Production Process

• 01

  Receiving the raw material

  Production begins when Raw material arrive in the “Raw Material receiving area”, unquestionably the most important part of our factory.

• 02

  Quality control

  Random samples are then taken from incoming Raw material to be analyzed at our laboratories to ensure the utilization of the best quality of raw material. Samples that do not meet the exacting standards(Halal and Food Grade) are returned to suppliers.

• 03

  CIP (Cleaning In Place)

  We have an automatic system of Cip. We use high-standard CIP Techniques in our factory, which are completed in five steps and take about 1.5 Hrs.

  Automatic advanced CIP system used for cleaning and Sanitization (Sterilization) of All eternal SS Pipelines, Juice Blending tanks and Pasteurization and having high Flow rate, Clean Agent, and High Temperature for suitable best efficiency.

• 04

  Processing

  Our recipes and processing techniques are scientifically formulated to deliver safe and nutritionally adequate products consistently. For example, we prepare products to provide an appropriate and consistent source of nutrients, avoiding any harm linked to over or under-dosing. We process food at optimum temperatures to retain its nutritious value while removing dangerous microorganisms and preventing the formation of harmful chemical contaminants.

• 05

  Blending

  This process describes the method of formation of a juice drink batch. Pulp is received from the store; sugar and other additives are received from the raw material store.

  Sugar syrup and additives are transferred to the batch mixing tank through pumps. All other ingredients are added in this tank as per the standard recipe so that a juice Nectar and Juice Drink is prepared.

• 06

  QC Testing

  Before a batch of product leaves our factory, it passes a ‘positive release’ test to confirm it is safe to consume. We carry out product compliance with internal and external standards for harmful compounds or microorganisms in the materials we use, the environment we operate in and also in our final products that reach the marketplace.

• 07

  Filtration

  Juice is passed through inline filter to remove any undissolved particles.

• 08

  Homogenization

  Juice is passed through homogenizer where it comes out with positive pressure so that all the dissolved particles are homogenized.

• 09

  Pesteurization

  Plate Heat Exchanger is type of heat exchanger called pasteurizer that uses metal plates to transfer heat between two fluids. It has major advantage over conventional heat exchanger in which fluids are exposed to a much larger surface area. PHE facilitates the transfer of heat and greatly increase the speed of the temperature change.

  Juice is pasteurized at 95°C +/-2°C to kill / inactivate bacteria and get commercially sterilized product. It is then cooled down at 35°C.

• 10

  Steam Generator

  Two Steam Generators having 600 square feet surface area are used to pasteurize the juice. These have two Ton capacity.

• 11

  RO Water

  SmartRoot industries also has world’s latest “reverse osmosis” technology to process water for juice Nectar Preparation.

• 12

  Filling (200ml and 1000ml)

  Filling is done aseptically by tetra pack filling machines; volume and design are controlled automatically. Sealed packs are pushed forward on conveyers and move towards the spray printer.

  Juices are filled in Tatra Pak aseptic paper. Aseptic Packaging technology is used to extend the shelf life of our product to a maximum of 12 months.

• 13

  Printer (Batch NOs and Expiries)

  After filling, on each pack, production date, expiry date & batch code is printed. This guides in tracing the batch and helpful for consumer.

• 14

  Straw Applicator

  Straws are applied to every pack with automatic machine, which is called TSA 21

• 15

  Cap Applicator

  Caps are applied to every pack with automatic machine, which is called Cap Applicator.

• 16

  Incubation

  This process outlines the quality requirement of checking the pasteurization performance/ efficiency of the process plant and aseptic filling efficiency of Tetra Pack machines.

• 17

  Storage / WareHousing

  We can accommodatepackaged products across 25,000 pallets for dry products and 6,000 pallets for frozen products in state-of-the-art warehouses located near our factory. A sample of each production batch is preserved in our laboratory to ensure traceability.

• 18

  Global Distribution

  We work with premier international forwarding agents who facilitate customs clearance and delivery of our goods. We work with our distributors to provide high-quality customer service and ensure that our products reach our customers on time and in excellent condition.