Our Process
State-of-the-Art infrastructure and top-class facilities, leading the spice industry with precision at every step.
We are leading the Spice Industry with State-of-the-Art Infrastructure and Top-Class Facilities
Cleaning and Sorting
Automated without hand touch
The cleaning and sorting processes are completely automated, so there is no human touch with the materials. This hands-free approach improves hygiene while simultaneously increasing productivity.
Removal of Contaminants
Advanced machinery is used to gently remove impurities like stones, dirt, metallic bits, and other undesired items.
The process can detect and eliminate undersized and large particles, as well as rotting and stained materials, ensuring that only high-quality products move further in the processing line.
Hygiene and Allergy Considerations
The processing line has separated cleaning areas to ensure the highest levels of hygiene. These segregated lines also cater to allergy sufferers, preventing cross-contamination during cleaning.
Removal of spoilt and Rotten material
Ensuring the greatest quality starts by conducting meticulous raw material sourcing. Our extraction plant has an exceptional capacity of 5,00,000 kg/day for removing damaged and decaying materials.
Grinding and Blending Technology
Hands-Free Grinding
Our production center has 35+ high-speed, high-volume grinding lines that work without human touch, ensuring maximum cleanliness and safety.
Hygiene and Allergy Segregation
Similar to the cleaning procedure, the grinding lines are separated to ensure stringent cleanliness standards and suit those with allergies, preventing cross-contamination.
Advanced Grinding Technologies
To maintain freshness and prevent the loss of volatile oils, different grinding processes are used, including.
High Production Capacity
We employ perfect grinding procedures to preserve freshness and avoid the loss of volatile oils, which are essential for flavor and aroma. With a significant grinding capacity of 3,000,000 kg/day, our plant can meet large-scale needs without compromising quality.
Individual Grinding Lines
We run 18 individual grinding lines, all of which are focused on different kinds of spices. This strategy keeps cross-contamination at bay and ensures that every spice is treated under ideal conditions, giving us to preserve the consistency and purity of our products.
Cryogenic Technology
Our structure, which was first established in India in 2012, has the world's largest cryogenic grinding machine for spices, ensuring the preservation of essential oils and flavors.
Blender
The blender is essential to preserving consistency in the finished product and ensuring that each batch meets our high-quality standards.
Hooper
The hopper functions as both a storage and feeding element, carefully pouring materials into the cryogenic system. It is meant to endure low temperatures while maintaining the materials' integrity.
Nitrogen conveyer
The nitrogen conveyor plays an essential role in cryogenic processing given that it conveys the material while preserving the extremely low temperatures required for productive grinding.
Mill
The cryogenic mill is used in the grinding process to finely grind materials at extremely low temperatures. This process preserves delicate supplies, such as essential oils, producing a superior product with enhanced flavour.
Cyclone
The cyclone separator removes fine soil from the airstream in the cryogenic process. It ensures that only the appropriate particles are collected, and bigger particles are recirculated for additional grinding.
Ground material
The ground material acquired after the cryogenic process is highly refined and consistent, with all-natural qualities preserved. The material is ready for additional processing, packing, or use in a variety of applications, ensuring superior quality.
Dust collector
The dust collector is essential for maintaining a clean and safe working environment by capturing any fine particles formed during the grinding process.
Cryogenic
High Pressured Liquefied Nitrogen Gas is used to control grinding chamber at (-150 C) as a result loss of essential oils, minerals, olio resins and aroma can be marginally minimized. Cryogenic Grinding Technology reduces the material to particle size in less time with higher efficiency, which is difficult to attain at ambient temperature grinding in conventional grinding units.
The advantages of Cryogenic Grinding Technology with Respect to Conventional Grinding Techniques are as under:
Cryogenic Grinding Technology |
Conventional Grinding |
|---|---|
Improves the natural Aroma by minimizing the loss of essential oils and olio resins (Approx. 3 – 10 % loss). |
In Conventional Grinding Technique the loss is about 15 – 43 %. |
Obtain finest particle size upto 50 micron (300 mesh). |
Size ranges from 500 – 1000 micron (150 – 30 mesh) in Conventional Grinding Techniques. |
Better in terms of higher natural aroma and natural colour due to lower grinding temperature. |
Loss of color and aroma due to heat generated in grinding chamber. |
Overall grinding capacity can be enhanced by 2 – 3 times as chilled process line & process equipment is not disturbed by thermal fatigue. |
Lower grinding capacity at higher power consumption. |
At Cryogenic temperature, the product at (–150 °C) cools down and crystalizes at the microscopic level and hence it becomes rock solid. This crystallization locks the oils in the product and makes it easy to be ground. |
While grinding, oil heats and evaporates making product dull and odorless. |
Cryogenically processed spices have longer shelf life than the conventionally ground ones due to higher Volatile oil in them. |
Due to loss of Oil, product life reduces substantially. |
Cold Grinding
This approach keeps the spices from overheating and preserves their natural aroma and flavor.
