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Green peas and IQF vegetables
IQF green peas, sweet corn, mixed vegetables, dehydrated peas
Green peas and IQF vegetables line by GEM Foodtech, Kolkata, India — capacity 1 to 15 tonnes of pods per hour, final yield 38% of raw intake, delivered as a turnkey plant with installation and commissioning worldwide.
The commercial reality
Peas are a clock business. Sugar converts to starch within hours of picking, so the distance from field to blancher is a quality specification, not a logistics detail. The whole line is designed to compress that time.
Process flow diagram
Generated for the standard configuration. Yours is redrawn to your product mix, capacity and site.
Process chart
Every stage with the equipment that performs it, the operating parameter and the control point that decides quality.
| # | Stage | Equipment | Parameter | Control point |
|---|---|---|---|---|
| 01 | Reception | Industrial elevator | Within 6 hours of harvest | Sugar to starch conversion limited |
| 02 | Shelling | Sheller and decorticator | Pea sheller, drum type | Pod and vine separated |
| 03 | Cleaning and grading | Grader and size sorter | Air cleaner, size grader, brine grader | Sizes and maturity separated |
| 04 | Washing | Fruit and vegetable washer | Cold water, chlorinated | Field load removed |
| 05 | Blanching | Blancher and cooler | Steam or water, 90–95 °C, 60–120 s | Peroxidase negative |
| 06 | Cooling | Blancher and cooler | Chilled water to 4 °C | Cooking arrested |
| 07 | Dewatering | Conveying and material handling | Vibratory dewatering and air knife | Surface water off before freezing |
| 08 | IQF freezing | IQF tunnel freezer | Fluidised tunnel, −35 °C, 8–12 min | Core temperature at −18 °C |
| 09 | Packing and cold store | Filling, sealing and packing line | Bulk or retail, metal detection | Cold chain maintained |
Mass balance
Basis of 1,000 kg of raw material. Change the tonnage below and the whole table rescales.
| Stage | Output, kg/h | Yield | Loss, kg/h | Where the loss goes |
|---|---|---|---|---|
| Pods received | 1,000 | 100% | 0 | — |
| Shelled peas | 400 | 40% | 600 | Pods and vine to cattle feed or silage |
| After grading and washing | 380 | 38% | 20 | Undersize and damaged to dehydration line |
| After blanching | 390 | 39% | 0 | Slight water pickup |
| IQF packed product | 380 | 38% | 10 | Freezer losses and fines |
By-products: Pods and vine as silage or feed; off-grade peas diverted to the dehydration line rather than dumped.
Equipment schedule
Core machines for this line. Conveying, tanks, CIP and utilities are added to suit the layout.
| Equipment | Capacity range | Function |
|---|---|---|
| Industrial elevator | Handling | Lifts washed or raw material between floor levels without bruising. |
| Sheller and decorticator | Separation | Cracks and separates shell from kernel on cashew, peas and corn. |
| Grader and size sorter | Separation | Separates by size or specific gravity before or after processing. |
| Fruit and vegetable washer | Preparation | Removes field soil, latex and surface load with recirculated, filtered water. |
| Blancher and cooler | Thermal | Inactivates enzymes, sets colour, then cools to arrest cooking. |
| Conveying and material handling | Handling | Moves product between stations without degrading it. |
| IQF tunnel freezer | Freezing | Individually quick frozen product with minimal ice crystal damage. |
| Filling, sealing and packing line | Packing | Weighing, filling, sealing, metal detection and case packing. |
Questions we get on this line
Why blanch before freezing?
Enzymes stay active below freezing and destroy colour and flavour over months of storage. A peroxidase-negative test is the standard proof.
Can one line do peas and sweet corn?
Yes, with a change of shelling and grading front end. Both seasons are short and rarely overlap, which makes the shared IQF tunnel excellent economics.
What capacity range does the green peas and iqf line cover?
Standard GEM Foodtech builds cover 1 to 15 tonnes of pods per hour. Larger duties are engineered to order — the right size is set by the raw material supply through the season, not the nameplate figure.
Is this supplied as a complete turnkey plant?
Yes. The Green peas and IQF vegetables line is delivered end to end — feasibility, pilot trial on your own material, engineering, manufacture in Kolkata, installation, commissioning and operator training — or as individual machines to fit an existing plant.
Want this line costed for your tonnage?
Send the raw material specification and the capacity you are targeting. You get a flow diagram, an equipment schedule and a budget number.