Choosing the Right Equipment for Makhana Processing—Ask a Food Technologist

Selecting the appropriate makhana machinery is critical in building a productive and sanitary makhana snack operation. Each of the makhana processing steps; cleaning, roasting, de-shelling, seasoning and packaging all have equipment selected for them, including sand roasters, grading machines, de-shellers, and vacuum packers, which require knowledge on the food industry. A food consultant or food technologist will assist with appropriate machinery selections, developing a compliant plant layout, and standardizing the production process. A Food consultant along with a food technologist helps to simplify, produce better quality products, and become regulatory compliant, thus the food industry professionals will be a beneficial addition to any makhana based snack setups.

Introduction

Makhana (fox nut) has recently gained popularity as a healthy snack food because of low-calorie, low fat and crunchy texture. The demand for roasted and flavored makhana has increased significantly. The demand for processing makhana has attracted many entrepreneurs to consider small to mid-scale makhana units. Choosing the right makhana machinery is important since it will be for small to mid-scale processing and to maintain quality. A professional food consultant or food technologist can be helpful in making sure you choose the right makhana equipment and design your snack setup for commercial-scale production.

Understanding the Makhana Processing Stages

Before selecting the machine, it is helpful to understand the steps in makhana processing.

1. Cleaning and Grading – Raw makhana is cleaned initially to remove dust, stones, and debris.
2. Roasting (Popping) – This is the most important step to roast the seeds in a bed of sand to puff them up.
3. De-shelling – The puffed makhana will need to be separated from the shells either manually or mechanically.
4. Grading & Sorting – Makhana is sorted into different sizes, quality grades, etc.
5. Roasting – A second, lighter roasting is completed at this stage before flavoring.
6. Flavoring and Seasoning – Flavor can add seasoning to make the taste better.
7. Packing – Finally, the makhana is put in packaging that is clean and won’t let moisture in.

In all these steps, precision and the correct machinery are important factors in terms of hygiene and consistency.

Key Makhana Machinery and Equipment

A food consultant can help you choose machines based on your size of production, your budget, and hygiene factors. The following are some typical makhana machinery:

• Vibro Grading Machine – It separates makhana into different sizes. Makhana needs to have a consistent size for uniform roasting.
• Sand Roaster – This is the most traditional machine but works effectively to puff raw makhana seeds.
• De-shelling Machine – This mechanical machine replaces the manual labor of de-shelling.
• Rotary Roaster/Air Roaster – The machinery is used for final roasting, and you have control overheating.
• Flavor Coating Drum – This equipment helps to ensure that the seasoning is evenly mixed and prevents breakage.
• Vacuum Packing Machine – It prevents oxidation reactions to help prolong shelf life and keeps products fresh.

For various snack setups, a food technologist can help to determine how to make machines work together & help you determine the proper steps of production.

Designing an Efficient Snack Setup

An effectively designed snack setup area for makhana leads to logical material flow, minimum handling and control of the hygienic environment. Some effective layout options include:
Separation of raw and finished areas to prevent contamination,
Ventilation and exhaust systems in the roasting areas
Food processing equipment surfaces in stainless steel
Separate storage areas for raw components and finished goods

Food consultants can help to design a HACCP compliant processing facility that meets FSSAI standards while optimizing productivity and space.

Role of a Food Consultant in Makhana Projects

Setting up a makhana processing unit, without engaging experts, inevitably leads to inefficient operations, inferior quality of finished product, and regulatory headaches. A trained food consultant or food technologist can provide:

• Assistance selecting the makhana machinery or equipment selection to meet your production objectives.
• Vendor connections to help procure reliable equipment at a competitive price.
• Standardization of processes to maintain taste, texture, and shelf-life.
• Assistance obtaining FSSAI regulatory compliance along with packaging and labelling.
• Cost estimating and scaling plans to accommodate future demand.

Conclusion

The success of a makhana brand is not only driven by high quality raw material, but also by the efficient, safe, hygienic processing of the product into value added foods. The decisions you make around your makhana machinery, the snack setup and flow of your snack food operation, and the design specifications will significantly influence the profit returned and brand value. Involving a food consultant as you start a project will shorten your time frame and assist in avoiding unnecessary trial and error costs and provide direction for a viable and successful scalable makhana business.As a startup, or as you grow an existing snack setup, ask a food technologist or a food consultant when it comes to food, guidance is everything.

FAQ

1. What machinery is needed for a makhana processing unit at small scale?
   The minimal upstream makhana snack setup required machinery would include cleaning unit, sand roaster, de-shelling machine, grading unit, flavouring drum, and packing machine.
2. How could a food consultant assist with a makhana processing plant?
   A food consultant would assist with selection of the appropriate makhana machinery and equipment for the making the makhana. In addition, the food consultant would design the layout of the plant, review and document the relevant food safety regulations and assure compliance, oversee the production process and design a method to promote continuous quality improvement.
3. Can I set up a home based or small scale makhana snack unit?
   Yes, it is possible to set up a small or compact snack setup as mini machinery is available for makhana snack processing. This option is mainly for local or more artisan-type production. A food consultant could help you evaluate the space available and what equipment would be required.
4. How do I choose the right makhana roasting machine?
   Depending on the production scale, either a sand roasting machine or an air roaster. If you are using sand roasting, you would have a “traditional” puffing machine. If you want to avoid oil and want to use a more modern roasting machine, you would look at a puffing machine or, as commonly referred to as an air roaster. A food consultant could assist you in making the best choice.