High-quality green peas are produced via an automated assembly line process consisting of “soaking → shaping → low-temperature frying → oil removal → seasoning/coating → cooling & packaging.” The core of this process lies in the “coating + segmented temperature-controlled frying” stages, as well as rigorous raw material selection and quality control.

The following description outlines the process according to actual factory workflow (combining publicly available data and industry-standard techniques to closely mirror a real production line):

 

1. Raw Materials: Specialized Green Peas

• Variety: Green-skinned, round-grain dried green peas (these are *not* fresh peas, but rather sun-dried ones).
• Requirements: Plump grains, uniform size, vibrant green color, free from mold and insect infestation, and a moisture content of ≤13%.
• Initial Factory Screening: Air separation to remove dust, vibration screening for size grading, and manual sorting to remove defective peas.

 

1. Cleaning + Soaking (The Critical First Step)

1.High-pressure spray washing to remove surface dust and impurities.

2.Transferred into large soaking tanks for immersion in clean water at ambient temperature:

• Duration: 8–12 hours (longer in winter, shorter in summer).
• Objective: Ensure the peas fully absorb water, leaving no hard core in the center, with a final moisture content of approximately 45%–50%.
• Function: Guarantees that the peas are crispy both inside and out after frying—preventing them from being undercooked in the center or cracking excessively.

3.Vibration draining after soaking: Ensures there is no free water remaining on the surface; otherwise, this would cause oil splashing and clumping during the frying stage.

 

III. Shaping / Pre-processing (Key Feature)

There are two main approaches in the industry:

• Traditional: Direct deep-frying → Prone to bursting, large cracks, and peeling skin.
• High-end: Initial light steaming / thermal setting (not cooked through) → Tightened skin, less prone to bursting during frying, and a more uniform, rounded shape.

Publicly available information mentions a combined steaming-and-frying process, the objectives of which are:

• Color Preservation: Achieving a more vibrant, emerald-green hue.
• Shape Retention: Minimizing bursting and bean breakage.
• Texture Preservation: Ensuring a consistent crispness both inside and out.

 

1. Multi-Stage Frying (Core Secret: Temperature + Time Control)

Utilizing a continuous, automated fryer—rather than batch frying in a single pot:

1.Stage 1 (Low-Temperature Dehydration):

• Oil Temperature: 135–145°C
• Duration: 7–10 minutes
• Condition: Beans float to the surface, turn slightly yellow, the skin sets, and most of the moisture is removed.

2.Stage 2 (High-Temperature Crisp-Setting):

• Oil Temperature: 160–165°C
• Duration: 2–3 minutes
• Condition: Golden-yellow with vibrant green highlights, uniform cracking, crispy texture without scorching.
• Strict Control: Do not exceed 170°C to prevent discoloration, bitterness, and the formation of harmful substances.

Frying Oil: High smoke-point palm oil / refined rapeseed oil; continuously filtered, replaced periodically, and monitored for acid value.

 

1. Centrifugal Oil Removal (Determines Greasiness)

Immediately after frying, the beans are transferred to a high-speed centrifugal oil extractor:

• Rotation Speed: 300–500 rpm
• Duration: 3–5 minutes
• Target: Oil content controlled within the range of 18%–22%
• Result: Dry surface texture, non-greasy feel, and less prone to flavor deterioration during storage.

 

1. Coating + Seasoning (Key to Flavor)

This constitutes the primary difference between high-end and standard fried peas: a thin layer of coating powder is applied first, followed by the seasoning.

1. While still hot (60–80°C), transfer the product into a rotary coating drum:

• First, apply a very thin base layer of starch / flour + dextrin (to enhance crispness, aid flavor absorption, and prevent moisture re-absorption).
• Next, add the seasonings: salt, sugar, MSG, garlic powder / crab roe powder / beef powder, etc. (adjusted according to desired flavor profile).

2.Tumble in the drum for 5–8 minutes to ensure the powder and seasonings adhere evenly; then, let the product rest (steep) for 5 minutes to allow the flavors to fully infuse.

• Garlic Flavor: Salt + Sugar + MSG + Garlic Powder + a small amount of aromatic spices.
• Crab Roe Flavor: Salt + Sugar + MSG + Crab Roe Powder + Cornstarch.
• Original Flavor: Salt + a small amount of Sugar + MSG.

 

VII. Cooling + Sorting

1. Air-Cooling Conveyor: Cool the product down to **≤30°C**. It is critical that the product cools completely; otherwise, it will lose its crispness and become soft after packaging.
2. Color Sorting + Manual Inspection: Remove burnt pieces, broken beans, and discolored kernels to ensure that every single piece is uniform in appearance and visually appealing.

 

VIII. Metal Detection + Packaging

1. Metal Detector: Scan for the presence of any metal fragments (a mandatory step for food safety compliance).
2. Automatic Weighing and Nitrogen-Flushed Pouch Sealing (Note: This is *not* vacuum packaging; nitrogen flushing better preserves crispness, prevents oxidation, and protects against flavor degradation).
3. Pack into outer cartons and transfer to storage; store in a cool, dry place.

 

1. Key Differences from Ordinary Fried Peas (One-Sentence Summary)

• Ordinary: Dry Beans → Soaking → Direct Frying → Salt Sprinkling → Large cracks, fragile texture, prone to becoming soft, and limited flavor variety.
• Premium: Carefully Selected Beans → Soaking → Shaping → Multi-Stage Temperature-Controlled Frying → Oil Removal → Coating + Seasoning → Cooling & Nitrogen Flushing → Round and intact shape, vibrant green color, superior crispness, highly resistant to becoming soft, and a richer, more consistent flavor profile.

 

Written by लिली डिंग

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