Abstract: Tortilla chips having improved flavor, sweetness and textural characteristics, as well as enhanced nutritional values, are provided using a combination of whole kernel dried corn and germinated grain such as corn to produce a masa dough. Germinated grain contributes a "sweet" flavor as a consequence of the high concentration of natural sugars in the sprouted material. The sprouted corn also contributes substantial fiber and nutritional values to tortilla chips. Specialized methods and systems for producing and processing masa dough having a germinated fraction are required as a consequence of the unique consistency and higher fiber content of the masa dough mixture.