Explore the Tayto Factory at a Castle in Northern Ireland

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Passing through the impressive stone gates of Tandragee Castle, one might anticipate tales steeped in history—feuds, conquests, and noble lineage. This venerable stronghold in County Armagh, Northern Ireland, boasts a legacy dating back 500 years, once standing as the residence of the O’Hanlon clan before transitioning to the possession of the Duke of Manchester in the 19th century.

While the castle’s past is rich with stories of conflict and transformation, it harbors a contemporary and cherished legacy within its walls—one that revolves around a beloved culinary innovation. Today, it is known for being the birthplace of one of Northern Ireland’s most recognizable snacks.

Since starting operations in 1956, the Tayto Group has been producing potato crisps, filling the air with the delicious aroma of frying potatoes in what were once the living quarters of warriors and nobility.

From Castle to Chip Empire

The transition of this castle into a thriving snack manufacturing hub can be largely attributed to Thomas Hutchinson, an enterprising individual who revitalized the dilapidated estate into the headquarters for Tayto after acquiring the rights to the Tayto name from Tayto Crisps from the Republic of Ireland, even though the two companies operate independently.

Hutchinson introduced a distinctive cheese-and-onion flavor and began production with a modest output of 972 packets each day. Fast forward nearly seven decades, and Tayto now produces millions of packets daily, cementing its status as the third-largest snack producer in the United Kingdom with a significant share of the Northern Irish market.

The company has also established a distribution network that caters to expatriates yearning for the taste of their childhood. “Tayto cheese and onion crisps are part of our upbringing; they taste like home to us,” reflects Kirsty Black, a Tayto Castle tour guide raised in the vicinity.

Discovering the Tayto Factory

Visitors can experience the operations firsthand through the Tayto factory tour, which includes insights into the brand’s heritage and production processes, along with an opportunity to meet the jovial mascot, Mr. Tayto. Ticket prices stand at £12.50 (about $16) for adults and £8 (roughly $10) for children aged 5 to 16.

Before embarking on the tour, participants are equipped with hairnets and protective gear, including shoe coverings. A friendly guide leads them to a spacious storage area, where Tayto stores around 20,000 tons of locally sourced potatoes harvested during the summer and autumn months.

As the tour proceeds, the irresistible scent of frying potatoes (the factory utilizes nearly 8,000 gallons of oil each day) fills the air upon entering the pristine production area. Guests are even invited to sample chips freshly cooked and taken directly from the conveyor belt.

Visitors can indulge in the unseasoned chips, experiencing their warm and delicate nature, which serves to emphasize why crisps can be so addictively delightful. These perfectly sliced potatoes are exceptional in delivering an ideal combination of saltiness and flavor with each bite.

Interestingly, within the castle structure lies a highly secure room that is accessible to only two employees. This is where the secret recipe for Tayto’s renowned cheese and onion flavor is combined, a closely guarded process that involves only a handful of ingredients mixed exclusively by these two individuals.

The Other Tayto

After completing the tour, one might be surprised to find that just across the border in the Republic of Ireland, a completely different entity produces its own range of crisps under the same name. The Southern Tayto operates its own facilities and has distinct flavors, albeit the humorous likeness in branding, including a character sporting a top hat.

In Belfast, if you order a bag of crisps, you are likely to receive the iconic bright yellow packaging of Northern Tayto. Conversely, in Dublin, you’re more likely to find the red, white, and blue packaging of Southern Tayto, often jokingly referred to as “Free Stayto.”

The age-old debate over which Tayto is superior varies from person to person. Generally, individuals tend to favor the brand they were exposed to during their formative years.

Notably, Oasis frontman Liam Gallagher, who has familial ties in the South, has declared his loyalty to Southern Tayto. Meanwhile, actor Jamie Dornan, raised near Belfast, champions the Northern version.

Tayto’s Cultural Footprint

In a 2022 segment on Jimmy Kimmel Live!, Dornan even proposed a new traditional Irish dish for St. Patrick’s Day—a simple yet nostalgic sandwich composed of chips, commonly referred to as a “Tayto smashie.”

He shared the preparation method, which includes using a basic slice of white bread slathered with mayonnaise, topped with several pieces of ham, followed by a generous handful of Tayto cheese and onion crisps, and finished with another slice of bread also coated in mayonnaise.

As he pressed down on the sandwich, the well-known crunch from the chips echoed, showcasing the origin of its name. Dornan humorously stated, “This could be the most thrilling event in your day, year, or even your life.”

While the O’Hanlon clan may have made quite a commotion during their attempts to reclaim the castle from King James I in the 17th century—an endeavor that ultimately left the castle in ruins before the Duke of Manchester took ownership—it is the uncomplicated yet satisfying crunch of a Tayto crisp that has, against all historical expectations, emerged as the castle’s most lasting legacy.

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