If you’ve ever opened a bag of potato chips, you’ve probably noticed that it’s not filled to the brim with chips. Instead, there seems to be a lot of air in the bag, leaving many people to wonder why potato chip companies would waste so much packaging material. The answer lies in the fact that the air inside the bag actually serves an important purpose. Why are potato chip bags pumped full of air?

Firstly, the air inside the bag helps to cushion the chips and prevent them from getting crushed. During the manufacturing and shipping process, bags of chips can be jostled around quite a bit, and without the air to provide a cushion, many of the chips would arrive at their destination in tiny little pieces. The air acts as a protective barrier, keeping the chips in their whole form.

Secondly, the air inside the bag helps to prevent the chips from going stale. When potato chips are exposed to oxygen, they can quickly become stale and lose their crispy texture. By pumping the bags full of nitrogen, chip companies can extend the shelf life of their product and ensure that customers get to enjoy the same fresh, crispy chips every time they open a bag.

Lastly, the air inside the bag serves an important marketing purpose. People tend to equate the size of a product with its value, so a bag that appears to be full of chips is more likely to be perceived as a better value than a bag that appears to be half-empty. By filling the bag with air, chip companies can create the illusion of a larger product, which can translate to more sales.

It’s worth noting that while the air inside chip bags serves a variety of important purposes, it’s not always necessary. In fact, many companies are now experimenting with new packaging designs that use less material and create less waste. Some have even developed “compressed” chips that take up less space in the bag, but still provide the same amount of snackable goodness.

Of course, filling the air is an additional function of the potato chip packaging machine, which can be selected according to the actual packaging needs or not.