Frozen Edamame Processing: Quality & Safety Standards

Frozen Salted Edamame: A Detailed Overview of the Processing Workflow

 

This document provides a comprehensive description of the manufacturing process for our frozen salted edamame, ensuring transparency and demonstrating our commitment to quality, safety, and traceability from farm to freezer.

 

 

I. Raw and Auxiliary Material Management

 

1-1. Raw Material Acceptance:

 

  All raw materials must originate from vegetable bases registered and approved by the official Inspection and Quarantine authorities. A crucial step is the pesticide residue testing, for which samples are collected 3 to 5 days prior to harvest. During acceptance, our quality control team not only verifies the quantity and quality of the edamame but also confirms its origin and cross-references the pesticide residue test results to ensure full compliance.

 

1-2. Temporary Cold Storage. 

 

  In cases where immediate processing is not feasible, the raw edamame is held in a temporary cold storage facility maintained at a temperature between 5°C and 15°C. To guarantee the stability of this environment, our Quality Control (QC) staff meticulously monitor and record the storage temperature every two hours.

 

B1–B3. Edible Salt Management:

 

  Our salt is sourced exclusively from approved suppliers. Any package that is damaged or shows signs of contamination is immediately rejected. The salt is stored off the floor and away from walls, adhering to a First-In, First-Out (FIFO) principle. Storage areas are clearly demarcated and labeled. The preparation of brine solutions is executed precisely according to the production requirements for specific concentrations.

 

C1–C3. Packaging Material Management

 

  Upon delivery, our warehouse manager inspects the shipping documents and third-party testing reports for all packaging materials. These materials are stored in designated zones, off the floor and away from walls, following the FIFO inventory system. Prior to use, inner bags undergo a sterilization process using UV or ozone for a minimum of 30 minutes. All necessary information, including the best-before date, production date, and registration number, is coded onto the packaging. Outer cartons are printed with clear markings and affixed with a CIQ (China Inspection and Quarantine) label.

 

 

II. Pre-treatment Process

 

1-3. Sorting and Conditioning

 

As the edamame moves along the conveyor belt, workers manually remove any defective items, including those with insect damage, underdeveloped kernels, discoloration, or any foreign materials.

 

1-4. Air Selection and Secondary Inspection.

 

An air selector is employed to blow away light impurities such as soybean fluff and leaves. Following this, a secondary manual inspection is conducted to remove pods with missing kernels, blemishes, or picking damage.

 

1-5. Washing

 

The edamame undergoes a bubble washing process with flowing water to thoroughly remove soil and other impurities. Our QC staff monitors the process by testing and recording the residual chlorine content, maintaining it at 5–8 ppm, every 30 minutes.

 

 

III. Blanching and Cooling Process

 

2-1. Blanching.

 

The blanching process is a critical step for enzyme deactivation. It is conducted in a 1% brine solution at a temperature of 98±2°C for a duration of 135±5 seconds. These parameters are strictly monitored and recorded by QC staff every 30 minutes.

 

03-3. Initial Cooling

 

Immediately after blanching, the product is transferred to a cooling tank. The water temperature is maintained at or below 30°C, with a residual chlorine level of 2–5 ppm, which is regularly tested.

 

04-1. Pre-cooling

 

After spray cooling, the product enters a secondary cooling tank containing ice water at a temperature of ≤15°C. The residual chlorine content is consistently maintained between 2–5 ppm.

 

IV. Brining and IQF Process

 

3-2. Brine Soaking

 

The edamame is soaked in an 8–9° Baumé ice-brine solution for 40 to 50 minutes. The concentration of the brine can be adjusted to meet specific customer requirements.

 

3-3. Draining

 

Excess surface water is removed through a series of vibration machines, climbing conveyors, and a final pre-IQF vibrator to ensure optimal freezing results.

 

3-4. IQF (Individually Quick Frozen).

 

The product is then individually quick-frozen. The air temperature inside the IQF tunnel is maintained at ≤-18°C, with an evaporation temperature of ≤-24°C. The entire freezing process is completed within 8 to 12 minutes. Our QC staff inspects and records these parameters hourly.

 

3-5. Weighing and Bulk Packaging

 

Post-freezing, any ice blocks or defective products are removed. The semi-finished product undergoes weight checks (using a 500g standard sample) every 30 minutes. Samples are taken every 2–3 hours for microbiological testing, and each batch is sampled for pesticide residue analysis.

 

 

V. Cold Storage and Repackaging Process

 

4-1. Semi-finished Product Cold Storage:

 

The bulk-packaged semi-finished product is immediately transferred to a cold storage facility maintained at a temperature of -18°C or below. The warehouse temperature is recorded by QC staff every two hours.

 

5-1. Repackaging from Storage

 

Repackaging is conducted in a climate-controlled room at ≤15°C. During this stage, a final inspection is performed to remove any foreign matter or defective products. The product is then weighed, bagged, and sealed according to customer specifications.

 

5-2. Sealing and Double-Check:

 

 A two-person verification process ensures the weight and seal quality of every bag. The net weight of each bag must be at least 101% of the customer's required weight to guarantee satisfaction.

 

 

VI. Final Inspection and Shipment

 

 

6-1. Metal Detection: Every single bag must pass through a metal detector.

 

The detector is calibrated with standard test pieces at the start of the shift, periodically during operation, and at the end of the shift to ensure its sensitivity and accuracy.

 

6-2. Cartoning:

 

The finished products are packed into cartons according to the specified quantity, which are then sealed and strapped. QC staff perform regular checks on the final weight, labeling, and markings.

 

6-3. Finished Product Cold Storage:

 

The final products are moved to a cold storage facility maintained at -18°C or below. They are stored separately by batch and specification for clear traceability. The storage temperature is checked and recorded every two hours by QC staff.

 

6-4. Shipment

 

Products are shipped only after passing both our internal inspection and the final inspection by the Entry-Exit Inspection and Quarantine department. Before loading, the shipping container is inspected for cleanliness and seal integrity. The entire loading process is completed within 90 minutes, with the container temperature controlled at ≤-15°C. During loading, QC staff conduct random checks on carton integrity, labeling, and weight. Photographs are taken and archived after the container is sealed.

 

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