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Process

Process of manufacturing Jams

Jams are made from fresh fruits or fruit pulps. Jams are packed in either bottles or in cans.

  • The fruit is washed thoroughly to remove dirt and pesticide residue with plain water having a 15-20 ppm of chlorine and finally rinsed in flowing water.
  • Complete peels are removed from the fruits. Peeled fruits are passed through the pulper to get fresh fruit pulp.
  • The required quantity of pulp is taken (45% of the total jam must be the extent of the fruit) and sugar is added to it and the mix is heated in the kettle. After attaining the required brix levels, pectin solution is added to the product. Pectin makes covalent bond with sugar and sets the jam at minimum 65 deg. brix in boiling condition a pH of below 4.
  • Once the jam is made the flavour, color and acidulant are added to it.
  • Jam is packed either in bottles, tubs or jars and goes for cooling.
  • Bottles, tubs or jars after cooling are kept in an incubation period for minimum 3 days and then labeled and packed in cartons for dispatch

Process of manufacturing No Sugar Added Jams

Jams are made from fresh fruits or fruit pulps. Jams are packed in either bottles or in cans.

  • Fresh fruits are procured from the wholesale market and transported to our works where they are unloaded and stored under hygienic conditions.
  • The fruit is washed thoroughly to remove dirt and pesticide residue with plain water having a 15-20 ppm of chlorine and finally rinsed in flowing water.
  • Complete peels are removed from the fruits. Peeled fruits are passed through the pulper to get fresh fruit pulp.
  • The required quantity of pulp is taken (45% of the total jam must be the extent of the fruit) and sorbitol is added to it and the mix is treated in the kettle. After attaining the required brix levels, pectin solution is added to the product. Pectin makes covalent bond with sorbitol & fruit pulp and sets the jam at 40 deg. brix in boiling condition a pH of below 4.
  • Once the jam is made the flavour, color and citric acid are added to it.
  • Jam is packed either in bottles and goes for cooling.
  • Bottles after cooling are kept in an incubation period for min 3 days and then labeled and packed in cartons for dispatch.

Process of manufacturing Tomato Sauce / Ketchup

  • Tomatoes on receipt in crates are scrutinized visually for red, red/yellow, borer, blight disease and green shoulder fruits as per quality plan and duly sorted.
  • Fruit is inspected visually and for TSS, flavor and color.
  • After inspection the fruits are washed first in a water flume and then in a washing tank with 15 ppm of chlorinated water and finally rinsed in flowing water.
  • Fruit is again subjected to visual inspection by trained workers.
  • Selected fruits go into the extraction section for crushing where a temp of 90 ±5° is maintained to inactivate the pectinase enzymes and for obtaining better lycopene content from the peels and also for better consistency in the final product.
  • After extraction, the juice is passed through Pulper where all the seed and fibers are removed and a clear juice is obtained.
  • The clear juice is collected in the steam jacketed kettle and evaporated to required brix by heating.
  • Required quantity of puree is taken and sugar, salt, spices etc. are added to it, along with preservatives.
  • The entire quantity is transferred to a steam jacketed kettle and boiled.
  • Edible starch is added to get better viscosity and avoid water separation.
  • Sauce is boiled upto the required brix (38°- 40°).
  • Edible starch is added to get better viscosity and avoid water separation.
  • Sauce is boiled upto the required brix (25°- 38°).
  • Required quantity of acidulant and spice oils are added to the finished product.
  • Sauce is packed in the vacuum filler and then corked by crown corking machine. Packed bottles are thoroughly cleaned and stored in godown.

Process of manufacturing Green Chilly Sauce

Green Chilly Sauce is made from the fresh green chilies.

  • Fresh Green chilies are cleaned and washed.
  • These are crushed and preserved with salt and acid.
  • Crushed chilies are then ground to required mesh size.
  • This is processed with other ingredients as per recipe and packed into bottles.

Process of manufacturing Soya Bean Sauce

Soya Bean Sauce is made from the specially fermented extract of processed soya beans.

  • Soya Beans and wheat (whole) are dry roasted, soaked and pressure-cooked.
  • The paste is inoculated with the starter and allowed to grow a specific mould for 72 hours.
  • The paste is then diluted with brine solution and allowed to ferment for 180 days.
  • Extract is drawn and processed with other ingredients as per recipe and packed into bottles.

Process of manufacturing Ready to Eat Foods

These are made from the fresh stock of inputs like vegetables, rice, pulses, masala etc.

  • These are cleaned and washed where required.
  • This is processed with other ingredients as per recipe and packed into containers.
  • These are then exhausted in a steam tunnel and then sealed.
  • The containers are then processed at desired temperature and pressure for specific time.
  • The containers are then cooled to room temperature and then labeled and packed into cartons.

Process of manufacturing Culinary Pastes

These are made from the fresh stock of inputs like Garlic, Ginger, Tamarind etc.

  • These are cleaned.
  • These are crushed and preserved with salt and acid.
  • These are then ground to required mesh size.
  • This is processed with other ingredients as per recipe and packed into bottles.

Process of manufacturing RTS Beverages & No Added Sugar Variants

RTS Fruit drink Beverages & No sugar Added Variants are made from fresh fruits or fruit pulps.

  • Fresh fruits are procured from the wholesale market and transported to our works where they are unloaded and stored under hygienic conditions.
  • The fruit is washed thoroughly to remove dirt and pesticide residue with plain water having a 15-20 ppm of chlorine.
  • Complete peels are removed from the fruits. Peeled fruits are passed through the pulper to get fresh fruit pulp.
  • The required quantity of pulp & water is taken and heated in the kettle till the required brix levels are attained.
  • Once ready the aspartame, essence, color and citric acid are added to it.
  • They are packed in suitable containers / bottles.

Process of manufacturing Fruit Drink Concentrate & Diet Sugar Free Variants

Fruit drink concentrates & No Added Sugar Variants are made from fresh fruits or fruit pulps.

  • Fresh fruits are procured from the wholesale market and transported to our works where they are unloaded and stored under hygienic conditions.
  • The fruit is washed thoroughly to remove dirt and pesticide residue with plain water having a 15-20 ppm of chlorine.
  • Complete peels are removed from the fruits. Peeled fruits are passed through the pulper to get fresh fruit pulp.
  • The required quantity of pulp is taken and heated in the kettle till the required brix levels are attained.
  • Once ready the aspartame, essence, color and citric acid are added to it.
  • They are packed in suitable containers / bottles.

Contact Us

Regd. Office & Factory Address

Megafoods Products Madras (P) Limited

  • Contact Person: Mr. Amit C. Vaishnav - Managing Director
  • Email: amit@megafoods.in, info@megafoods.in
  • Address: D-3, SIDCO Industrial Estate, Ambattur, Chennai - 600 058. India.
  • Mobile: +91 98844 55605

Administrative Address

  • Address: 3-C, Bijayati Towers, 72 Halls Road, Kilpauk, Chennai – 600010
  • Phone: +91-44-26445605

To get in touch with our various departments you could contact us at the respective email addresses given below:-

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