How IS makhana made

Introduction

Makhana is a highly nutritious and versatile product that has been gaining popularity globally. This comprehensive guide delves into the detailed process of makhana production, from water lily germination to seed collection to the final product ready for consumption. Making the makhana is an intensely long tough and skilled labour intensive process, resulting in high market price.

1. Water Lily Seed Formation

Makhana, commonly known as fox nuts, are derived from an aquatic crop, the water lily. The fields where the cultivation is supposed to happen is filled up with 1.5 feet of water. Seeds are sown in December. As the new year progresses, these seeds sprout, and by January and February, the initial growth is evident with leaves surfacing on the pond. Farmers must also ensure that an optimum water level of 1 ft. height is maintained throughout the growing period of seedlings. Within two months, large thorny leaves form a dense cover over the water. Flowering of the water lily plant starts in April and peaks during May.

Mid-May marks the start of the fruiting period, with each plant yielding 6 fruits and an average of 75 to 125 water lily seeds, commonly called makhana seeds. When summer comes the fruits start to rot and release the makhana seeds inside the water itself. These makhana seeds, once released into the water from the burst fruits, float temporarily before descending into the pond's bottom. After the fruiting phase, the vast leaves are either removed or left to decompose in the water, naturally enriching the soil. The makhana seeds, now resting at the pond's base, are manually collected from August to October. This collection process involves deep diving and is quite labor-intensive.

2. Scraping of makhana seeds from lake bottom:

Approximately one month after sowing, water lily seeds or makhana seeds in the soil reach the optimal stage for harvesting from the muddy waters. However, it's important to note that not every makhana seed is suitable for harvest; some may be malformed or not fully matured. Simultaneously, it's crucial to harvest the mature makhana seeds promptly. If left in the pond for too long, they lose their ability to pop, a key quality for Makhana.

Harvesters skillfully gather the makhana seeds by hand as they float to the surface, guiding them into a specially designed basket known as a 'Gaja'. This basket plays a crucial role in both cleaning the seeds and separating them from the surrounding mud. Or they may need to be scooped out from the bed of the pod with the help of a horn shaped split bamboo. Farmers engaged in Makhana cultivation typically yield an impressive 100 to 200 kilograms of seeds daily. Despite these meticulous efforts, collecting every single makhana seed from the pond remains an unattainable goal. The nature of makhana seeds, being small and heavy, adds to the challenge. Some of these dense seeds inevitably sink to the bottom of the pond, eluding the farmers and remaining hidden in the depths. This aspect of the harvesting process underscores the inherent difficulties and complexities in efficiently gathering these aquatic seeds.

The harvesting of water lily seeds, from which Makhana is derived, is generally conducted in two distinct phases each season. The second phase of the harvest proves to be more challenging due to the reduced availability of seeds. During this phase, laborers are tasked with meticulously searching for seeds missed in the initial harvest, often hidden deep in the mud. While the first harvest might bring in up to 150 kilograms of seeds, the second phase often results in a significantly lower yield, sometimes as little as 10 kilograms.

3. Cleaning and Drying the Seeds :

The meticulous cleaning of makhana seeds (aka water lily seeds), often found nestled at the pond's bottom, is more than just a routine procedure; it's a crucial step in quality assurance. Surrounded by natural elements like mud, dirt, seashells, and aquatic plants, these seeds require thorough cleaning to achieve the desired purity. This process is not just a mere task but a significant determinant of the final product's quality. Overlooking this step is not an option when striving for excellence. Each seed's journey from the depths of the pond to the final product is marked by this essential cleaning phase, ensuring that only the best, most pristine makhana seeds make their way to consumers.

After cleaning, the water lily seeds are sun-dried, reducing moisture by up to 20%. After drying for about two hours in the Sun, their inside turns starchy. Now the quality and amount of Sunlight will determine whether the makhana seeds will pop or not.

4. Two Stage Roasting of dried seeds :

Initial Gentle Roasting

Use of Clay Pan: The first stage of roasting is carried out in clay Pan. Why clay and not iron? Its slow heating property is perfect for the delicate makhana seeds, preventing burning which is a risk with faster-heating iron woks.
Temperature Management: Controlling the temperature is key. The makhana seeds are fragile and can't endure high heat, making the choice of the Pan material crucial. The sun-dried water lily seeds are generally heated in cast in clay pan by placing them over fire and stirring them continuously. The surface temperature of the pan varies from 250° C – 300° C and time for heating is nearly 5 to 6 minutes.

