How curiosity drove a line operator to change PepsiCo’s potato chip production

How curiosity drove a line operator to change PepsiCo's potato chip production

Some of the best ideas start with uncertainty. Felix Stan's advice: trust your instincts, test your thinking, and put your idea out there. It just might be the game-changing solution your team needs.

As a Lean and Productivity Projects Manager for PepsiCo in Bucharest, Romania, Felix is driven by curiosity and a constant search for better ways of working. Over 25 years, he's learned that the best ideas often come from the people closest to the challenge.

Curiosity drives Stan's approach. "I enjoy finding opportunities that others may overlook and turning ideas into solutions that create measurable value for the business," he said.

That mindset led to an innovation that reduced waste in potato chip production, earned the first patent originated from PepsiCo Romania and was ultimately implemented at facilities around the world.

Trading one calling for another

Stan's career path took an unexpected turn. After studying at a Romanian Orthodox theological seminary, he realized his future lay elsewhere. In 2000, he joined Star Foods, a Romanian snack food company that later became part of PepsiCo, as a line operator and quickly found his professional home.

Those first days on the factory floor were "very intense," requiring quick problem-solving and constant learning. Over time, Stan built deep expertise in potato chip production, earned a Global Site Expert Trainer certification and became a trusted mentor to colleagues.

Years of hands-on experience also gave him a unique perspective on the production process. While watching potatoes transform into chips, Stan identified an opportunity to reduce starch loss during slicing. Confident in his idea, he partnered with operators on the night shift to test a solution.

"I was driven by ambition and perspective to bring about change," Stan said. "I studied the process extensively, and I believed the solution was right." He was. The innovation reduced waste, earned the first patent originated from PepsiCo Romania and was later implemented in facilities around the world.

An idea becomes a breakthrough

This led to a game-changing idea for the Bucharest factory, and ultimately, PepsiCo worldwide. Stan's innovation significantly reduced potato waste during the slicing process. The solution was validated by the University of Cambridge, patented in 2015, and later implemented across PepsiCo plants globally. For his achievement, Stan received the Circle of Champions Award, which honors top frontline operations and supply chain employees.

"At first, I did not fully understand the business impact of the idea, but as I saw it being implemented in different countries, I became even more proud," Stan said. The scale of it really hit home when he was invited to PepsiCo's plant in Kirkwood, N.Y., to help implement the solution there.

"Knowing that something I contributed created value and made a difference across the organization is incredibly rewarding," he said.

Today, Stan's focus extends well beyond a single idea. He works across operations to improve productivity, strengthen manufacturing standards and identify new opportunities to make processes more efficient.

That work is guided by a simple belief. "There is always a better way to do something," he said, "even if a process already works well."

It's the same mindset that keeps him energized after more than two decades - and the same advice he offers anyone just beginning their own career: stay curious. He also helps pass that knowledge on through PepsiCo Romania's Technical Boot Camp Internship program, where he has mentored four cohorts of future engineers.

Through PepsiCo, he found opportunities to learn, travel, share knowledge across countries and turn ideas into real business impact. It's a journey that continues to surprise him, driven by the same curiosity that first drew him onto the factory floor decades earlier.

"Knowing that my work can improve safety, productivity, quality, or sustainability is what keeps me engaged and excited to come to work even after 25 years," he said.

This story is part of A Unique Flavor - a series spotlighting incredible people across PepsiCo with bold ambitions and standout talents.

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