Process

Ensure the highest quality

Our Process

Our process is designed to ensure the highest quality and seamless delivery to global markets. We begin by sourcing premium honey from trusted beekeepers, focusing on purity and sustainability. After rigorous quality checks, the honey is packaged and labeled to meet international standards. We work with reliable logistics partners to ensure timely and safe shipping to our customers worldwide. With a commitment to transparency and traceability, we ensure that every jar of honey reaches you in perfect condition, maintaining its natural goodness.

Quality Assurance

Collection

At Abjay, we take quality and safety seriously, which is why we have an advanced in-house laboratory equipped with the latest technology to conduct essential chemical and microbiological assessments. Our laboratory is capable of performing a wide range of critical tests, including those for antibiotic residues and C4 sugars, ensuring that our honey meets the highest purity and safety standards.

Our lab is outfitted with state-of-the-art instruments such as EA-IRMS, LC/MS-MS, HPLC, Gas Chromatographs, ELISA, Brookfield Viscometer, Spectrophotometer, Honey Colour Grader, and Water Activity Analyzer. These instruments enable us to conduct precise, in-depth analysis for quality control, ensuring that our honey is free from contaminants and adheres to its natural properties.

A team of technically skilled and experienced scientists manages the testing procedures, rigorously analyzing the honey and ensuring compliance with both national and international standards. We adhere to guidelines set by organizations such as USFDA, EU Codex, FSSAI, AGMARK, and BIS to guarantee the safety and authenticity of our products.

Our laboratory follows internationally recognized methods of analysis validated by bodies like AOAC, CODEX, and the EU, as well as standard national methods outlined by BIS and FSSAI. This adherence to proven protocols ensures the accuracy, reliability, and consistency of every batch of honey we produce.

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Ensuring Excellence

Raw Material Inspection & Test

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Upon arrival, the honey from farms is assigned a unique batch number to ensure accurate identification and traceability. A composite sample is drawn from each bucket and sent to our inhouse laboratory for comprehensive testing. This includes:

  • Organoleptic Sensory Evaluation : Assessing the honey’s taste, aroma, color, and texture to ensure it meets premium quality standards.
  • Chemical Analysis : A thorough examination of the honey’s chemical composition to detect any contaminants and verify its natural composition.
  • Heavy Metal Assessment : Testing for the presence of heavy metals to guarantee safety and compliance with regulatory standards.
  • Sugar Profile Testing : Confirming the authenticity of the honey through an analysis of its sugar composition, ensuring it is free from adulteration.
  • Residue Monitoring Plan : Monitoring for any potential pesticide, antibiotic, or other harmful residue to ensure purity and compliance with industry standards.
  • Honey is accepted only if the test results align with the rigorous quality standards, ensuring that it meets both safety and purity requirements before it proceeds to the next stages of processing.

Subsequently, the approved honey is utilized for batch planning, aligning with customer specifications such as color, floral source, Fructose-to-Glucose ratio (F/G), etc. The approved material is then allocated to production for processing. Our standard batch sizes range from 20MT to 40MT, tailored to meet specific customer requirements.

Honey Refining

De-Crystallization and Filtration

The first step in honey processing is the melting process, which improves its manageability for further handling. This takes place in a specially designed stainless steel chamber that uses hot air as the heating medium, ensuring even and controlled warming. The chamber is equipped with air circulation baffles that enhance the airflow, promoting efficient melting. Below the chamber, collection trays are positioned to gather the melted honey.

After melting, the honey is passed through mesh filters to remove any unwanted particles or impurities, ensuring only pure, clean honey proceeds to the next stage in the processing cycle. This step is crucial for maintaining the honey’s quality and purity before further processing.

Our facility features specialized 20 KL (kiloliter) capacity tanks, designed to handle up to 28 metric tons of honey simultaneously. These tanks are equipped with stainless steel propeller-type agitators, powered by slow-speed motors. The agitators ensure that the honey is thoroughly homogenized, creating a uniform, cohesive batch of up to 20 metric tons. This process is crucial for maintaining consistent quality and ensuring that the honey is evenly mixed before it moves to the next stage of production.

Ensuring the consistency

Moisture Control and Honey Blending

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The honey extracted from the melting chambers is transferred to stainless steel storage tanks, constructed from raw SS304 material, with a capacity of 25 metric tons. These tanks are equipped with three-blade stainless steel agitators, operating at slow speeds to ensure proper homogenization of the honey. To achieve vertical homogenization, the honey is circulated from the bottom to the top within the tank, ensuring even consistency throughout the batch.

The process of dehumidification and moisture reduction is a critical step, wherein the moisture content of the honey is reduced to less than 19%. This is accomplished using a heat exchanger and a vacuum cone. The honey is fed directly from the raw tank through the vacuum cone, with flow regulated by a flow meter and valve. After exiting the vacuum cone, the honey is carefully monitored for moisture content to ensure it falls below the 19% threshold.

Following this, the honey is transferred to finished tanks for further processing. Moisture levels are continually checked at 30-minute intervals to guarantee consistent moisture reduction.

Our advanced processing facilities feature flash heating and cooling units, filtration systems, and pumps that transport the honey to settling tanks. Once in the settling tanks, the honey is allowed to rest for a designated period, ensuring it is free of any air bubbles or impurities. After settling, the honey undergoes thorough parameter testing in our laboratory to ensure it meets the required quality standards before it is ready for packaging and distribution.

Packaging Excellence

Packaging & Warehousing

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The honey is carefully stored in 25MT finished tanks for a settling period before it is packaged for distribution, either in bulk or retail quantities. For bulk packaging, the honey is passed through a final 80-mesh sieve filter to ensure purity, and then filled into 50Kg food-grade plastic containers or 300Kg epoxy-coated MS drums using automated filling machines.

For retail packaging, an additional de-waxing and filtration process is applied to ensure that the honey meets the highest quality standards. Our automated filling line allows us to pack honey in a wide range of sizes, from 5g to 25Kg, utilizing food-grade PET or glass bottles, as well as buckets, depending on customer specifications.

Throughout the filling process, samples are meticulously collected and sent to an external laboratory for final testing, ensuring each batch meets our stringent quality requirements. To further streamline operations, our spacious warehouse is equipped with a computer-controlled inventory system, facilitating efficient tracking and ensuring smooth, well-organized shipments of all honey products.