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OUR FACTORY


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As we are one of the main Vanilla Beans Producers in Sri Lanka, we always take
extra steps to keep consistent quality of our Cured Vanilla beans during the
production process. Hence our vanilla manufacturing process starts from vanilla
cultivation to ensure we receive organic vanilla beans from our farmers.
Throughout our all processing steps we maintain proper food handling methods to
get best Quality Vanilla Beans. Our unique vanilla curing process where our
staff are carefully following the 7 steps in production to ensure optimal
vanillin production.


STEP 1: COLLECTING HARVESTED GREEN BEANS

 * Vanilla growers in Sri Lanka harvest green beans mainly in November, December
   and July, August to some extent.
 * In order to get the quality cured beans, it is important to harvest matured
   green beans using correct harvesting indicators.
 * Farmers need to know the time taking to ripe vanilla beans from pollination
   and maturity level in vanilla bunch.
 * It is important to have extensive knowledge in different Steps in Vanilla
   Cultivation. Therefore during vanilla harvesting time, our Vanilla
   Development Officers give advice to harvest quality vanilla pods.
 * Once they harvested matured green beans, they need to be cleaned and
   separated beans from the bunch.
 * Then our collection officers collect green beans from different farmers in
   the region and transport them in boxes to avoid damage to the beans.






STEP 2: CLEANING GREEN BEANS

 * Once we receive the green Vanilla beans from the farmers and collectors, we
   double check if the beans are properly ripened, if they are in correct shape
   and without damage.
 * Then we clean them to make sure they do not have any foreign materials as we
   received the beans from different farmers’ hands.
 * We washed them thoroughly to ensure the beans were clean enough to proceed to
   the killing process.






STEP 3: KILLING PROCESS

 * This process of killing is important to stop growing vanilla beans and
   encourage the vanillin creation process.
 * Then we submerge green vanilla beans in the warm water for the required time
   to stimulate to generate Vanillin.
 * Also during this process we encourage Vanilla coloring to change from green
   to brown.






STEP 4: VANILLA CURING PROCESS

 * This process is a very important step in the Vanilla beans production
   process. With  many years of experience in curing we do vanilla sun drying
   for 1-2 months.
 * During this process we reduce 40-50% of the water from the beans.
 * Once they dried they were placed in special boxes to encourage the curing
   process.
 * After sun drying we need to do slow drying  in room temperatures for 1-2
   months to reduce moisture to 50-60%.
 * During this slow drying process the Vanillin content developed to the highest
   level.






STEP 5: GRADING AND QUALITY CHECKING

 * During the Grading process we separate unprocessed beans, damaged beans,
   discolored beans, beans that got fungus.
 * Further the grading done for the lengths and the moisture content as well.
 * The length of Vanilla beans vary from 10cm to 18cm, where the price of
   Vanilla beans vary with the length and the moisture content.
 * Our cured Vanilla beans are checked by our staff to ensure they are perfectly
   cured.
 * We identify cured beans by rolling the beans around two fingers or tie a knot
   using the beans.
 * Due to moisture level and the curing process, beans do not break when rolling
   or tying a knot.
 * Also staff are checking the other features of a quality vanilla bean.
 * They have a dark brown and oily appearance, fleshy and soft texture, desired
   length (6-8″) with straight beans.






STEP 6: STORING CURED VANILLA BEANS

 * Vanilla Beans Storing is an important aspect in the production process.
 * We need to give optimum storage conditions to maintain moisture level while
   controlling the fungus development.
 * The best temperature for storing is from 15-29 C where the room is not too
   hot or cold.
 * We cover it with wax paper and store it in a dark place in air tight boxes.






STEP 7: PROCESSING WHOLESALE AND PRIVATE LABEL ORDERS

 * Its is important to maintain consistent quality beans and have enough stock
   as a Wholesale Vanilla Beans Manufacturer.
 * Therefore we plan our production in order to cater increasing demand from
   bulk orders and private Labels.
 * Some of the customers we do private label according to their required 
   packaging with their designs.
 * Through our vacuum packaging we make sure customers get fungus free premium
   quality vanilla beans.
 * Even though we are a big manufacturer, we accept small orders for family
   consumption. Most of those customers praised about the quality of vanilla
   beans that are used for baking, vanilla extracting and other Vanilla beans
   recipes  





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Our Company started in 2010 on a small scale with the least infrastructure and
know-how. With the gradual expansion, we were able to export our vanilla
beans to many countries around the world.

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