What Are Popped Chips? Healthy or Just Hype?

There is a new kind of crunch taking over the snacking scene, and it doesn’t come coated in grease. Popped chips bring a healthy yet flavourful option to the table with their airy texture and clean label appeal. 

Made with clean ingredients and a process that skips fryers altogether, they show that better-for-you alternatives don’t have to fall flat. But can they really be considered healthy chips, or is the buzz louder than the benefits?

Let’s take a closer look at how popped chips are made, their nutritional value, and how they stack up against other favourites in the ongoing comparison of baked vs popped vs fried snacks.

Table of Contents

1. How Are Popped Chips Made?
2. Nutritional Profile of Popped Chips
3. Popped vs Fried vs Baked Chips
4. Are Popped Chips Actually Healthy?
5. What to Look for in a Good Popped Chip?
6. Best Time to Eat Popped Chips
7. Bottom Line

How Are Popped Chips Made?

Popped chips are typically made by placing whole grains like rice or lentils into a chamber where they’re exposed to high heat and pressure. As the pressure is released, the natural moisture inside the grains expands rapidly, causing them to puff up into a light, airy texture.

While many brands add oil or fry their chips during this process, at AOF we keep it cleaner. Our Brown Rice Crisps start with whole-grain brown rice, foxtail millet, and red gram that go straight into the popping chamber—no frying, no added oil. Heat and pressure work their magic, creating the signature puffy crunch.

Once popped, we lightly spray them with sunflower oil and toss them in flavourful seasoning so it clings perfectly, giving a delicious burst in every crunch. The crisps are then cooled and carefully packed to preserve freshness and crunch. Varieties like popped potato chips and popped multigrain chips cater to different tastes while supporting mindful snacking.

Nutritional Profile of Popped Chips

Popped chips are known for their clean formulation and ingredient transparency, making them a popular choice among health-conscious snackers. They have:

1. Lower Fat Content

Popped chips are made using heat and pressure, with only a light spray of oil to help seasoning stick—resulting in far less fat than traditional deep-fried chips.

2. Fewer Calories

The popping method reduces calorie density, making these healthy chips suitable for calorie-conscious snacking.

3. Clean Ingredients

Made with 100% whole grains, popped crisps align well with the standards of clean label snacks.

4. Flavour Variety

AOF’s Brown Rice Crisps feature a bold selection of four flavours: Black Truffle, Smokey Barbecue, Cream & Onion, and Indian Spicy Hot, offering something exciting for every palate.

Here’s the nutritional value of our popped brown rice crisps per serving (20g):

Popped vs Fried vs Baked Chips

When it comes to snack choices, understanding the difference between popped, fried, and baked chips can help you make better decisions.

Popped chips are made by applying intense heat and pressure, without the need for any oil. This gives them a delicate crunch while keeping the fat and calorie count noticeably low. Their light crunch comes from clean ingredients like rice or lentils, making them a healthy, guilt-free, and low-calorie choice.

Fried chips, on the other hand, are cooked in hot oil, which gives them their signature crunch but also makes them high in fat and calories. They regularly feature ingredients like preservatives and artificial flavour enhancers. So, while being a favoured option for their taste, it’s wise to consume them in moderation.

Baked chips are oven-cooked, usually with minimal oil. They fall somewhere between popped and fried chips in terms of nutrition. While they contain less fat than fried chips, their texture is typically denser than popped varieties.

Are Popped Chips Actually Healthy?

Popped chips check many of the boxes for healthy snacking. Cooked using only heat and pressure, they’re considered oil-free snacks during the cooking process, with just a light spray of sunflower oil added afterwards to help seasoning stick. This keeps them far lower in fat and calories than fried alternatives, while still delivering a light, crispy texture without the heavy grease—making them perfect for mindful, everyday snacking

As clean label snacks, many popped chips are made from simple, wholesome whole grain ingredients; they’re often gluten-free and vegan. Still, it's wise to check for sodium levels and flavour enhancers depending on the brand. 

What to Look for in a Good Popped Chip?

Here are a few key things to consider if you're looking for truly healthy chips that fit your lifestyle:

• No chemicals: Choose chips free from synthetic processing agents or harmful residues.
• Non-GMO: Look for options made with non-GMO corn, rice, or lentil bases for clean sourcing.
• No preservatives: Avoid chips that use preservatives to unnaturally extend shelf life.
• Sustainably sourced: Select products made with responsibly grown ingredients and eco-conscious practices.
• No artificial colours: Go for chips coloured naturally, without synthetic dyes or colour enhancers.

Best Time to Eat Popped Chips

While popped chips are a healthier alternative to fried snacks, timing still matters when it comes to mindful snacking. The best occasions to treat yourself to them responsibly are:

1. Mid-Morning or Afternoon Snack

Popped chips make a great light snack between meals. Their lower fat and calorie content helps curb cravings without weighing you down.

2. Pre-Workout Fuel

For a quick pre-workout carb boost, a small portion of popped chips, particularly whole grain types, can provide light, sustained energy.

3. Movie Nights or Social Settings

Swap fried chips for popped ones during movie time or parties. They offer crunch and flavour without the guilt, making them a better-for-you choice for casual munching.

4. Late-Night Cravings

Compared to greasy snacks, air popped chips are a smarter pick if you're snacking late. Just keep an eye on the sodium levels to avoid disrupting sleep.

Bottom Line

When it comes to healthy snacking, popped chips really do earn their place. Cooked using only heat and pressure, they’re oil-free during the cooking process and finished with just a light spray of sunflower oil—making them a smart choice for those wanting to avoid greasy snacks.

At AOF, we believe mindful eating should still taste amazing. That’s why we source clean, nutrient-dense ingredients with real flavour.

Our Brown Rice Crisps are made with foxtail millet and brown rice, giving you a gluten-free, oil-free, and vegan snack that’s packed with bold flavour and zero guilt. Try them now and snack without the guilt!