San Carlo black crisps: what dark patches and sprouting marks mean

A snack lover reached for a bag of crisps one evening and was alarmed by what she found: several slices were darkly discoloured, with some showing sprouting marks.

What many people know only from horror stories about processed foods happened to an Italian consumer: a bag of San Carlo crisps contained clearly blackened areas and remnants of potato sprouts. The woman contacted the editorial team of a consumer magazine seeking an explanation. The manufacturer issued a detailed response, offering reassurance while also stressing the limits of even rigorous quality checks.

What happened inside the bag of crisps

The customer bought a bag of “San Carlo Light” at a supermarket in Orbassano at the end of February 2026. After opening it, she spotted several crisps with extensive black areas, while others had marks that she interpreted as early potato sprouts. She considered this a clear quality defect, particularly as the product is intended to be eaten straight from the packet without further preparation.

Black marks on crisps can look alarming, but they are often a visual defect rather than an immediate health risk.

In her complaint, she said the discovery was “potentially risky to consumers’ health”. To support her claim, she included photographs of the crisps and supplied all details of the product, batch and best-before date.

The consumer’s complaint in detail

The customer first approached San Carlo’s customer service directly. When she had received no reply after several days, she involved an editorial team specialising in consumer reports. Above all, she wanted answers to three questions:

• What causes the dark areas and apparent sprouting marks?
• Is there a health risk from eating the crisps?
• What checks does the manufacturer carry out on products of this kind?

Her choice of words illustrates how seriously the incident affected her confidence: she described it as a “serious” occurrence that did not match the quality promise of a well-known snack brand. Such responses are common when food shows visible irregularities, especially in products marketed heavily on brand image and apparent perfection.

San Carlo responds to the black crisps

San Carlo initially thanked the editorial team for forwarding the case and said that it treats every piece of feedback from the market “with great attention”. According to the company, its internal quality team reviewed the matter, relying chiefly on the submitted photographs of the crisps.

Its assessment of the images reached a clear conclusion: specialists believe the dark patches were caused by natural irregularities in the potatoes. In other words, they were not burnt crisps or foreign objects, but parts of the tuber that had become more deeply discoloured during processing and frying.

The manufacturer classifies the dark patches as natural potato defects – unattractive, but harmless according to San Carlo.

The producer cites several factors that can encourage these irregularities, particularly during the winter months:

• Seasonal influences affecting potato storage
• Bruising caused by transport and storage (“compression”)
• Characteristics of individual tubers that become clearly visible only when fried

The company says that the affected batch was produced in January, a period when potatoes are generally more sensitive to storage conditions.

How rigorous are quality checks at crisp manufacturers?

San Carlo refers to “very strict checks” and modern sorting technology designed to remove defective tubers and slices at an early stage. Large crisp factories generally use optical scanners and metal detectors. Before packaging, these systems remove discoloured crisps, those that are too small or too large, and foreign objects.

However, the manufacturer acknowledges that, with a natural product such as potatoes, it is impossible to prevent every visual blemish 100 per cent of the time. Some defects are barely visible before frying and emerge only through heat and browning reactions. As a result, unusually dark slices can occasionally end up in a bag.

The company’s key message to concerned consumers is that its internal review found the reported defects did not affect either the safety or edibility of the product. The crisps therefore remain fit for sale – they simply look less appetising.

How dangerous are black areas and sprouts really?

Many consumers immediately associate black patches on crisps with acrylamide, a substance that can form in starchy foods at high temperatures. Acrylamide is suspected of increasing cancer risk and is closely monitored by authorities. Crisps that are heavily burnt should indeed not be eaten.

In this case, however, the manufacturer refers to natural colour variations in the potato rather than completely burnt areas. Without laboratory testing, it is difficult to judge from appearance alone how high the possible acrylamide level may be in individual crisps. As a rule, industrially made crisps remain within guideline levels set by EU and national authorities.

Signs of sprouting on potatoes can also appear worrying. Experts advise against using fresh potatoes with substantial, well-developed sprouts, as levels of certain toxins, including glycoalkaloids such as solanine, can increase. In crisp production, though, the tubers are washed, peeled, sliced and heated intensely. This substantially reduces sprouts and parts of the problematic substances.

A simple rule remains sensible for consumers: if individual crisps appear badly burnt or look unappetising, it is best to leave them in the bag. The remaining slices that look normal are generally not a problem.

What consumers can learn from the San Carlo case

The case demonstrates how sensitively consumers react to visible irregularities, and how important clear, understandable company responses are. Buyers expect a high, consistent standard of quality, particularly from branded products. When one crisp looks dramatically different from the rest, it can come as a real shock.

This overview of typical causes and appropriate responses may help:

How to store crisps safely and make a complaint

Storage after purchase matters as well as the production process itself. Heat build-up, direct sunlight and major temperature changes can all impair crisp quality. A cool, dry place is ideal, much as it is for coffee or chocolate.

Anyone who notices an irregularity should do more than complain; it is better to proceed methodically:

• Take photographs of the affected crisps and the packaging
• Record the batch number, best-before date and place of purchase
• Use the manufacturer’s contact form or email address
• Consider informing the retailer as well, especially if several packets are affected

Many manufacturers respond as a gesture of goodwill, offer replacement products or start an internal investigation. Such reports can be valuable to companies in identifying weaknesses in their supply chain.

Transparency rather than panic: what the case reveals about the snack market

The San Carlo incident is not a food scandal, but it is a typical example of the balancing act between a natural raw material and the perfect industrial snack. Potatoes grow in the ground with all their natural inconsistencies. The industry tries to turn them into evenly golden crisps, but ultimately encounters physical limits.

Consumers benefit from taking a measured view: not every dark patch means poison, and not every visual flaw presents a health danger. At the same time, customers are entitled to expect transparency, prompt replies and understandable explanations when something in the bag does not look as advertising suggests it should.

Those wishing to take further precautions can choose heavily fried snacks less often, pay attention to portion sizes and vary their choice of savoury snack alternatives. That way, an evening with crisps remains an occasional pleasure – even if the bag happens to contain a black sheep in the form of a dark slice.