Lay's BBQ chips are loaded with inflammatory seed oils (canola, corn, soybean, sunflower) plus artificial additives like maltodextrin and caramel color. This clean version uses avocado oil for frying and a homemade BBQ seasoning blend with real spices, eliminating all processed ingredients while delivering authentic smoky-sweet BBQ flavor.
Based on: BARBECUE FLAVORED POTATO CHIPS
· Makes approximately 40 servings
· Serving: 28g (about 15-20 chips)
Why This Recipe is Seed Oil Free
Commercial BARBECUE FLAVORED POTATO CHIPS from Lay's often contains inflammatory seed oils like canola, soybean, or sunflower oil. This homemade version replaces them with healthier fats like butter, ghee, coconut oil, or avocado oil — giving you the same great taste without the processed oils.
The original BARBECUE FLAVORED POTATO CHIPS may also contain artificial dyes. Check it on DyeFreeCheck to find out.
Ingredients
Organic russet potatoes
1.2kg (about 2.5 lbs) · Organic Valley or local organic farm
The base - russets have ideal starch content for crispy chips that hold seasoning well
Clean substitute for torula yeast - provides umami depth and slight cheese-like richness
Instructions
Step 1. Wash and scrub 1.2kg organic russet potatoes thoroughly but leave skins on (nutrients are in the skin). Using a mandoline slicer or very sharp knife, slice potatoes into paper-thin rounds, approximately 1-2mm thick. Consistency is crucial - uneven slices will cook unevenly. Immediately place sliced potatoes in a large bowl of cold water to prevent browning and remove excess starch. Soak for 15-20 minutes, then drain and pat completely dry with clean kitchen towels. Any moisture will cause dangerous oil splattering.
Step 2. Heat 500ml avocado oil in a heavy-bottomed pot or deep fryer to exactly 350°F (175°C). Use a candy thermometer for accuracy - too low and chips will be greasy, too high and they'll burn before crisping. Work in small batches of 6-8 potato slices to avoid overcrowding, which drops oil temperature. Fry each batch for 2-3 minutes until golden brown and crispy, using a slotted spoon to move them gently for even cooking. Remove and immediately drain on paper towels or a wire cooling rack.
Step 3. While potatoes fry, prepare the BBQ seasoning blend. In a medium bowl, combine 20g organic coconut sugar, 12g Redmond Real Salt, 8g organic smoked paprika, 4g organic onion powder, 3g organic garlic powder, 6g organic tomato powder, and 4g nutritional yeast. Whisk thoroughly to eliminate any lumps - mineral-rich salts and powders tend to clump. Add 8g (1/2 teaspoon) blackstrap molasses and mash it into the dry mixture using a fork until evenly distributed. The molasses will darken the blend and add complex sweetness while replacing artificial caramel color.
Step 4. Season the hot chips immediately while the oil is still warm on their surface - this helps the seasoning adhere properly. Working with one batch at a time, sprinkle approximately 1-2 teaspoons of BBQ seasoning over each batch of warm chips and toss gently in a large bowl to coat evenly. Taste and adjust seasoning as needed - some prefer more salt, others more smoky paprika. The seasoning will seem intense at first but mellows as it sets.
Step 5. Allow seasoned chips to cool completely on wire racks for 10-15 minutes before storing - this final cooling ensures maximum crispiness. Store in an airtight container with parchment paper between layers to prevent sticking. These chips are best consumed within 3-5 days for optimal freshness and crunch. For serving, measure out 28g portions (about 15-20 chips depending on size) to match commercial serving sizes. Re-crisp day-old chips by spreading on a baking sheet and warming in a 300°F oven for 3-4 minutes.
Storage
Store in airtight containers with parchment paper between layers. Best consumed within 3-5 days. Re-crisp in 300°F oven for 3-4 minutes if needed. Keep seasoning blend in sealed jar for up to 6 months.
Cost Comparison
Cost per serving (homemade)$0.16
Cost per serving (store-bought)$0.89
Savings82%
Significant upfront investment in quality ingredients, but massive per-serving savings. The spice blend ingredients last for 10+ batches, making subsequent batches even more economical at around $0.08 per serving.