At Frontline Food Consultants and Engineers, we offer specialized consulting services for setting up Packed and Processed Peanut production facilities. From Site Selection and Analysis to Licensing and Permitting, we assist you in setting up an efficient, compliant production line for processing peanuts at scale. Our team provides expertise in Equipment Finalization and Procurement, ensuring you have the right roasting, frying, seasoning, and packaging equipment. Additionally, we offer Architectural and Structural Design services to optimize your facility’s layout for high-volume production.

Our services extend to Process and Mechanical Engineering, where we optimize the production of peanuts from raw material handling to final packaging. We assist in the Installation and Commissioning of Equipment and the design of Utility Systems (water, electricity, steam) to ensure smooth operations. We also help implement Food Safety and Sanitation Programs to ensure your peanut products consistently meet food safety standards and retain their quality during storage and distribution.

What are Roasted Peanuts?

Packed and Processed Peanuts are ready-to-eat snacks that are roasted, fried, or coated with spices and packaged for long-term shelf stability. These peanuts are prepared using traditional Indian spices and cooking methods, creating a variety of flavors and textures that appeal to a wide range of consumers. Packaged peanuts are a popular snack, valued for their high protein content and versatility, offering both plain roasted options and spiced varieties. 

Producing roasted peanuts requires specialized equipment such as peanut roasters to evenly roast the peanuts at controlled temperatures. Mixing and seasoning machines are used to coat the peanuts with salt or flavors, ensuring consistent application. Cooling conveyors allow the roasted peanuts to cool evenly before packaging. Weighing and portioning machines ensure precise servings. While filling and sealing machines package the peanuts in airtight containers or bags to preserve freshness and prevent spoilage. Quality control systems monitor roasting times, temperature, and product consistency to ensure high-quality roasted peanuts in every batch.

Types of Packed and Processed Peanuts

  • Roasted Peanuts: Dry-roasted peanuts with or without salt, are known for their crunchy texture and long shelf life.
  • Masala Peanuts: Spiced peanuts coated in a blend of traditional Indian spices like chili powder, turmeric, and cumin, offering a bold, flavorful snack.
  • Fried Peanuts: Deep-fried peanuts, often seasoned with salt and spices for extra crunch and flavor.
  • Coated Peanuts: Peanuts coated in a batter of gram flour and spices, deep-fried to create a crispy, spicy shell around the peanut.

Technical Processes for Packed and Processed Peanuts

1. Raw Peanut Preparation

  • Peanut Sorting and Cleaning: Raw peanuts are sorted to remove any foreign matter like stones, dust, or broken nuts. Peanuts are cleaned using mechanical or water-based cleaning systems to ensure the removal of impurities.
  • Blanching (Optional): Some peanut varieties, particularly roasted or fried peanuts, may be blanched to remove the skin. This process involves heating the peanuts and then passing them through mechanical bladders to remove the outer skin layer.

2. Roasting or Frying

  • Dry Roasting: For roasted peanuts, the peanuts are placed in large-scale industrial roasters, where they are heated at temperatures between 160-180°C for 15-30 minutes. This process creates a crunchy texture and enhances the nutty flavor. The roasting time is adjusted based on the desired level of crispness.
  • Frying: For fried peanuts and coated varieties, peanuts are fried in oil at 160-170°C until they achieve a crispy exterior. After frying, they are transferred to de-oiling machines to remove excess oil and ensure a consistent, non-greasy finish.

3. Flavoring and Seasoning

  • Spice Coating: For masala peanuts and coated peanuts, a spice blend is applied after roasting or frying. Seasoning drums are used to coat the peanuts evenly with a mixture of spices like chili powder, cumin, coriander, and salt. For coated peanuts, the batter is prepared by mixing gram flour with spices, and the peanuts are dipped into the batter before frying.
  • Oil Spraying (Optional): Light oil spraying is sometimes used to help the spices adhere better to the peanuts and to enhance flavor.

4. Cooling and Packaging

  • Cooling: After roasting or frying, peanuts are cooled in conveyorized cooling systems to bring them to ambient temperature. Proper cooling is crucial to preserve the crunchy texture and prevent the buildup of moisture.
  • Packaging: Peanuts are packed in moisture-resistant, air-tight pouches or containers to preserve their freshness and prevent staleness. Modified Atmosphere Packaging (MAP) or nitrogen flushing is used to extend shelf life by preventing oxidation and preserving the flavor and texture of the peanuts.

Engineering of Packaging Materials for Packed and Processed Peanuts

1. Vacuum-Sealed Packaging

  • Objective: Preserve freshness and prevent staleness.
  • Materials: Multi-layer, moisture-resistant plastic films that offer strong barriers against oxygen and humidity.
  • Benefits: Vacuum sealing ensures that the peanuts remain crunchy and flavorful by minimizing exposure to air, which can cause the peanuts to become soft or rancid.

2. Modified Atmosphere Packaging (MAP)

  • Objective: Extend the shelf life by removing oxygen from the packaging and replacing it with inert gases.
  • Materials: Packaging films with gas-barrier properties, combined with nitrogen flushing to displace oxygen.
  • Benefits: MAP helps preserve the texture and taste of peanuts over a longer period, preventing oxidation, which can cause rancidity in high-fat products like peanuts.

3. Eco-Friendly Packaging Solutions

  • Objective: Provide sustainable packaging options that appeal to environmentally conscious consumers.
  • Materials: Recyclable plastic films, paper-based pouches, or biodegradable materials.
  • Benefits: These eco-friendly packaging options meet the growing consumer demand for sustainability while ensuring product protection and maintaining the freshness of the peanuts.