Automated Processing Flowchart
We combine mechanical speed and manual auditing to guarantee the highest export-grade dehydrated vegetables.
Farm Selection & Sourcing
Fresh red, white, and pink onions and garlic are directly sourced from local farmers in the Saurashtra region. Our quality officers perform initial moisture mapping and field checks. Only clean, healthy crops free of soil, root damage, and sunburn are processed.
Hygienic Cleaning, Peeling & Slicing
Crops are fed into automatic dry peeling units utilizing pneumatic air pressure, minimizing hand contact. They are then cleaned in triple-stage wash tanks with food-safe sanitizers, and precision-sliced to exact dimensions (2mm to 4mm) to ensure uniform drying characteristics.
Controlled Continuous Tunnel Dehydration
Slices are spread evenly onto continuous multi-stage stainless steel belt dryers. Clean hot air is blown through the beds at tightly monitored, downward-stepping temperature cycles (80°C down to 55°C). This preserves the critical volatile onion oils, natural flavors, and pungency values while preventing caramelization.
Sortex Color Sorting & Metal Detection
Dried products pass through advanced Buhler Sortex optical sorting systems to isolate and eject yellow/red peels, root fibers, and discolored specks. Post sorting, the flakes pass through high-frequency magnetic bars and dual-channel metal detectors (detecting ferrous down to 1.0mm, non-ferrous to 1.2mm, and SS to 1.5mm).
Vibratory Sifting & Custom Mesh Sizing
Sorted ingredients flow onto mechanical vibratory sifting decks. Using screen sizes calibrated for international standards, we separate the output into precise market grades: Flakes (5-25mm), Chopped (3-5mm), Minced (1-3mm), Granules (0.2-1mm), and Powder (100 mesh/custom mesh sizing).
B2B Protective Packaging & Container Loading
Finished products are instantly packed into dual food-grade polyethylene inner bags to block moisture absorption. The outer layer is secured using multiwall kraft paper sacks or heavy double-corrugated cartons. All packages are labeled, palletized, and loaded into ocean containers under temperature-controlled shipping protocols.