this potato, which is not yet available to the public.

Douches’ research contributes to combating global hunger; he has bred disease-resistant varieties for farmers in Nigeria, Kenya, Rwanda, and Bangladesh. His work also supports U.S. chip manufacturers, happy consumers, and Michigan’s $2.5 billion potato industry. While Idaho is the top U.S. potato producer overall, Michigan leads in supplying potatoes for chips.

Currently, about 50 distinct potato varieties are cultivated for chips in the United States, according to the National Chip Program. This cooperative unites Michigan State and 11 other university breeding initiatives with growers, chip companies, and the U.S. Department of Agriculture.

The drive to enhance these varieties is ongoing. The National Chip Program assesses approximately 225 new potato varieties annually and chooses 100 for additional testing, stated Tim Rendall, director of production research at Potatoes USA, the trade organization that manages the chip program.

Phil Gusmano, vice president of purchasing at Better Made Snack Foods—a Detroit-based chip maker since 1930—said the tight collaboration between researchers, farmers, and chip companies is rare in the food business. He noted that Better Made collaborated closely with Douches during the development of two varieties the company currently uses.

“We could discuss the ideal size and other requirements for a high-quality chip,” Gusmano said. “The best part is they listen to our input, because creating a potato that doesn’t suit the end processor’s needs isn’t beneficial for anyone.”

Developing a new potato variety can require up to 15 years, Douches noted. The humble potato has a surprisingly complex genetic makeup, with four chromosomes per cell instead of the two found in most species, including humans. This complexity makes it challenging to forecast which traits will appear in cross-bred plants, he explained.

“We can never lock in a trait and guarantee it passes to the next generation, so it’s extremely hard to find a potato that possesses every characteristic we desire,” Douches said.

Douches developed his passion for potato breeding and genetics in graduate school. At Michigan State, he concentrates on chipping potatoes because Michigan is a major producer. The Michigan Ag Council reports that roughly 70% of the state’s potato harvest is processed into chips. The council estimates that one in every four bags of potato chips made in the U.S. includes potatoes from Michigan.

One of the greatest challenges of Douches’ 40-year career has been breeding potatoes that can be stored for almost a year. Traditionally, farmers stored harvested potatoes in large piles at about 50 degrees Fahrenheit (10 degrees Celsius). Colder temperatures increase sugar levels in the tubers, resulting in darker chips, while warmer conditions promote rot.

“You might think they’re just inanimate objects, but they are actually respiring and breathing,” Douches said. “When you store them, they only have a two- to three-day window where conditions are ideal.”

His Manistee variety, released in 2013, can be stored safely until July at 45 F (7.2 C). His new bioengineered potato can withstand storage at 40 F (4.4 C).

Gusmano explained that Better Made previously had to source potatoes from outside Michigan for half the year because locally harvested potatoes could only be stored until February. Now, the company uses newer varieties like Douches’ Mackinaw potato, which can be stored until July and resists several common diseases.

“We no longer need to ship potatoes from across the country to be fried here in Michigan,” Gusmano said. “Now, they come from just an hour and a half away, year-round.”