Why don't potato chip companies save money on packaging and fill smaller bags all the way instead of filling large bags half-way?
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Answer:
The chips are packed to almost to fill the bag at the factory, adding nitrogen gas right before the bags are sealed to provide an inert oxygen free atmosphere to preserve freshness, but the vibration during transport makes them settle. Also a puffy bag acts as a dampener to prevent chip breakage.
Luis Villa at Quora Visit the source
Other answers
It is considerably more important to deliver product that is of good quality. The minor expense of extra film, combined with free air, allows for a package that protects the chips from breakage.
Gregg Beaty
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