1Receipt & inspectionPeeled carrot and potato (peeled at our packhouse, before the IQF line), peas in the pod, corn on the cob or cauliflower heads are received with the packing material; quality inspection accepts the lot or sends it back; accepted lots move to pallets and raw-material storageQuality inspection per lot; lot IDAccept or send back; raw-material storage by lot
Peeled carrot and potato (peeled at our packhouse, before the IQF line), peas in the pod, corn on the cob or cauliflower heads are received with the packing material; quality inspection accepts the lot or sends it back; accepted lots move to pallets and raw-material storage
Parameter shown: Quality inspection per lot; lot ID
Control / record: Accept or send back; raw-material storage by lot
2Cutting / depoddingFed by elevator to the cutter: dicer set to 6.4 mm or 9.25 mm, slicer for coins; peas are depodded (two recovery drums reclaim grains, the rest goes to cattle feed), corn kernels are cut from the cob, cauliflower is cut by hand into 20–50 mm floretsCut size and tolerance; blade change intervalBlade integrity check (glass & brittle-plastics / sharps register)
Fed by elevator to the cutter: dicer set to 6.4 mm or 9.25 mm, slicer for coins; peas are depodded (two recovery drums reclaim grains, the rest goes to cattle feed), corn kernels are cut from the cob, cauliflower is cut by hand into 20–50 mm florets
Parameter shown: Cut size and tolerance; blade change interval
Control / record: Blade integrity check (glass & brittle-plastics / sharps register)
3Air cleaningAir cleaning removes light foreign matter from the cut product (not used for peas; cauliflower goes from cutting straight to the bubble washer)Visual check at the outfeedForeign-matter removal
Air cleaning removes light foreign matter from the cut product (not used for peas; cauliflower goes from cutting straight to the bubble washer)
Parameter shown: Visual check at the outfeed
Control / record: Foreign-matter removal
4Inspection beltTrained inspectors remove defects and foreign material on a slow belt fitted with a magnet rod. Inspection belts; no optical sorter.Inspector count per shift; belt speedForeign-matter and defect removal record; magnet check
Trained inspectors remove defects and foreign material on a slow belt fitted with a magnet rod. Inspection belts; no optical sorter.
Parameter shown: Inspector count per shift; belt speed
Control / record: Foreign-matter and defect removal record; magnet check
5ScreeningVibrating screen mesh removes fines and undersize; an elevator with a second magnet rod feeds the balancing tankScreen mesh conditionSolid-waste removal; magnet check
Vibrating screen mesh removes fines and undersize; an elevator with a second magnet rod feeds the balancing tank
Parameter shown: Screen mesh condition
Control / record: Solid-waste removal; magnet check
6WashingSurface washing, then a bubble washer with chlorine dosing; the wash water is discharged to the effluent treatment plantChlorine 150 ppm in the bubble washerWash-water chlorine record
Surface washing, then a bubble washer with chlorine dosing; the wash water is discharged to the effluent treatment plant
Parameter shown: Chlorine 150 ppm in the bubble washer
Control / record: Wash-water chlorine record
7Steam blanching Continuous steam blancher; enzyme inactivationTemperature and dwell: 85–95 °C for 2–5 minOPRP-01 in the HACCP plan: blanch temperature and time; peroxidase test negative per batch
Continuous steam blancher; enzyme inactivation
Parameter shown: Temperature and dwell: 85–95 °C for 2–5 min
Control / record: OPRP-01 in the HACCP plan: blanch temperature and time; peroxidase test negative per batch
8Cooling & de-wateringChilled-water cooling straight after the blancher, then a vibratory shaker removes surface water so the product does not clump in the tunnelChilled water 5–10 °C with 50 ppm chlorineCooling-water temperature and chlorine record
Chilled-water cooling straight after the blancher, then a vibratory shaker removes surface water so the product does not clump in the tunnel
Parameter shown: Chilled water 5–10 °C with 50 ppm chlorine
Control / record: Cooling-water temperature and chlorine record
9QA inspection beltVisual and QA inspection belt after cooling, with a magnet rodDefects against the product specificationQA inspection record; magnet check
Visual and QA inspection belt after cooling, with a magnet rod
Parameter shown: Defects against the product specification
Control / record: QA inspection record; magnet check
10Fluidised-bed IQF freezing Even feeding into the continuous fluidised-bed tunnel; product suspended on cold air; 3 MT/hr; a magnet on the outlet hopper; product is passed through the tunnel again if the temperature variesTunnel −20 to −35 °C for 3–15 minOPRP-02 in the HACCP plan: tunnel temperature and residence time
Even feeding into the continuous fluidised-bed tunnel; product suspended on cold air; 3 MT/hr; a magnet on the outlet hopper; product is passed through the tunnel again if the temperature varies
Parameter shown: Tunnel −20 to −35 °C for 3–15 min
Control / record: OPRP-02 in the HACCP plan: tunnel temperature and residence time
11Metal detection Packaging inspection belt with a magnet rod, then the metal separator before packing; rejects are diverted. Metal detection; no X-ray.Sensitivity: Fe 1.0 mm, non-Fe 1.2 mm, stainless 1.8 mmCCP-01 in the HACCP plan: test-piece checks; rejected product segregated
Packaging inspection belt with a magnet rod, then the metal separator before packing; rejects are diverted. Metal detection; no X-ray.
Parameter shown: Sensitivity: Fe 1.0 mm, non-Fe 1.2 mm, stainless 1.8 mm
Control / record: CCP-01 in the HACCP plan: test-piece checks; rejected product segregated
12PackingWeighing and bulk packing into the ordered format; labelling and stitching; lot and date codingNet-weight control; coding fieldsWeight-check record; label verification
Weighing and bulk packing into the ordered format; labelling and stitching; lot and date coding
Parameter shown: Net-weight control; coding fields
Control / record: Weight-check record; label verification
13Frozen storage ISPM-15 pallets, stretch-wrapped, corner boards; 3,600 MT frozen storage at −18 °C or below; FIFO by lot; racking [COPY TBC]Cold store at −18 °C or belowOPRP-03 in the HACCP plan: cold-store temperature record
ISPM-15 pallets, stretch-wrapped, corner boards; 3,600 MT frozen storage at −18 °C or below; FIFO by lot; racking [COPY TBC]
Parameter shown: Cold store at −18 °C or below
Control / record: OPRP-03 in the HACCP plan: cold-store temperature record
14Reefer dispatchContainer pre-trip inspection; stuffed at the plant dock; product at −18 °C at dispatch; dataloggers placed; sealed and photographed; hauled to ICD Dadri on a genset-equipped chassis and railed to Mundra or Nhava Sheva; own reefer fleet for domestic supplySetpoint −18 to −21 °C per buyer; vents closed; humidity control offLoading checklist; datalogger IDs on the packing list
Container pre-trip inspection; stuffed at the plant dock; product at −18 °C at dispatch; dataloggers placed; sealed and photographed; hauled to ICD Dadri on a genset-equipped chassis and railed to Mundra or Nhava Sheva; own reefer fleet for domestic supply
Parameter shown: Setpoint −18 to −21 °C per buyer; vents closed; humidity control off
Control / record: Loading checklist; datalogger IDs on the packing list