Kaju Factory | Factory मे kaju कैसे बनते है || 5 Days Process || Kaju Manufacturing | Vitthal cashew

This is Maharashtra and Vidarbha’s one of the biggest Kaju processing plant

Vitthal Cashew
Address:- Borgaon Manju Akola

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Cashew (Kaju) Processing Process in a Factory

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1️⃣ Raw Cashew Procurement & Storage
• Raw Cashew Nuts (RCN) are sourced from farms in India or imported from Africa.
• The raw nuts are cleaned and dried to reduce moisture (to around 8–10%).
• Stored in jute bags in a well-ventilated area to avoid fungal growth.

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2️⃣ Roasting / Steaming

There are two common methods:

🔸 Steam Roasting (Modern & Hygienic)
• Raw nuts are steamed in a cooker for 20–30 minutes at ~100–120°C.
• Softens the shell and loosens the kernel inside.
• Preferred in large-scale “Keshav”-type automated plants.

🔸 Drum Roasting (Traditional)
• Nuts are roasted in rotating drums using firewood or cashew shell oil.
• Gives a smoky flavor but produces more waste and fumes.

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3️⃣ Shell Cutting / Shelling
• After roasting, shells are cut open manually or by machines.
• The cashew kernel inside is removed carefully to avoid breakage.
• Workers often use hand cutters or semi-automatic shell cutting machines.

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4️⃣ Drying (Oven Drying / Hot Air Chamber)
• The shelled kernels (still covered with a thin testa/skin) are dried in a hot air oven at 60–70°C for 6–8 hours.
• This step removes moisture and helps loosen the brown skin.

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5️⃣ Peeling
• After drying, the brown testa (outer skin) is removed.
• This is done either manually or through air suction peeling machines.
• The result is the clean, white cashew kernel we eat.

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6️⃣ Grading
• The peeled cashews are graded by size, color, and quality using sieves or electronic graders.
• Grades include:
• W180, W210, W240, W320, W450 (Whole grades)
• Splits, Pieces, and Baby Bits (Broken grades)

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7️⃣ Quality Inspection
• Kernels are inspected for:
• Moisture content (ideal: 3–5%)
• Broken or discolored pieces
• Contamination (dust, husk, etc.)
• Food safety and hygiene checks (FSSAI, ISO, HACCP) are done here.

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8️⃣ Packaging
• Kernels are vacuum-packed or nitrogen-flushed to prevent rancidity.
• Common pack sizes: 1 kg, 5 kg, 10 kg tins or pouches.
• Proper labeling with grade, batch, and date is done.

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9️⃣ Cashew Shell Oil (Byproduct Recovery)
• Cashew shells contain Cashew Nut Shell Liquid (CNSL) — a valuable industrial oil.
• It’s extracted and used in paints, brake linings, lubricants, and resins.

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🔟 Storage & Dispatch
• Finished cashew kernels are stored in a cool, dry warehouse.
• Distributed to wholesalers, exporters, or directly to retail brands.

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⚙️ Machinery Used in a Kaju Factory
• Steam Boiler or Cooker
• Shell Cutting Machine
• Dryer / Hot Air Oven
• Peeling Machine
• Grading Machine
• Vacuum Packing Machine

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📈 By the Numbers (Typical Medium Unit Example)
• Processing capacity: 1–2 tons/day raw nuts
• Kernel yield: 22–25% (from raw nut weight)
• Labor requirement: 50–100 workers (mix of manual & machine work)