Process Flow :

Roasting:

The purpose of roasting is to make outer shells breakable without damaging the kernels inside. Reduced breakage of kernels adds to high yield in processing.

Shelling:

The purpose of shelling is to separate the outer shells from the kernel with the minimum or no damage to the kernel.

Hot Chamber (Dryer):

The purpose of hot chamber is to remove the moisture from kernel, thus enabling easy removal or peeling of the outer skin "Testa / Husk".

Cooling:

The purpose of cooling is to bring back the temperature, which enables easy removal of outer skin (Husk). Cooling is essential & important in order to have low breakage of kernels during peeling.

Peeling:

The purpose of peeling is to remove the outer skin "Testa" using peeling knives, which is manually done.

Grading:

The purpose of grading is to separate different kinds of Cashew kernels into uniform grades depending on Color, Size and characteristics, which is hand picked.

Packing:

The purpose of packing is to ensure freshness & quality of cashew kernels from the place of manufacture up-to consumer.

Processing Raw Cashew to Cashew Kernels:

There are various levels or stages involved in processing Raw Cashew nut into Finished Kernels.

Raw cashews normally have moisture, hence they are sun dried in an open yard and moisture content is reduced. For the accomplished quality and for yielding good deal kernel, it is essential that the nuts be well dried. With a good drying, they not only stand well, but also get good texture and also easy to process.

Well-dried raw cashew nuts are then packed in uniform quantity and preserved in airtight rooms, thus avoiding raw cashews to get de-based. Storage also means preserving nuts. Hence, Fumigation is carried out in order to protect nuts from pests.

Roasting (Steaming) is the process where heat in the form of steam is passed on to the raw nuts, so that the outer shell softens and facilitates the removal of kernel from the shell. Here raw cashew nuts are put in a container and steam is passed on to them for specific time. The nuts after roasting are scattered on the floor in a thin layer for cooling which takes around 6-8 hours and later, sent for shelling.
Cutting or De-shelling is the process where the roasted or steamed nuts are cut-open using machines. Here the machine used either are hand operated or both hand & foot operated. The nuts are to be fed one by one between two blades shaped to fit the contour of the cashew nuts, which are adjusted by means of foot pedal depending on the size of the nut. Steamed nut is positioned between the blades and cut to the depth of the shell, the kernel from the shell is then separated.

Here we have two products, Cashew kernel, which is separated from the shell and Shell, which is used in extraction of oil i.e., Cashew Shell Oil (C.N.S.L)

The Hot Chamber (Drying) Process is where shelled nuts are stacked in a chamber and heated. Latest approach towards heating is by using Hot air circulation type hot chamber. This technique is new as against the old technique where the walls were heated and nuts had to be re-placed in order to maintain uniform temperature. Here labor cost was quite high and so was the attention towards the whole process. This is method still exists but is slowly phasing-out.

Advantages in Hot chamber have been more than expectation and so is the quality and output. In a Hot chamber Cashew Kernels are spread in Aluminum perforated or wooden trays, stacked in Trolleys within the chamber and hot air is blown into the chamber & circulated during the whole process of drying. Here temperature can vary from 75-85^o Degree and so is the duration, which is normally about 6-8 hours. Temperature control is easier in Hot Air Circulation Chamber than the old one. Temperature control is the key in the whole process. Too much of heat will change the texture and color of the kernels and too little temperature will keep the Kernels wet. Here, temperature will be uniform in any corner of chamber, which cuts the cost of inter changing and re-placing the nuts within the chamber.

Hot Chamber capacity varies as per different processing capacity. Maintenance of the hot chamber is easier and Steel trolleys are easily movable. Aluminum Perforated trays are easy to carry, hygienic and easy to clean and maintain them.

We at Vinayaka Ensure that your process is not only convenient but also reliable and sees that maximum care and attention is paid throughout the whole process.

Peeling refers to removal of skin i.e., Testa (Red Skin) from the kernel. This is done after drying the kernel in the drier. Testa loosens after drying and removal of this skin gets easier. Peeling is done by hand with a specially designed knife, which is termed as peeling knife.

Here we a have two more by-products, Cashew Testa (Husk), Reject Cashew Nut (Non-Edible).

The grading is the process, which comes after Peeling the red skin, the kernels are sorted out into wholes and are graded into different sizes on the basis of the number of wholes per lb, according to the International standards & specifications.

Processed nuts have to be well packed and preservatives to be used, in order to maintain quality and prevent them from any fungal or pest attack.

Micro-particles are removed by passing graded Kernels through dust removal machines. Here pressurized air is blown on to the nuts in a closed chamber and is directly fed to Tin filling machine.

Kernels graded are then packed as per Export standards. Tins are vacuumized, and are filled with the carbon-dioxide gas with the help of gas filling equipment known as "Vita-pack” immediately lids are soldered and tins are made airtight.

High performance, high standards in production and quality being the prime aim in a Cashew Engineering, we ensure that you have it all.