Manufacturing & Quality Process | Starr Food Export LLP | Farm to Dehydration

World-Class Dehydration Standards

Preserving Nature • Delivering Excellence

Standardized 9-Stage Manufacturing Ecosystem

At Starr Food Export LLP, every single batch of onion and garlic begins directly in rich Indian soils and undergoes an unbroken chain of precision engineering, climate-controlled dehydration, multi-pass optical grading, and rigorous laboratory checkpoints.

I

Phase 1: Harvest & Preparation

Stages 01 – 03 • Farm Intake, Wash & Slice

II

Phase 2: Thermal Dehydration

Stages 04 – 06 • 5-Stage Hot Air, Hulling & AC Cooling

III

Phase 3: Optical Sorting & Pack

Stages 07 – 09 • Sortex Laser, Manual QC & Export Packaging

Phase 01: Raw Material Arrival & Preparation

01

Stage 01 Intake & Sourcing

RM Arrival from Farm

Fresh Raw Material (RM) comes straight away from contracted agricultural farms in Bhavnagar and Gujarat's fertile onion belts. Each harvest arrives at our intake gates under clean transport conditions for immediate intake quarantine and batch tracking.

Mandatory QC Gate Active Verification

Visual Inspection TSS Measurement Foreign Contamination Checking

02

Stage 02 Hydro-Cleaning

Washing & Surface Sanitation

Washing of raw material through the latest state-of-the-art cleaning method. High-velocity multi-tank bubblers remove surface dirt, field residues, and adhering microbes while preserving raw bulb integrity.

Mandatory QC Gate Active Verification

Sanitizer PPM Check Recirculating Water Purity Audit

03

Stage 03 Mechanical Cutting

Slicing & Spreading on Belt

Automated high-precision stainless steel cutters slice peeled onions uniformly. Slices are mechanically distributed in an even, thin layer across continuous food-grade conveyor belts for consistent exposure to airflow.

Mandatory QC Gate Active Verification

Slice Size Checking via Vernier Caliper Uniform Bed Depth Validation

Phase 02: Multi-Stage Thermal Dehydration & Hulling

04

Stage 04 Primary Dehydration

5-Stage Multistage Hot Air Drying

Onion slices progress through a specialized 5-stage continuous hot air drying tunnel. Controlled multi-temperature graduated zones gently extract water without caramelizing or burning, ensuring authentic pungency, natural white/red hue, and nutrient retention.

Mandatory QC Gate Active Verification

Moisture Measurement Continuous Zone Temperature Profiling

05

Stage 05 Secondary Finishing

Second Stage Hot Drying

The secondary hot drying phase performs precision moisture balance across all batches. This critical finishing step stabilizes shelf life, eliminates internal moisture pockets, and locks in crisp texture for export durability.

Mandatory QC Gate Active Verification

Final Moisture Measurement (< 5-6%) Crispness & Brittleness Check

06

Stage 06 Cooling, Hulling & Aspiration

AC Room Cooling & Skin Hulling

Dehydrated onion slices are moved through food-grade conveyors to an Air-Conditioned (AC) room and get cooled in a cold dryer. Onion slices then pass through a precision huller machine where kapcha and kibbled are separated, and remaining skins are cleanly stripped away via efficient air aspirators.

Mandatory QC Gate Active Verification

Vegetable Impurities Ratio Checking Maintain Temperature & Humidity of Environment

Phase 03: Optical Sortex, Manual Inspection & Packaging

07

Stage 07 Optical Sortex Grading

Sortex Machine Color & Root Sorting

Kibbled sorting by modern Sortex machines. Ultra-sensitive high-resolution cameras and optical ejectors inspect every passing particle at high velocity to instantly eject onion roots, dark flecks, scorched pieces, and extraneous impurities.

Mandatory QC Gate Active Verification

Foreign Matter Check Color Consistency & Defect Ratio Verification

08

Stage 08 Human Verification Belt

Manual Sorting Belt Inspection

Sorted onion kibbled passes through an intensely illuminated manual sorting belt. Experienced quality inspectors stationed along the belt conduct double-verification to hand-pick and remove any remaining foreign bodies or subtle irregularities.

Mandatory QC Gate Active Verification

Check Foreign Bodies Contamination Final Batch Grade Classification

09

Stage 09 Hermetic Packing

Customized Packing & Export Loading

The finished dehydrated products are packed in heavy-duty food-grade polybags and placed inside multi-ply kraft paper bags or robust corrugated boxes as per the customized requirement of our global customers. Stored on clean fumigated pallets ready for shipping.

Mandatory QC Gate Active Verification

Packaging Material Inspection Heat Sealing & Tare Weight Check

Need Tailored Product Specifications or Custom Packing?

From customized mesh sizes (Flakes, Chopped, Minced, Granules, Powder) to private labeling in kraft paper bags or cartons, Starr Food Export LLP delivers reliable, consistent agri-food products worldwide.

Inquire For Order