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PRODUCTION PROCESSES: from cultivation to final product

 

Raw carrots and other vegetables must first go through a preventive washing process before going to wherever their designated production may be.

At first the new material mass is immersed in a wash bunker full of drinkable water from our own wells.

After the first station phase, the raw carrots are washed accurately in special “rubbing” washing machines where dirt is washed away by an up and down rubbing process. Immersed in pure water, there is no addition of external substances in this wash.

Wash carrots Aureli

Fresh produce packaging

After the washing phase, carrots designated for “fresh” production undergo the selection process through a close net conveyor-belt.

In the first part of the process, selection is focused on eliminating outside matter such as stones and earth clods. Non-suitable carrots are thus rejected.
Suitable carrots are separated based on their dimensional calibre-length and diameter. Specially calibrated machines at an elevated precision level carry out the calibre selection based on customers needs.

Aureli's Fresh production

Packing is carried out in various ways according to the market needs. Trays, bags, small cases of different capacities are used; either standard or provided by the customer himself.
The finished product is always really fresh, worked, packaged and shipped daily (without taking from the stock), identified by production batch and harvest date.

Fresh Convenience production (Baby Carrots)

The particularly delicate production of fresh convenience (baby carrots) is achieved in completely controlled environment and atmosphere.

Production of Baby Carrots Aureli

The baby carrots or baby snack carrots undergo the “cutting” process after an initial selection process for external matter or product defects.

The baby carrot comes from a long, thin carrot which is particularly soft and sweet, devoid of the so-called “core”, the internal part of the tap-root.

After the cutting process calibration occurs according to the desired diameters.
The different calibres go through a peeling process that leads to the detachment of the external tap-root skin.

The peeled and cut product is brought to be selected again with mechanical processes under the strict control of specialized personnel.

On finishing the product is packaged in humidity controlled packs at different calibres and weights: from 200 grams to 800 grams, from I (finer), II or III (thicker) calibres.

Juices, Puree and Concentrates production

Puree of carrots and concentrated carrot juice produced by the farm Aureli

The transformation into carrot juices, purees and concentrates is carried out by focusing on the organoleptic characteristics of the product. In fact, Aureli offers juices containing excellent nutritional values: solar colour, raised degree of sugar, a high Beta-Carotene content.
Only “qualified” products can be transformed: therefore the product quality is already guaranteed from the beginning of the process.

The high quality of the transformed product results as custom of particularly accurate cultivations and especially from a highly specialized production process. This custom has been shaped by years of experience matured by Aureli in the carrot and vegetables transformation field.

 

The transformation from agriculture to food occurs within a complex work cycle beginning with a preventative “peeling” of washed and selected carrots.
Once the peel and the pulp are successfully separated there is a final manual selection by a selection counter in which the possible product residues (which escaped the initial checks) are eliminated.

The selected and peeled product is then minced and in a series of steps is then worked in appropriate polishing machines in order to become juice or purees.
The extremely refined product is pasteurized in order to eliminate all bacterial impurities.

 

The concentrate production goes through a final work phase after juice production: the concentration and elimination of the juice’s water content.
The process can achieve a degree of concentration equal to 9 times its single strength reaching 70° brix, depending on the vegetable type.

The various transformed products are packaged in aseptic bags or placed in refrigerated bulks ready for delivery.
Aseptic packaging is carried out by using automatic aseptic fillers. Juice, puree or concentrate production for tank trucks requires no warehousing-as soon as the production process has finished it is immediately mixed in the tank and ready for delivery.

Dehydrates and powder production

Carrots and other vegetables fit for dried foods and powder production, once washed are then selected based on the their nutritional content, especially high fibres and vitamins levels.

The product is first placed in drying machines of various types, achieving temperatures up to 130°C in order to obtain a humidity level less than 7%.
The process is kept under strict control of farm production labs which carry out systematic sample taking during the production phase.

The final product of the process is vegetable dehydrates-little bits of dried product to be packed in paper bags or to be grinded in dedicate mills for the production of carrot or other vegetables flours at different granule sizes.
The product is then packaged in paper alimentary bags for industrial-use.

 

Carrot powder is excellent ingredient used for baked food or confectionary (pasta, bread, cracker bread sticks, cookies) to make “gluten-free” products for people who are intolerant to gluten.

 Production of flour and dried Aureli

Bottling

The bottling line brings to healthy and organic juices production, 100% carrot or mixed with fruits as well as vegetables mix or single vegetable juice with no added water, preservatives or sugars.
The production starts with a careful testing of the beginning materials-juices or fruit puree (orange, pineapple, apple)-and the selection of the best carrot juice for bottling. The various ingredients are put in steel tanks and then diffused in a mixing basin according to the appropriate recipe quantities. Then there is a subsequent first control phase in order to verify the pH levels of the mix.

Following this is the pasteurization and filtering to then combine the mix in the “hot” bottling system.
The bottles are then preventively washed and checked internally. The sealing step occurs automatically with twist-off security caps.

At that point of the process, the bottles undergo a further pasteurization passing in the special tunnel where the temperature-first at high levels-decreases until it arrives at the environmental level, where the jar exits the tunnel.

The last quality inspection is preceded by the labeling and packaging phase. The juice bottles ready for use undergo quarantine during which a micro biotic analysis is carried out as well as inspections of the safety seal.

Aureli produces fruit juices