Manufacturing Process

Our Process

From Farm to Finished Product

Our manufacturing process combines traditional expertise with modern technology. Equipped with machinery from Buhler (Switzerland) and IMAS (Turkey), we ensure every batch meets the highest standards of quality and consistency.

Raw Material Sourcing & Inspection

We source premium quality maize from trusted local farmers in the Bagalkot region, which produces approximately 20% of Karnataka's total maize output. Each consignment undergoes rigorous inspection for moisture content, foreign matter, and quality parameters before acceptance.

Cleaning & Grading

The raw maize passes through advanced multi-stage cleaning equipment that removes stones, dust, chaff, and other impurities. A dedicated grading system separates the maize by size and quality, ensuring only the best kernels proceed to the milling stage.

Conditioning & Tempering

The cleaned maize is conditioned with precise moisture and temperature controls to optimize the milling process. This critical step ensures the germ separates cleanly from the endosperm, resulting in superior quality grits and flour.

Milling & Grinding

Using state-of-the-art Buhler (Switzerland) and IMAS (Turkey) roller mills and hammer mills, the conditioned maize is precisely ground to achieve the desired particle size distribution. Our advanced milling process allows us to produce a wide range of products — from coarse grits to fine flour.

Sieving & Classification

The milled material passes through a series of plansifters and purifiers that separate different particle sizes with precision. This classification ensures each product meets its specific granulation specifications, whether for brewing, snacks, or baking applications.

Quality Control Testing

Every batch undergoes comprehensive quality testing in our in-house laboratory. Parameters tested include moisture content, particle size analysis, color, texture, microbiological safety, and organoleptic properties. Our FSSC 22000 certified quality management system ensures complete traceability.

Packaging & Storage

Finished products are packed in food-grade packaging under hygienic conditions. Our packaging options include 25kg and 50kg PP bags, with customization available for bulk orders. Packaged products are stored in a clean, dry warehouse before dispatch.

Logistics & Dispatch

With excellent connectivity to major ports (Karwar, Goa) and airports (Goa, Hyderabad, Belgaum, Hubli), we ensure timely delivery to domestic and international customers. Our logistics team coordinates every shipment with care and precision.

Technology

World-Class Machinery

Buhler Technology

Swiss-engineered milling equipment for precision grinding and consistent particle size distribution.

IMAS Machinery

Turkish-made processing machines known for durability, efficiency, and high throughput capacity.

Automated Systems

Fully automated production line with PLC controls for consistent quality and minimal human intervention.

Quality Assurance

In-house laboratory with advanced testing equipment for continuous quality monitoring.

Special Process

Authentic Nixtamalization for Corn Masa Flour

For our Corn Masa Flour, we employ the traditional nixtamalization process — an ancient technique that has been used for thousands of years in Mesoamerican cuisine. This process involves cooking and steeping dried corn in an alkaline solution, usually lime water.

Nixtamalization offers several critical benefits:

Releases bio-available niacin (Vitamin B3)
Increases calcium content significantly
Improves protein quality and digestibility
Creates the characteristic masa flavor and aroma
Produces pliable dough ideal for tortillas and tamales
Reduces mycotoxin levels for food safety