Introduction
Behind every polished lentil or sorted chickpea lies a multi-step industrial journey filled with precision, technology, and quality control. From farm fields to food-grade packaging, pulses undergo rigorous treatment to ensure they are clean, safe, and ready for domestic or export markets.
This article offers a comprehensive walkthrough of the complete pulses processing line workflow, showcasing how Alloy Industrial Sourcing turns raw agricultural output into high-value finished goods.
Stage 1: Raw Material Intake & Receiving
The process begins at the factory gate. Pulses arrive in bulk via trucks or containers. They’re unloaded into intake hoppers, where material flow is controlled to prevent damage or spillage.
Key Operations:
• Elevation conveyors move product efficiently
• Manual or camera-based inspection may be used to identify extremely poor-quality loads
• Feed rate is adjusted for downstream consistency
Stage 2: Pre-Cleaning
Raw pulses typically carry large impurities such as twigs, pods, and stones. The pre-cleaning unit removes these using:
• Vibrating screens to eliminate large and small foreign particles
• Air aspiration to extract lightweight debris like husks or dust
This stage protects downstream equipment and begins the first phase of hygienic handling.
Stage 3: Magnetic Separation
Ferrous metal contaminants are often picked up during harvesting or transport. Using magnetic separators, these fragments are removed to:
• Protect equipment like polishers and sorters
• Comply with food safety regulations
• Eliminate the risk of metal ingestion in final product
Alloy Industrial’s systems use high-intensity rare-earth magnets for efficient removal even at high flow rates.
Stage 4: Destoning
One of the most critical safety steps, destoning machines separate heavier materials from pulses using:
• Air pressure differentials
• Oscillating screens
• Fluidization principles
This ensures removal of:
• Pebbles
• Sand particles
• Bone fragments
It’s a mechanical filtering stage that ensures a contaminant-free stream.
Stage 5: Grading and Size Sorting
Each pulse variety (lentils, chickpeas, peas) has commercial classifications based on size and shape. Using:
• Rotary or cylindrical graders
• Sieve-based screens
The product is sorted into uniform size categories. Oversized, undersized, or broken grains are removed.
Benefits:
• Ensures batch consistency
• Improves pricing and marketability
• Aligns with packaging formats
Stage 6: Gravity Separation
Grading by weight helps separate healthy, dense grains from lighter, underdeveloped or insect-damaged ones.
Equipment Highlights:
• Precision-controlled gravity tables
• Adjustable deck angles for different pulse types
This step boosts product quality and reduces unwanted loss in later stages.
Stage 7: Optical Color Sorting
A modern must-have in any export-capable plant, color sorters use:
• High-speed cameras
• LED lighting systems
• Software-based object recognition
They scan each grain for:
• Discoloration
• Mold
• Insect damage
Selected impurities are removed via targeted air jets, increasing visual and hygienic appeal.
Stage 8: Polishing (Optional, Market-Specific)
Some markets require polished pulses for retail appeal. The polishing unit:
• Buffs the grain surface
• Removes micro-dust
• Adds visual shine
Polishing is common for lentils and polished chickpeas, especially in Gulf and European export markets.
Stage 9: Final Quality Check
Here, both automation and human inspection are applied to double-check product integrity. Technologies used may include:
• Moisture sensors
• Bulk density testers
• Manual spot sampling
Products that pass are released for packing.
Stage 10: Weighing, Packing, and Sealing
The final step transforms bulk pulses into retail or wholesale-ready products.
Features of Alloy’s Smart Packaging Systems:
• Automated weighers with programmable fill volumes
• Vertical form-fill-seal (VFFS) systems
• Heat sealing for food safety
• Labeling, batch coding, and traceability
The finished product is now ready for palletizing, storage, or export.
Integrated Control and Monitoring
Alloy’s systems are often integrated with SCADA or PLC-based control panels, allowing:
• Real-time data tracking
• Remote diagnostics
• Line-wide synchronization
• Production reports
This ensures efficiency, quality, and operational control.
Why Choose Alloy Industrial Sourcing?
Alloy doesn’t just supply machines—we provide complete, customized solutions:
• Engineering design based on pulse variety and market
• Full project execution from idea to commissioning
• Strict adherence to ISO and HACCP
• After-sales service, spare parts, and remote support
Whether you’re launching a new factory or upgrading an existing one, our solutions adapt to your needs.
The journey from farm to final product is long, complex, and incredibly precise. But with Alloy Industrial’s turnkey pulses processing lines, it becomes seamless, efficient, and fully compliant with international standards.
✨ Ready to take your legume production to the next level?
Request a free consultation today or explore more on our Services page.
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