1Raw-material intakeProcessing-grade Nantes carrots arrive from the cold store or field by plot lot; weighed; visual and residue-record checkIntake temperature (from 0–2 °C storage); lot IDSupplier/plot approval; residue record per lot
Processing-grade Nantes carrots arrive from the cold store or field by plot lot; weighed; visual and residue-record check
Parameter shown: Intake temperature (from 0–2 °C storage); lot ID
Control / record: Supplier/plot approval; residue record per lot
2Pre-wash & destoningFlume wash with stone trap; soil removalWater change frequency; chlorine/ozone dose if used [COPY TBC]Wash-water monitoring log
Flume wash with stone trap; soil removal
Parameter shown: Water change frequency; chlorine/ozone dose if used [COPY TBC]
Control / record: Wash-water monitoring log
3Washing, polishing & inspectionRotary washer / polisher; manual and mechanical inspectionThroughput [COPY TBC — IQF pre-wash capacity]Foreign-matter removal
Rotary washer / polisher; manual and mechanical inspection
Parameter shown: Throughput [COPY TBC — IQF pre-wash capacity]
Control / record: Foreign-matter removal
4Peeling & trimmingPeel [COPY TBC — method]; top-and-tail; the foliage and trim stream leaves for feedPeel loss % (internal)—
Peel [COPY TBC — method]; top-and-tail; the foliage and trim stream leaves for feed
Parameter shown: Peel loss % (internal)
Control / record: —
5Inspection beltTrained inspectors remove green shoulder, blemished roots and foreign material on a slow belt before cutting. Inspection belts; no optical sorter.Inspector count per shift; belt speedForeign-matter and defect removal record
Trained inspectors remove green shoulder, blemished roots and foreign material on a slow belt before cutting. Inspection belts; no optical sorter.
Parameter shown: Inspector count per shift; belt speed
Control / record: Foreign-matter and defect removal record
6Dicing / slicingDicer set to 6.4 mm or 9.25 mm; slicer for coinsCut size and tolerance; blade change intervalBlade integrity check (glass & brittle-plastics / sharps register)
Dicer set to 6.4 mm or 9.25 mm; slicer for coins
Parameter shown: Cut size and tolerance; blade change interval
Control / record: Blade integrity check (glass & brittle-plastics / sharps register)
7Steam blanching Continuous steam blancher; enzyme inactivationTemperature and dwell (typical 90–98 °C, 2–4 min for dice)Control point per the HACCP plan: peroxidase test negative per batch
Continuous steam blancher; enzyme inactivation
Parameter shown: Temperature and dwell (typical 90–98 °C, 2–4 min for dice)
Control / record: Control point per the HACCP plan: peroxidase test negative per batch
8CoolingChilled-water or air cooling immediately after blanchExit temperature (typical ≤ 10 °C)Cooling-water hygiene
Chilled-water or air cooling immediately after blanch
Parameter shown: Exit temperature (typical ≤ 10 °C)
Control / record: Cooling-water hygiene
9De-wateringVibratory dewatering before the tunnel; surface moisture control prevents clumpingSurface-moisture check—
Vibratory dewatering before the tunnel; surface moisture control prevents clumping
Parameter shown: Surface-moisture check
Control / record: —
10Fluidised-bed IQF freezing Continuous fluidised-bed tunnel; product suspended on cold air; crust freezing then core freezing; 3 MT/hrAir temperature −30 to −40 °C; product core ≤ −18 °C at exitControl point per the HACCP plan: core temperature at tunnel exit
Continuous fluidised-bed tunnel; product suspended on cold air; crust freezing then core freezing; 3 MT/hr
Parameter shown: Air temperature −30 to −40 °C; product core ≤ −18 °C at exit
Control / record: Control point per the HACCP plan: core temperature at tunnel exit
11Post-freeze inspection & metal detection Frozen inspection belt; metal detection (Fe / non-Fe / SS test pieces) before packing. Metal detection; no X-ray.Detection limits (typical Fe 1.5 mm, NFe 2.0 mm, SS 2.5 mm)Control point per the HACCP plan: hourly test-piece checks
Frozen inspection belt; metal detection (Fe / non-Fe / SS test pieces) before packing. Metal detection; no X-ray.
Parameter shown: Detection limits (typical Fe 1.5 mm, NFe 2.0 mm, SS 2.5 mm)
Control / record: Control point per the HACCP plan: hourly test-piece checks
12PackingBulk 10 kg / 25 kg poly-lined cartons; foodservice 4 × 2.5 kg; retail pillow packs [COPY TBC — retail bagger]; check-weigher; lot and date codingNet-weight control; coding fieldsWeight-check record; label verification
Bulk 10 kg / 25 kg poly-lined cartons; foodservice 4 × 2.5 kg; retail pillow packs [COPY TBC — retail bagger]; check-weigher; lot and date coding
Parameter shown: Net-weight control; coding fields
Control / record: Weight-check record; label verification
13Palletising & frozen storageISPM-15 pallets, stretch-wrapped, corner boards; 3,600 MT frozen storage at −18 °C; FIFO by lot; racking [COPY TBC]Store temperature log; door-open managementContinuous temperature monitoring with alarm [COPY TBC]
ISPM-15 pallets, stretch-wrapped, corner boards; 3,600 MT frozen storage at −18 °C; FIFO by lot; racking [COPY TBC]
Parameter shown: Store temperature log; door-open management
Control / record: Continuous temperature monitoring with alarm [COPY TBC]
14Reefer dispatchContainer pre-trip inspection; stuffed at the plant dock; product core ≤ −18 °C at stuffing; 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 core ≤ −18 °C at stuffing; 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