Frozen Onion Ring Production Stages
Our facility, which became operational in December 2024, has a production capacity of approximately 2 tons of finished product per hour. By using fresh onions, the taste and flavor of the onion are preserved in our onion rings.
In the frozen onion ring production process, our primary goal is to preserve the freshness of our products for an extended period using the flash-freezing method. In addition, we ensure food safety by strictly adhering to hygiene and sanitation principles at every stage, while enabling the product to be ready to serve in a short time (2.5 minutes).
Raw Material Acceptance
Onions sourced from our contracted farmers are accepted according to raw material quality acceptance criteria. Onions that meet the raw material storage quality standards are stored in special crates, initially at higher temperatures, then gradually at 0 - 2°C. Before production, the crated onions are brought into a room at -2°C.
Tip Cutting & Peeling
Onions taken into the bunker are sized and transferred to production with the help of an elevator. The long stems and tip ends are removed by cutting. The cut onions are peeled in a peeling machine using air assistance.
Sorting & Selection
The peeled and cleaned onion bulbs are processed on the sorting and selection conveyor before being sliced. In this stage, any defective or unpeeled onion bulbs are identified and removed.
Onion Slicing
Peeled onions are transferred to the slicing line via a conveyor belt and are cut into the desired size.
Mixing
Auxiliary ingredients (wheat flour, starch, binder, salt, breadcrumbs) are added to the chopped onions to prepare the onion dough mixture.
Forming
The onion dough is shaped into the desired ring form with the help of a molding machine.
Liquid Coating
The formed onion rings are passed through a liquid coating to ensure better adhesion of the granular coating and to achieve the desired flavor.
Granular Coating
Onion rings that have been coated with liquid are passed through the granular coating machine to achieve the desired crispiness and flavor.
Individual Quick Frozen (IQF)
IQF (Individual Quick Frozen) is an advanced system and application in frozen food technology. With this method, food products are rapidly frozen in a spiral freezer at -40°C. This process occurs as the water inside the products freezes, allowing the foods to have a long shelf life without the use of additives. To prevent nutrient loss during the process, the cell membranes in the food must not be ruptured. Therefore, the temperature of the food must rapidly drop to -5°C. Flash freezing slows down and halts all microbial activities. Freezing is a very natural method of preservation; the only difference between this method and a household freezer is that the product’s temperature is rapidly lowered to -18°C through flash freezing.
Packaging & Boxing
Products coming out of the freezer are packaged. Relevant regulatory information is printed on the package using a coding device. The packaged products then pass through metal detection and weight control before being placed into boxes.
Packaging & Boxing
Products coming out of the freezer are packaged. Relevant regulatory information is printed on the package using a coding device. The packaged products then pass through metal detection and weight control before being placed into boxes.
Storage
Boxed products are stacked on pallets and stored in warehouses at -18°C until they are shipped.