.Process
Processing line is a very important stage to determine the future production capacity. The initial process of receiving raw materials that will enter the factory will be selected based on weight and officers will record important data from incoming raw materials such as production capacity, next harvest time, location and area of planting land. Good data collection at the beginning will make it easier for the factory to determine the factory’s ability to produce flour and chips. This stage will be managed starting from the transportation of raw materials into the factory, washing, chopping, flouring to packaging flour and chips according to the standards and procedures. conditions in the factory must also be considered environmental conditions to maintain the cleanliness and sterility of the work area.
This processing line is very important and the aim to producing quality chips and yellow konjac flour and adjusting the production tempo according to market demand. At this stage it is also important to maintain the cleanliness and sterilization of the factory area to meet the international requirements that have been set to be able to enter the international market.
The result of this stage is having a good quality production for powder and chips of yellow konjac, also complete the international requirements in processing activities in the factory area and product sterilization to enter the international market.
The PIC on duty will instantly register the harvested tubers that have reached the production area through trucks. The weight of the incoming tubers, the tuber harvesting area, vehicle and driver data, and the time for the next tuber harvesting are all needed. Bulbs that have been successfully recorded will be instantly placed in an iron box, which will be piled to the capacity of the current box and hauled by forklift as mobile tuber transportation to the manufacturing machine.
The crop will be weighed in the box provided as soon as it arrives to PT. Mitra Porang Nusantara’s facility. The field PIC will be in charge of determining the weight of the tubers arriving. The lowest weight requirement for bulbs that may be processed by manufacturing machinery is 1.2 kgs. Bulbs weighing less than 1.2 kgs will be utilized as seeds once again.
PT. Mitra Porang Nusantara is a firm that works with yellow konjac’s farmers in the area. During the initial stage of cooperation with the factory, the harvest received from farmers who work with the factory will collect data on the origin of the tuber harvest, including the area, harvest capacity, harvesting time, and land registration. The effectively sorted data will be highly valuable in calculating the factory’s future production capacity so that the factory’s demands may be addressed appropriately.
The manufacturer has approved a tuber cleaning procedure that will employ a decent equipment and drinkable water. Factory personnel must guarantee that the tubers are free of dirt residue throughout the washing process. Bulbs that have been certified to be clean are ready to move on to the next step. The machine operator will check that the machine settings are accurate and that the tuber washing process follows the established guidelines.
The clean konjac tubers will be gently delivered to the tuber cutting machine stage. Our system is to slice tubers into 0.3-0.5mm thickness in order to get a 12% of the water content of dried konjac within 3 hours drying cycle. This will ensure the quality of the dried konjac stays at the top with a higher grade of glucomannan purity achieved. The machine operator will make proper machine settings and verify that the tuber cutting operation follows the established protocols.
Bulbs that have been cut and cleaned will be immediately transported to a drying machine, where they will be dried in a 7-layers automatic dryer for roughly 3 hours. We are using advanced drying machinery where each of the 7-layers has a different temperature control system to make sure to protect the quality of konjac during the process. The operator of the oven machine will ensure that the unit is properly set up and that the tuber chip drying process proceeds smoothly in line with established regulations.
Crushing will change the size of large solid particles into smaller particles from the yellow konjac chips. Our hammer milling machine is built with food-grade material (Stainless Steel) and designed specifically to process konjac by continuously hammered crushed dried konjac with 24 high-speed rotating hammers on the three groups of hammer wheel rotors in the machine (the linear speed of the hammer is 68m / s). During the process, the refined konjac powder crystal and starch are peeled off, and the starch with light specific gravity (calcium oxalate, ash, protein, cellulose, and other materials) is sucked away through the fan behind the main machine, while the refined powder particles (Glucomannan powder) with heavy specific gravity stay in the main machine cavity.
The refined powder output by the host automatically enters the air supply pipe for cooling and enters the separation tank for further separation of starch powder, so as to achieve the purpose of rapid cooling of refined powder and further separation of residual ash powder. Finally, it enters the vibrating screen to separate the material head (the material not finely powdered), so as to obtain konjac refined powder with high purity of Glucomannan content up to >70%.
The refining process involved advanced machinery specially built with food-grade material (Stainless Steel) with the working principle of using a high-speed rotating blade (linear speed 45.96m / s). During this process, the konjac powder resulting from the hammer milling process collide with each other to peel off the ash powder and impurities attached to the powder. The lighter ash powder substances are separated through the separator, so as to obtain a high-quality refined powder with high viscosity, fewer black spots, bright color, and regular crystal. This process will enhance the quality and purity of Glucomannan content up to >85%.
It is calculated using 25 kg / 50 Kg / with the request of special designed bags that have been created in compliance with international standard packing specifications in the process of packing chips and flour. Packaged chips and flour are immediately deposited in a storage facility that meets strict cleanliness and sanitation standards.
The procedure of distributing correctly packaged chips and flour into customized bags will be provided according to the capacity specified by consumers. For local demand, a diesel truck with a capacity of 5 tons each trip is utilized, and for consumer demand outside the export market, a container with a capacity of 20 feet (20 tons) and 40 feet (27 tons) is used.
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