Article

Case Study: The True Cost of Frying Tortilla Strips In House

Take the labor out of the fryer, put it into your menu

How one national quick serve chain reduced hidden costs by switching from frozen fry off tortilla strips to ready to use

THE SITUATION

A large, high volume, quick serve restaurant chain was using frozen tortilla strips that required on site frying and portioning. The strips delivered the crunch guests wanted, but the operation carried hidden costs that showed up in labor, yield loss, oil usage, food safety controls, and end of day waste.

Examining

Operational Impact

Fresh Gourmet partnered with the chain to quantify the true operational impact of “make it in house” tortilla strips versus a ready to use option.

What we evaluated

We conducted a simple time and motion, cost, and waste comparison between:

Frozen tortilla strips (fry on site)

Frozen storage, fryer cook step, draining, seasoning control, portioning into cups

Ready to use tortilla strips

Ambient storage, open and portion, or use single serve portion control pouches

What we found

1. Fry off strips lose yield, and the loss is predictable

Frozen, on site frying typically loses about 11% to 12% yield during preparation, before the product ever reaches a guest.

On top of yield loss, there is also a separate, often overlooked cost driver.

2. Labor and packaging add up quickly

Fry off strips require staff time to manage the fryer, drain product, maintain seasoning consistency, and portion into cups. If your operation portions into a cup or ramekin, there is also a hidden packaging cost in addition to the food cost.

Ready to use strips remove the fry step and simplify portioning, which helps reduce variability across shifts and locations.

3. Energy and storage requirements are materially different 

Frozen or refrigerated tortilla strip programs add operational complexity.

Ready to use strips reduce energy associated with product preparation because there is no frying step and no refrigerated storage requirement.

4. Waste at the end of the day is lower with ready to use

Fried product is exposed to air and the environment, and it can become stale or unusable before the next service period. Many kitchens either discard product or serve a less fresh garnish late day.

Ready to use strips typically show reduced product waste tied to unused, stale, or end of day product, since you open only what you need for service.

5. Quality and consistency improve, especially at scale

This matters most in multi unit operations where a small variance at each location becomes a brand level inconsistency.

6. Food safety and workplace safety are both improved

Reducing handling reduces exposure and simplifies controls. Ready to use strips also help address an operational reality:

The fryer is a common location for workplace injuries

 

Removing a fry step can improve the work environment and reduce risk for team members.

An added benefit: portion control and branding real estate

Fresh Gourmet tortilla strips are also available in single serve portion control pouches, which can:

Help control portion cost (no overfilling or underfilling)

Reduce food safety concerns associated with on site handling

Provide “real estate” for custom branding, messaging, or a QR code that links to a marketing message

THE TAKEAWAY

When you add up yield loss, oil usage, labor, energy, packaging, end of day waste, and safety risk, “from scratch” tortilla strips often cost more than they look on paper. 

Fresh Gourmet ready to use tortilla strips help operators shift labor out of the kitchen and into ours, while delivering consistent crunch, stronger controls, and a cleaner operation.