Resting Period, also known as tempering

Post-Roast Rest: This phase allows the seeds to acclimatise and prepare for the next stage of roasting. The heated seeds need to be kept in appropriate conditions for up to three days, also known as the tempering of foxnut seeds. This process helps in loosening the kernels within the hard seed coat.

The Second Roasting

Iron Woks for Strength: Now that the seeds are more resilient, they are transferred to iron woks. The choice of iron here is deliberate – it evenly distributes heat, essential for the popping process.
Gradual Heating: The foxnut seeds are carefully heated in a series of iron woks, ensuring each seed reaches the optimal temperature for popping. Now the foxnut seeds become ready for the grand moment - POP.

5. Popping of the roasted seeds :

Listening for the Pop

The Sound of Readiness: A barely audible crackling sound signals that the makhana seeds are ready to pop. This sound is a critical indicator for the workers.

Technique and Skill

Popping with a Wooden Hammer: Workers use a special wooden hammer to pop the seeds. The process requires skill and precision, as each seed may need a different level of force to pop. Once the foxnut seeds begin to crackle, they are kept on a hard surface and hit with the wooden hammer. The seed coat then breaks due to pressure and the inside whitish kernel pops out from the black seed.

Efficiency in Popping

Yield from Roasting: Not all seeds pop – in a batch of 100 kg, only about 35 kg will transform into high-quality makhana.

6. Polishing and Grading :

Polishing the makhana prepares them for the market with an appealing, glossy look. After that, the makhana are graded by a sieve based on their sizes after popping. The size is measured in a unit of measurement called 'Suta', where 1 Suta = 3.17 mm. So a 3 Suta makhana will be roughly 9.51 mm in diameter. More the Suta, higher the price of the makhana. At Sounak Global, we only deliver the highest and best quality makhana to out international clients. So we pick the 5 Suta makhana only and prepare them for shipping abroad. Handpicking is essential even among the 5 Suta makhana, since given the huge size of Sounak Global makhana, a significant percentage of the 5 Suta makhana tend to get flattened out due to pressure. Using our skilled handpickers, we eliminate all such makhana which tend to get flattened, and only keep the nice round ball shaped ones for the delight of our international customers.

7. Roasting in a Rotary Roaster:

Why again roasting ? Wasn't it already roasted ? You bet it was. But that was for the purpose of popping the black seeds to reveal the inner whitish kernel. Now we need to make this foxnut crunchy. For this, we again roast the foxnut into a rotary roaster. The rotary roaster operates with a continuous tumbling action. This motion ensures that the foxnuts seeds are evenly exposed to heat, preventing them from sticking to each other or to the surface of the roaster. The temperature within the rotary roaster is precisely controlled. Typically, makhana is roasted at temperatures ranging from 180°C to 200°C (356°F to 392°F), but this can vary based on the specific type of roaster and desired crispiness. After roasting for 10 to 15 minutes, the foxnuts are cooled down to room temperature.

8. Flavoring of Roasted Makhana :

Selection of Flavors: Decide on the flavors to be used. Common choices include salt, pepper, cheese, herbs, chili, garlic, onion, and even sweet flavors like honey or cinnamon.
Mixing Ingredients: Prepare the seasoning mix by combining the chosen ingredients. The proportions depend on the desired flavor intensity and the specific recipe being used.
Applying the Seasoning: The foxnut is loaded in batch in a large drum or tumbler similar to the Rotary Roaster. A liquid form of seasoning, often mixed with a small amount of oil or water, is sprayed onto the foxnut as it rotates inside the tumbler. As the drum rotates, the makhana gets evenly coated with the seasoning. In our manufacturing unit, we always use best quality Olive Oil for the seasoning purpose.
Air Drying: After seasoning, the foxnuts are left to air dry to ensure the flavors are well-absorbed and the texture remains crisp.

9. Packaging & Exporting Worldwide:

We understand that packaging play a pivotal role in reaching international markets. We always ensure that the packaging design resonates with the cultural and aesthetic preferences of the target market. Sounak Global always chooses high-quality, durable packaging materials that can withstand long transit times and varying environmental conditions, combined with nitrogen flushing and airtight sealing to ensure that the makhana inside remains crisp and tasty for 12 months. Needless to say, Sounak Global adheres to the food safety and handling regulations specific to each target country for exporting purposes.