Photo via Fast Company
The potato chip industry relies on far more sophisticated science than most consumers realize. Researchers across the country have spent generations developing specialized potato varieties designed to thrive in diverse climates, resist disease, withstand extended storage, and deliver consistent quality. As consumer preferences shift—such as the recent move toward smaller snack portions—breeding programs must continuously adapt their work to meet evolving market demands.
Michigan has emerged as a critical hub in this agricultural innovation ecosystem. According to the Michigan Ag Council, approximately 70 percent of the state's potato crop is processed into chips, and industry estimates suggest that one in every four bags of potato chips sold in the U.S. contains Michigan-grown potatoes. This concentration reflects both the state's agricultural advantages and the tight collaboration between university researchers, farmers, and major snack food manufacturers like Better Made Snack Foods, a Detroit-based producer operating since 1930.
The breeding process itself is remarkably complex and time-consuming. Developing a single new potato variety can take up to 15 years, according to David Douches, a Michigan State University professor leading the school's Potato Breeding and Genetics Program. The challenge stems from the potato's unusual genetic structure—each cell contains four chromosomes, compared to two in most species—making it difficult to predict which traits will transfer between generations. Recent breakthroughs, including bioengineered varieties that can be stored at lower temperatures without spoiling, promise to streamline supply chains and reduce the need for cross-country sourcing.
The practical benefits are already evident in the supply chain. Better Made previously sourced potatoes from across the country for half the year because Michigan's fall harvest could only be stored until February. Today, using newer varieties developed by Douches that remain viable until summer and resist common diseases, the company sources potatoes year-round from farms just 90 minutes away. This localization reduces transportation costs, improves freshness, and strengthens the regional agricultural economy—demonstrating how scientific innovation can create measurable competitive advantages for manufacturers.
