Flowchart - Coconut

 

 

Step 1: Receiving of Raw Materials

 

Shipments of coconut are delivered to our factory in Batu Pahat, Johor, on a daily basis. Each delivery is weighed to determine the net weight of the cargo. 

 

 

 
 

 

Step 2: Harvesting of Coconut Water

 

  • A hole is drilled into the coconut and the coconut water is harvested
  • The coconut water is immediately sent to the processing line in another section of the factory (see Coconut Warer)

 

 

 

 
 

 

Step 3: Shelling

 

The coconut meat, complete with the testa (brownish skin) is separated from the shell. 

 

 
 

 

Step 4: Pairing

 

The testa is separated from kernel (the white coconut meat).

 

 
 

 

Step 5: Sorting & Washing

 

  • Kernel that does not meet our stringent quality standards are removed and sent to another section where coconut oil is extracted for industrial use (e.g. lotions, shampoos)
  • The good quality kernel continue on through the process and are washed to remove unwanted particles.
 

 

 
 

 

Step 6: Grinding

 

The cleaned white kernel is chopped into smaller pieces, passed through the screen of the hammer mill where the coconut meat is finely shredded.

 

 

 
 

 

Step 7: Pressing

 

  • Coconut milk is extracted from the finely shredded coconut meat.
  • The coconut milk is pasteurized, chilled, and stored in storage tank.
  • The pressed coconut residue is further processed into Low Fat Desiccated Coconut (see LFDC).

 

 
 

 

Step 8: Filling & Packing

 

  • The coconut milk will be packed into:
    - UHT Aseptic packaging (Tetra Pak cartons)
    - Retort packaging (cans)
  • Coconut Cream Powder
    - Coconut milk is transformed into coconut cream powder via a spray drying process
    - The coconut cream powder is later packed into PE bags or aluminum foil in accordance to the customers' requirements

 

 

 
 

 

Step 9: Warehouse

 

The Finished Goods are transferred to the warehouse in transit to our customers.

                                     

 

 

 

Flowchart - LFDC

 

 

Step 1: Receiving of Raw Materials

 

The coconut residue is received from the milk extraction section

 

 
 

 

Step 2: Blanching

 

The coconut residue is subjected to steam to eliminate pathogenic microbes. 

 

 
 

 

Step 3: Drying

 

The product is passed through a dryer and the moisture content of the desiccated coconut is reduced to less than 3%.

 

 

 
 

 

Step 4: Sieving

 

This ensures the consistency in the particle size of the final product.

 

 
 

 

Step 5: Metal Trapping

 

This safety measure is to ensure any metal based foreign particles are removed.

 

 
 

 

Step 6: Packing & Weighing

 

  • The product is hot sealed in 25kg LDPE bags.
  • The LDPE bag is further protected by packing into a multi-ply kraft paper bag.

 

 
 

 

Step 7: Warehouse

 

The Finished Goods are transferred to the warehouse in transit to our customers.

 

 

Flowchart - Coconut water

 

 

Step 1: Receiving of Raw Material (coconut water)

 

  • Freshly harvested coconut water is received from the harvesting stations.
  • The coconut water is immediately cooled, stored in chilled storage tanks.

 

 
 

 

Step 2: Pasteurization

 

  • The coconut water is pasteurized to eliminate pathogenic microbes in order to prolong the shelf life.
  • The pasteurized coconut water is then cooled once again to maintain its natural taste.

 

 
 

 

Step 3: Blending

 

  • The taste of natural coconut water varies due to many factors, such as, weather, time of harvest, soil conditions, etc.
  • Natural fruit sugar (fructose) and Vitamin C is added to achieve a consistency in taste.

 

 
 

 

Step 4: Sterilization

 

The coconut water is then sterilized, cooled and stored in an aseptic tank.

 

 
 

 

Step 5: Filling

 

The coconut water is filled into TetraPak Prisma Aseptic packaging (330ml / 500ml).

 

 
 

 

Step 6: Warehouse

 

The Finished Goods are transferred to the warehouse in transit to our customers.

 

 

Flowchart - Kerisik (Toasted Coconut Paste)

 

 

Step 1: Receiving of Raw Material

 

Shipment of kernel (complete with testa) is received based on production requirements.

 

 
 

 

Step 2: Sorting & Washing

 

  • Kernel that does not meet our stringent quality standards and other foreign particles are removed.
  • The good quality kernel continue on through the process and are washed.

 

 
 

 

Step 3: Grinding & Mixing

 

  • The cleaned kernel is chopped into smaller pieces, and the coconut meat is finely shredded.
  • Salt is added.

 

 
 

 

Step 4: Toasting

 

The mixture is subjected to controlled heat to enhance the flavor of coconut.

 

 
 

 

Step 5: Colloid Milling

 

The mixture is then milled into a paste-like form.

 

 
 

 

Step 6: Metal Trapping

 

  • The paste is passed through a magnetic bar.
  • This safety measure is to ensure any metal based foreign particles are removed. 

 

 
 

 

Step 7: Packing

 

The toasted coconut paste is left to cool before packing in hygienic food grade polybags.

 

 
 

 

Step 8: Warehouse

 

The Finished Goods are transferred to the warehouse in transit to our customers.