Vacuum Grinding
Used to enhance the freshness and lifespan of spices.
Low Friction Grinding
Reduces the degradation of spices all over the grinding process, giving rise to better-quality products.
Food Grade Materials
All grinding equipment is made of food-grade SS304 and SS316 steel wherever the material comes into direct contact, ensuring the greatest levels of safety and cleanliness.
Blending
Modern blending machines are utilized to produce a specifically unified mixture, ensuring consistent flavor across all spices.
Roasting
An essential first step in bringing out the taste and aroma of our spices is roasting. Lowering the moisture level of the spices, this procedure not only enhances their flavor profile but also helps to preserve them by increasing their shelf stability.
Fortification
To improve the nutritional value of our spices, we fortify spices with the necessary nutrients. The meticulous control of this process preserves the balance between flavor and its nutritional advantages.
Good Manufacturing Practices (GMP)
1. Hygiene and Cleanliness
To avoid contamination and ensure product safety, it is essential to maintain a clean and hygienic atmosphere. This entails strict personal hygiene standards for employees, proper disposal of trash, and routine cleaning of premises and equipment.
2. Quality Control
Under GMP, a strong quality control system is necessary. To make sure they fulfill quality standards, this involves extensive testing of raw materials, materials used during processing, and finished products. Any deviations need to be carefully examined, and appropriate action needs to be taken.
3.Training and Competence
To carry out their duties, staff engaged in the manufacturing process need to be suitably qualified and trained. Employees are kept up to date on industry best practices and safety standards by regular training programs.
4. Facility and Equipment Maintenance
To ensure that the devices operate as planned and do not contribute to product contamination or quality issues, GMP requires that facilities and equipment be properly maintained and calibrated.
5. Managed Production Practices
All manufacturing processes must be precisely specified, controlled, and validated by GMP to ensure consistency and adherence to requirements. This requires precise measurement, close monitoring of important parameters, and strict commitment to process controls.
6. Documentation and Record-Keeping
A key component of GMP is accurate documentation. To ensure traceability and accountability, thorough records of the manufacturing procedures, quality control testing, equipment upkeep, and employee training must be maintained.
Dry Storage
Hygienic Storage
Our dry storage facility is designed to maintain the highest hygienic specifications, with a total capacity for storage of 35,00,000 kg.
Regular Fumigation
The facility is fumigated regularly to keep pests and rodents out, ensuring a safe environment for spice storage.
Cold Storage
Temperature-Controlled Environment
Our cold storage facility maintains an ideal temperature of 10 °C, which is essential for maintaining the freshness and quality of spices.
Large Capacity
The cold storage facility has a capacity of more than 50,000,000 kg metric tons, making it ideal for storing significant quantities of spices.
Pest-Rodent Free & Monitored Zone
The cold storage area is fumigated and microbiologically checked regularly to ensure it remains pest- and rodent-free, safeguarding the spices' quality.
IBC (Intermediate Bulk Containers).
Intermediary Storage
IBCs are used for transitory material storage, ensuring that spices are safely held between processing stages without sacrificing quality.
Bulk Bag & Packaging Material
Reusable Bags
We use reusable bags to reduce plastic waste, which aligns with our sustainability goals.
High-Density Material
The packaging material is high-density, which ensures that the products have a longer shelf life.
Three-Layer Packaging
Our packaging consists of three layers that form a complete shield between the product and the outside environment, preserving the spices from infestation and ensuring freshness.
Packaging Solutions
Automated Packaging
Our packaging process is completely automated, ensuring no human touch occurs with the products during packaging.
That ensures a high level of hygiene and accuracy during the packaging process.
Accurate and Sustainable Packaging
The automated technique assures proper packaging, which reduces waste and increases efficiency.
We utilize high-density, reusable bags that increase the shelf life of our products, and our packaging materials include recycled plastic and paper, which helps to promote sustainability.
Quality QA/QC Lab
Our cutting-edge Quality Assurance and Quality Control (QA/QC) Lab has been designed to meet the highest standards for product safety and quality. Equipped with state-of-the-art equipment and cutting-edge technology, our lab performs strict chemical analysis, adulteration checks, microbiological testing, and agrochemical testing to ensure the integrity of our products.
