Multivariate assessment of acrylamide formation and processing variables in fast-food French fries under real-world frying conditions

Acrylamide, a probable human carcinogen formed via the Maillard reaction, remains a key food safety concern in carbohydrate-rich fried foods such as French fries. This study investigates acrylamide formation under real-world frying conditions, integrating precursor composition and operational practices through a multivariate approach. A total of 48 samples (frozen par-fried potato strips and freshly fried French fries) were collected from four major fast-food chains in Malaysia. Acrylamide concentrations were quantified in both frozen par-fried strips and freshly fried fries using LC-MS/MS. In addition, precursor sugars (glucose, fructose, sucrose) and moisture content were analysed only in the frozen par-fried strips using HPLC. On-site frying conditions, including frying time, temperature, and oil usage, were recorded to capture operational variability. Significant differences in acrylamide concentrations were observed among chains (159–609 µg/kg; p < 0.05), and these variations, despite adherence to SOPs, were largely attributable to operational inconsistencies and human factors. Multivariate analyses (XLSTAT) revealed sucrose, frying time, moisture, and fructose as dominant contributors to acrylamide variability, collectively explaining 69.5 % of the total variance. Principal Component Analysis (PCA) demonstrated strong positive associations between acrylamide, sucrose, and fructose, while glucose exhibited an inverse trend. Agglomerative Hierarchical Clustering (AHC) further differentiated chains based on frying and compositional profiles. This study provides the first integrated assessment of precursor composition and operational practices in Malaysian fast-food settings using multivariate modelling. The findings support targeted mitigation strategies through both raw material management and process optimisation to reduce acrylamide risks in commercial French fries.

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