How we turn fresh fruit into
shelf-stable crunch.
Industrial freeze-drying at −40°C preserves what heat destroys — colour, flavour, nutrients and shape. Here is the full process, from farmer to container, step by step.
Three phases. Zero compromise.
Lyophilisation works because water skips its liquid phase entirely. No heat means no nutrient loss, no shape change, and no added chemistry.
Freeze
−40°CRapid blast freeze forms micro-crystals that protect cellular structure.
Primary Dry
0.5 mbarUnder deep vacuum, ice sublimates directly into vapour — no liquid phase, no heat damage.
Secondary Dry
< 3% H₂OResidual bound water is removed until final moisture hits spec — long shelf life, full flavour.
Farm to container, one continuous chain.
Every stage is documented, measured and audit-ready.
Sourcing & Harvest
Partner farms in Maharashtra, Gujarat, Karnataka, Kerala, Himachal and Punjab deliver fruit at peak ripeness. Every batch is barcode-tracked to the farm and harvest date. Quality is inspected on arrival — rejected lots never enter the line.
- ✓Contract farmers only
- ✓QR-coded crate traceability
- ✓On-arrival grading
Washing & Preparation
Fruit is washed in food-grade ozonated water, peeled/cored/sliced as required, and laid out on stainless-steel trays. Slice thickness is standardised per SKU (typically 5–8 mm for fruits, 3–4 mm for vegetables) to ensure uniform drying.
- ✓Ozonated wash
- ✓Calibrated slicing
- ✓Stainless tray loading
Flash Freezing
Trays enter blast freezers at −40°C. Rapid freezing creates tiny, uniform ice crystals — this protects cell walls, which is why freeze-dried fruit holds its shape and colour far better than slow-frozen or dehydrated fruit.
- ✓−40°C blast freeze
- ✓Micro-crystal formation
- ✓Cell-wall protection
Vacuum Sublimation
Frozen trays move into the lyophilisation chamber. Pressure is lowered to 0.5–1 mbar and gentle heat is applied. Ice sublimates directly to vapour without passing through liquid — removing 99%+ of water while nutrients and flavour stay put. Cycles last 18–36 hours depending on fruit.
- ✓0.5–1 mbar vacuum
- ✓Zero heat damage
- ✓99%+ water removal
Lab Quality Control
Moisture, water activity, microbiology and pesticide residue are tested on every batch at our NABL-grade in-house lab and by an independent third-party laboratory. A Certificate of Analysis (COA) is generated and travels with the shipment.
- ✓Karl-Fischer moisture
- ✓NABL third-party
- ✓Full MRL panel
Nitrogen Packing
Product moves immediately into a humidity-controlled packing room. Pouches and cans are nitrogen-flushed to displace oxygen and sealed with moisture barriers. Bulk B2B is packed into food-grade poly-lined kraft bags inside cartons.
- ✓N₂ flushed packaging
- ✓Moisture-barrier film
- ✓Humidity-controlled room
Export Documentation
Phytosanitary certificates, certificates of origin, APEDA RCMC, HACCP declarations, ingredient specs, nutritional labels (FDA/EU/GCC formats), and shipping docs are prepared before the container is booked.
- ✓Phytosanitary + APEDA
- ✓Market-specific labels
- ✓Full COA + MSDS
Container & Shipping
FCL and LCL shipments dispatched from JNPT, Mumbai, Mundra, and Chennai ports. FOB, CIF, and DDP Incoterms supported. Real-time container tracking shared with the buyer.
- ✓JNPT · Mumbai · Mundra
- ✓All incoterms
- ✓Live tracking
What freeze-drying preserves — that heat destroys.
Vitamins & Enzymes
Vitamin C, B-complex and heat-sensitive enzymes survive freeze-drying almost entirely. Dehydration loses 40–60%.
Natural Colour
Anthocyanins and carotenoids stay intact. Our strawberries stay red, our pomegranate stays ruby.
Volatile Aromatics
The aroma compounds that make mango smell like mango? Preserved. Heat boils them off.
Structure
Cell walls intact means fruit rehydrates to near-fresh, or crunches cleanly when eaten dry.
Want to audit our facility?
Serious buyers are welcome. Book a live virtual tour or a physical visit — we'll share complete documentation in advance.
Book a facility tour →