State-of-the-Art Lab
Modern technology is used in our in-house lab, managed by experienced and knowledgeable staff members who manage the material approval and rejection procedure. Maintaining a clean and controlled environment is our top priority to ensure the accuracy of the testing outputs.
Chemical Analysis
The lab ensures that only the best materials are used by doing chemical analyses on more than 100 different kinds of spices. Over forty distinct test kinds are conducted. We can detect small quantities of undesirable compounds owing to our advanced tools, ensuring the healthiness of the product.
Including
1. Chemical Analysis
a. Color in Chilli
The vibrant color of chili peppers is mostly due to the presence of pigments such as chlorophyll and carotenoids. Our analytical methods accurately measure these pigments to ensure the consistency and quality of the chili's color.
b. Capsaicin Content in Chilli
By precisely calculating the capsaicin content, we can evaluate and standardize the spiciness of our chili products, ensuring they meet the required heat levels for various culinary applications.
c. Moisture Content
Our methods of analysis precisely monitor the water content of materials, assisting in maintaining the correct moisture levels that avoid spoiling and assure long-term quality.
d. Total Ash
This measurement technique is significant in determining the purity and nutritional value of spices. By analyzing the ash content, we ensure that our products meet regulatory requirements while retaining their high quality.
e. Curcuminoid Content in Turmeric
Our testing techniques accurately evaluate turmeric quantity, ensuring that our turmeric products are high in these beneficial chemicals while delivering consistent color and potency.
f. Piperine Content in Pepper
Testing piperine content ensures that our pepper products retain their strong, distinct flavor, thereby increasing their culinary and nutritional benefits.
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Volatile oil Content
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Acid-Insoluble Ash
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Non-volatile Ether Extract
2. Adulteration Checks
We conduct comprehensive checks to make sure that only authentic substances are utilized and to detect any instances of tampering in raw materials and completed products.
3. Microbiological Testing
This is done to ensure that the spices are free of hazardous germs. Our microbiological tests enable us to detect hazardous germs, assuring that our products are safe to consume and free of microbial contamination.
Hi-Tech Instruments Available
Our lab is outfitted with many cutting-edge tools to produce accurate results.
Including: -
Metler-Toledo Balance
for highly precise and accurate sample measuring.
Moisture Balance
used to calculate a product's moisture content, which is essential to preserving its stability and quality.
Near Infrared Spectroscopy
a non-destructive technique for determining a sample's moisture, fat, protein, and other compositional elements.
Double-beam UV spectrophotometer
It is essential to measure the absorbance and transmittance of UV light in samples to calculate the quantities of chemicals.
Carl-Fischer Apparatus
used for efficient moisture analysis, especially on materials with low moisture content.
Ph Meter
To measure a sample's pH or alkaline status, which is essential for food and chemical product quality management.
Distillation Unit
utilized for temperature separation of mixes and fluid filtration.
Colony Counter
makes it easier to count bacterial colonies correctly in microbiological testing.
Laminar flow
filters air to create a sterile work environment and shields the test sample from contamination.
Certifications
1. FSSAI:
We ensure compliance with food safety standards, and our production facility is certified by the Food Safety and Standards Authority of India.
2. USFDA:
Also, the US Food and Drug Administration has certified us, which shows our commitment to maintaining strict quality and safety standards.
3. Spice Board & APEDA:
Our credibility in the spice industry is strengthened by certifications from the Spice Board and the Agricultural and Processed Food Products Export Development Authority (APEDA).
4. Halal:
Our products meet a variety of dietary needs and are certified Halal.
5. ISO 22000 & HACCP:
We ensure that our products are safe and of the highest caliber by following the Hazard Analysis and Critical Control Point (HACCP) system and ISO 22000 standards for food safety control.
6. Directorate of Industrial Safety and Health (Gujarat)
Authorized by the Directorate of Industrial Safety and Health, ensuring operational compliance with safety and labor regulations in Gujarat.
7. Factual Assessments and GEAC Certifications
Demonstrating our commitment to food safety and quality management, aligned with global FSSC 22000 standards.
8. Willow Glen Certification
Registered with the US Food and Drug Administration, affirming compliance with the Bioterrorism Act and Food Safety Modernization Act for global food safety standards.
9. Global Water Safety Compliance
Ensuring compliance with environmental regulations under the Air Act, Water Act, and hazardous waste management standards, authorized by the Gujarat Pollution Control Board.