Industrial Roasting & Processing Pipeline
Operating in the heart of Bihar’s makhana cultivation belt since 2005. Take a transparent look inside our multi-stage sorting, zero-oil hot-air convection roasting, automated micro-mist seasoning, and continuous nitrogen sealing lines.
State-of-the-Art Processing Plant in Katihar, Bihar
Located directly within the fertile makhana harvest heartland of Katihar, our 12,000+ sq. ft. industrial facility bridges rural farm ponds with international export shelves. By processing within hours of raw harvest, we eliminate middlemen, prevent transit moisture spoilage, and guarantee 100% farm-to-pack integrity.
The 9-Stage Roasting & Packaging Pipeline
Explore our end-to-end industrial manufacturing flow in Katihar, Bihar. Each station is operated under standardized Hazard Analysis Critical Control Points (HACCP) and ISO 22000 protocols.
Mechanical Size Grading & Pre-Cleaning
Operating on calibrated vibratory oscillation sieves, raw popped foxnuts are separated by precise kernel diameter. Mechanical airflow dedusters remove microscopic husk particles and immature popped seeds, ensuring only pristine, uniform spheres move forward into the thermal roasting lines.
Precision Hot-Air Convection Roasting
Unlike commercial deep-fried snacks, our industrial convection roasting tunnels circulate precision-controlled dry laminar hot air across rotating conveyor beds. This non-contact roasting uniformizes internal moisture extraction, achieving an ultra-crisp fracture without caramelizing or scorching the foxnut albumen.
Automated Micro-Mist Tumbling & Seasoning
Freshly roasted foxnuts enter a continuous rotary stainless steel coating drum. High-pressure atomizing nozzles disperse a micro-mist of cold-pressed oil, immediately followed by electro-vibratory spice feeders dispensing proprietary seasoning blends (Himalayan Pink Salt, Peri Peri, Cream & Onion, Mint, Tangy Tomato, etc.) for flawless 360-degree adhesion without breakage.
In-Line Laboratory Assay & Moisture Control
Every production lot undergoes mandatory analytical validation in our Katihar plant QA laboratory. Technicians evaluate moisture percentages via halogen moisture analyzers, screen for aflatoxins and peroxide values, conduct organoleptic crunch sensory panels, and verify zero foreign material before releasing the lot for packaging.
High-Speed Automated Multi-Head Packing (VFFS)
Our automated packing bays deploy high-precision multi-head combination weighers integrated with vertical form-fill-seal (VFFS) bagging machines. Foxnuts are weighed with milligram precision, dropped through sanitary funnels, and encapsulated into multi-layer barrier laminate pouches without human hand contact.
Nitrogen Flush & Hermetic Heat-Band Sealing
To safeguard flavor aromatics and prevent lipid oxidation, each pouch is flushed with 99.9% pure food-grade nitrogen gas right before passing through continuous hermetic heat-band sealers. This preserves that freshly roasted crunch and aroma for 9 to 12 months without chemical preservatives or artificial antioxidants.
Cleanroom Quality Audit & Secondary Carton Packing
Within our positive-pressure cleanroom zone, trained packaging operators wearing sterile hairnets, aprons, face masks, and medical-grade gloves conduct secondary QA inspection. Every finished pouch is inspected for legible laser batch codes, expiry dates, seal tightness, and packed into master shippers with moisture desiccants.
Palletized Storage & Warehouse Bay
Finished master cartons are stacked on fumigated heat-treated export pallets (ISPM-15 compliant) and stretch-wrapped to prevent ambient moisture ingress. Racks are organized by flavor, batch identifier, and destination market with systematic First-In-First-Out (FIFO) barcoded warehouse management.
Pan-India Freight & Global Container Logistics
Strategically situated in Katihar, Bihar with immediate access to national highways and trans-shipment rail lines, our outbound fleet transports palletized shipments directly to major Indian metropolitan hubs and dry ports (ICDs) / Kolkata/Haldia ports for ocean container freight to North America, Europe, the Middle East, and Asia-Pacific.
Book On-Site Plant Visit
We welcome snack brand founders, institutional procurement officers, wholesale distributors, and export auditors to visit our 12,000+ sq. ft. continuous roasting, automated seasoning, and cleanroom packaging facility in Katihar, Bihar.