Blanched pistachio kernels

Harvest

Pistachios being used for the production of blanched green kernels are being harvested approximately one month before the regular Pistachio harvest takes place to ensure the dark green color of the kernels. The later the pistachio is being harvested, the riper it becomes, and therefore the bigger the kernel will be, but at the same time the color fades from dark green to a light green/yellow.

Harvesting of Pistachios for the production of green kernels happens manually. As the wooden shell is still closed at that time, the kernel is naturally protected against insect damage and contamination (for example by Aflatoxin).

Processing

After harvesting at first the fruit flesh is being removed mechanically by rubber mills from the pistachios.

All pistachios being used for the blanched pistachio kernel production are sorted manually afterwards and only the fully closed shell pistachios are being used for further processing to provide the safest possible product. Thereafter the shell is being cracked mechanically in a mill and the kernels are being separated from the shells.

To remove the violet skin from the kernel, they are being blanched at approximately 80°C. This process scales off the skin from the kernel and thereafter the skin, which is lighter than the kernels, can be sucked away.

All remaining skin is being wiped and rubbed off manually during the visual control on the conveyor belt. During this step inferior kernels are also being sorted out.

Thereafter the peeled kernels are being dried mechanically with warm air.

In the next step the kernels are being sorted manually according to the color in different grades: Super, AA, A, B, C, D, E, Splits.

During this process impurities and inferior kernels are being sorted out.

Before packing the kernels pass another visual quality control and a metal detector.

Finally the peeled kernels are being vacuum-packed in 12.5 kg net polybags and controlled by a metal detector once more.

Now they are ready to be shipped to the export markets and being used as an ingredient in the meat, confectionary, bakery, ice-cream and spice industry and more often also in the gastronomy.

Processing Facilities

Our major supplier and partner for blanched pistachio kernels “KERMAN HAPPY NUT” employs approximately 400 workers, out of which 390 are involved in the production and 10 in the administration. Depending on the production and season the factory produces in one or two shifts of 10 hours each at 5 days in the week. The max. production capacity is 800.000 kg green peeled pistachio kernels.The building and production facilities are approximately 5 years old and were specifically planned and built for the production of green peeled pistachio kernels.

The facilities are regularly (once per week) being cleaned and machines maintained or modernized, if necessary. All production halls are air-conditioned and warehouses are being cooled. All employees, working in the in the green peeled kernel production process were trained in respect to hygienic issues and processing of food.

All employees are obliged to wear overalls, cover their hair and wear masks. These are being washed and cleaned professionally in the company. Hands and uncovered parts of the body have to be thoroughly washed. This is being continuously controlled.

A medical checkup of the workers takes place on a regular basis. Smoking is prohibited. A factory canteen exists. Also separate changing rooms, bathrooms and lockers.