If Quavers are a staple in your meal deal line-up, you might want to prepare yourself for some surprising revelations. A clip from the BBC’s Inside The Factory series has left many Brits shocked—and even a little horrified—after learning the detailed process behind making the beloved snack.

Hosted by comedian Paddy McGuinness, the episode pulls back the curtain on the iconic Quavers production process at a factory in Lincoln. The journey of how Quavers go from dough to crispy, cheesy curls has intrigued some and grossed out others, with many saying they’ll never look at the snack the same way again.

Let’s dive into the surprising revelations from the episode, including what makes Quavers so unique—and divisive.

Quavers: Not Technically Crisps?!

For over 50 years, Quavers have been a household favourite in the UK, with 500 million packs produced annually. But here’s the first twist—despite their appearance and association with potato-based snacks, Quavers aren’t technically classified as crisps.

Why? They’re made from potato starch powder, a by-product of the crisp-making process, rather than whole slices of potato. This revelation left many viewers questioning their snack choices.

One Twitter user exclaimed, “Do me a Quaver—our whole lives have been a lie!” Another commented, “Inside The Factory is both fascinating and horrifying. Quavers aren’t even real crisps!”

The Quaver creation process left a lot of viewers with a bad taste in their mouths (**BBC**)

How Are Quavers Made? The Step-By-Step Process

Paddy McGuinness’s behind-the-scenes tour revealed the surprisingly complex process behind these curly snacks. Here’s how Quavers are made:

Mixing the Ingredients:
The process begins with combining starch powder, fine rice, and soya flours in a massive mixer. A “mild seasoning” of salt, pepper, onion powder, and yeast is added to the mix for flavour.
Creating the Dough:
Water is then added to form a dough, which is thoroughly mixed before being shaped.
Extrusion and Shaping:
The dough is forced through a machine called an extruder, which works similarly to a pasta maker. A thin, one-millimetre-thick sheet resembling lasagna emerges from the machine.
Steaming and Cooling:
The dough is stretched over rollers and passes through an 18-meter-long steamer. Here, moisture levels are raised to 40%, making it pliable enough to be manipulated into the iconic curly shapes.
Cutting and Frying:
The dough is cut into small pellets measuring 13mm by 40mm, with a staggering 7,900 pieces cut every minute. These pellets are fried in sunflower oil heated to 200°C. Within 20 seconds, the heat turns the water inside the dough into steam, puffing up the curls while contracting them into their signature shape.
Adding the Cheese Powder:
The final step involves coating the crispy curls in cheese powder. This is done in a massive metal drum, ensuring that every curl gets its irresistible cheesy flavour.

The Divide: Fans vs. Critics

While some viewers found the process fascinating, others were left uneasy by how industrialized the production is. Comments on social media ranged from shock to outright horror:

One viewer tweeted, “#InsideTheFactory is a wake-up call. Quavers are ultra-processed snacks with little nutrition. Big Food has been making us unhealthy for decades.”
Another wrote, “I’ll never think about Quavers the same way again after watching how they’re made.”

On the flip side, some fans were unfazed—or even more appreciative of the snack.

“Watching Inside The Factory just made me crave Quavers. Imagine hating ultra-processed food—Quavers are a work of art!”
“Do I care how Quavers are made? Absolutely not. Pass me a bag!”

This divide highlights the growing debate around ultra-processed foods and their role in modern diets. If you’re curious about what qualifies as ultra-processed, check out this guide to processed foods.

A Nostalgic Favourite Since 1968

Quavers have been a staple in the UK snack scene since their launch in 1968. Over the decades, they’ve maintained a loyal fan base thanks to their light texture and cheesy flavour. Despite the revelations, their popularity shows no sign of waning.

The dough wasn’t the most appealing thing to look at (**BBC**)

The Lincoln factory producing Quavers has been operating for over 50 years, and its ability to churn out 500 million packs annually proves just how much Brits love their cheesy curls.

The Bigger Conversation: Processed Foods in Modern Diets

While some viewers dismissed the manufacturing process as “too industrial,” others saw it as a reflection of the larger issue of ultra-processed foods in our diets. Quavers, like many snacks, fall into this category due to their reliance on processed ingredients and additives.

Studies have shown that consuming too many ultra-processed foods can lead to health issues such as obesity and heart disease. Want to learn more about how ultra-processed foods impact your health? Read this article on ultra-processed food risks.

Social Media Buzz: The Internet Reacts to Quavers Revelation

The BBC episode featuring the Quavers factory tour caused a stir on social media, sparking a mix of shock, curiosity, and nostalgia. From memes to heated debates, here’s a roundup of reactions that captured the internet’s attention:

Shock and Horror:
“Watching #InsideTheFactory and just learned that Quavers aren’t technically crisps?! My entire life has been a lie. Link to Tweet.”
Nostalgia Meets Curiosity:
“Say what you want about how they’re made, Quavers are still the GOAT snack. Paddy McGuinness, you’re doing the Lord’s work. Link to Instagram Post.”
Debating Ultra-Processed Foods:
“Quavers are another reminder of how much ultra-processed food we consume. Watch #InsideTheFactory and see for yourself. Link to Facebook Post.”
Unfazed Fans:
“Who cares how Quavers are made? Just hand me a bag and some dip. Loved seeing this on @BBC. Link to Tweet.”
Meme Energy:
Some users even turned their reactions into memes, captioning photos like:
“‘Quavers aren’t crisps’ is the plot twist I didn’t see coming. Link to Reddit Discussion.”
Healthy-Eating Advocates:
“Watching how Quavers are made on #InsideTheFactory has made me rethink my snack choices. Ultra-processed foods are everywhere! Link to Instagram Post.”

The lively discussions underscore how food production can evoke strong emotions. Whether you’re shocked, amused, or indifferent, there’s no denying the cultural impact of Quavers.

Social Media Reactions: A Mixed Bag

The episode sparked a lively debate on social media, with many Brits sharing their thoughts. Here are some standout reactions:

“My mum said she’ll never buy Quavers again after watching how they’re made. I think I’ll stick to fruit.”
“Cheering at my TV while watching Paddy McGuinness make Quavers. It’s a British institution!”
“Ultra-processed or not, Quavers are still my go-to snack. Don’t care how they’re made!”

The debate over ultra-processed foods continues, but one thing is certain: Quavers remain a snack that stirs strong opinions.

Final Thoughts: Do You Still Love Quavers?

Whether you find the Quavers production process fascinating or off-putting, one thing is clear—these cheesy curls have cemented their place in British snack culture. For fans, Quavers represent more than just a snack; they’re a nostalgic treat that has been delighting taste buds since 1968. Their light, crispy texture and unmistakable cheesy flavour keep them a top pick in meal deals and snack cupboards nationwide.

On the other hand, critics argue that Quavers—and similar ultra-processed foods—reflect the larger issue of unhealthy eating habits in modern diets. The intricate, industrialized process revealed in Inside The Factory raised eyebrows, sparking debates about whether snacks like these should still hold their iconic status.

So, where do you stand? Does knowing the step-by-step journey of how Quavers are made change how you feel about them? Are you in the camp of “ignorance is bliss,” or do you see this as an opportunity to rethink your snack choices? We’d love to hear your thoughts! Join the conversation in the comments section below or share your opinions with us on social media using #QuaversDebate.

Curious to learn how other iconic snacks are made? Inside The Factory dives into the processes behind many household favourites, offering an inside look at the fascinating (and sometimes surprising) world of food production. Catch the full series on BBC iPlayer and discover the stories behind the snacks you love.

Featured Image Credit: BBC