A Group of 10 to 20 workers segregate ripe and unripe fruits from the lot. Unripe fruits are kept aside in a separate lot to ripen in the near days and the ripened fruits are carried by the workers to be put on the conveyor belt to be taken for production.
Nearly 1000 tonnes of mangoes are sorted out in a day and the ripe fruits are fed to the conveyor belts.
A few workers stand on either side of the conveyor belts to ensure that only good ripened fruits move on the conveyor and remove any decayed or un ripened fruits found on the conveyor.
The ripened fruits moves on the conveyor belt and reaches washing machine.
It is being thoroughly washed in the water mixed with chlorine to remove the bacterias from the skin.
They are again dipped in the normal water and thoroughly cleaned again and fruits are then sent to the next stage.
Mangoes thus cleaned with fresh water are then sent to cutting conveyor. On each side of the conveyor belt nearly 30 persons engage in removing the stem attached to the fruits. In addition to this, any damaged fruits if found will also be removed at this stage. These food grade fruits are moved to the next stage called De – stoner through the 40 feet food grade conveyor belt.
In the De-stoner the outer skin and the hard seed are separated. The pulp from the fruits get collected in a tank.
De-Stoner is the wonder machine which extracts only the pulp leaving aside skin and the hard mango nut.
The pulp thus collected in the tank is sucked through the screw pump and flows through the SS pipes to reach the pulper.
This two-in-one pulper has the capacity of 5 tonnes. Filters made up of wood and nylon materials are fitted in this. The process of filtration of the pulp takes place here. Fruit fibers and other dross in the pulp are removed at this stage.
Pure fruit pulp is then collected in a tank called finisher tank. The pulp collected in this tank is ready for process. This pulp is normally called cold pulp
The cold pulp will be sent to the holding tank before heating.
Cold pulp is being sent through SS Pipe to the equipment called Pre-Heater. Here the pulp is heated making use of steam by providing 60 ‘ to 70 ‘ centigrade of heat.
The heated pulp is then collected in the collection tank.
This pulp is again sent to the De-Canter machine for removing dross which appear in the pulp as black and brown specs.
Dross free, bacteria free, pure mango pulp is ready and it is received in the collection tank.
The pulp from the collection tank is pumped to the sterilizer and initially the pulp is heated up to 110 ‘ centigrade with help of steam which flows in the reverse direction.
Subsequently the pulp is sent to the cooling module. In this cooling module the temperature of the hot pulp is stabilized to 28 ‘ to 30 ‘ centrigrade with the help of chilled water which flows on the reverse side of the module. This effect of heating and subsequent cooling provides with the pulp free from lively organisms.
Entire quality control process is totally mechanized and controlled by the technicians who operate on the computer panel attached to the sterilizer.