Visit a Mahuva plant during the main production season, follow the onion from the gate to the packed carton, and check each step against your specification. Look at hygiene, drying control, foreign body control, the lab and the records that link a lot back to its raw material.
A plant that looks quiet in the off season can look very different at full speed. Plan your visit for roughly February to May, when most plants are drying fresh onion. Our general guide to what a factory audit should contain gives the wider checklist.
Before the visit
- Ask for the plant's certificates, HACCP plan and product list.
- Ask which products are made on site and which are bought in from other plants.
- Ask for recent lab reports for the products you want.
- Agree that you can see every area, including drying, milling and storage.
- Bring your specification so you can compare it with what you see.
Raw onion intake and preparation
- Where does the onion come from, and is there a record of each supplier and lot?
- Is raw onion stored off the ground, covered and away from the process area?
- How are onions peeled, and how are roots and tops removed?
- Is wash water treated and tested, and is the level of any chlorine or other agent controlled?
- Are slicers clean, maintained and checked for broken blades?
Drying
Most Mahuva plants use multi-stage belt dryers. Ask how temperature is controlled and recorded in each stage, and how often moisture is checked at the dryer outlet. Poor control causes browning and high moisture, which are covered in our articles on browning and moisture levels.
Check that the area around the dryer is enclosed and clean. Open sides let in birds, insects and dust. Look for any sign of sun drying on open ground, which some lower-grade product may still see.
Milling, sorting and packing
- Sieves and screens: are they intact, and is there a record of checks for broken mesh?
- Magnets and metal detectors: where are they, how are they tested, and what happens to rejects?
- Colour sorters or hand picking tables: are they used for the grade you want?
- Packing room: is it separate, clean and controlled for people, hair and pests?
- Labels: does each carton carry a lot number that matches the plant's records?
Lab, storage and records
Look at the in-house lab. It should test moisture, particle size and appearance on each lot at least. Micro and residue tests are usually sent to outside labs. Ask to see real recent results and compare them with external reports.
Check the finished goods store for pallets, temperature, humidity and pest control. Then pick one finished lot and ask the plant to trace it back to its raw onion and dryer records. If they can do that quickly, the system works.
How we help
We are close to Mahuva and audit dehydration plants in season, with photos, a written report and sealed samples sent to an NABL-accredited lab. You get the real factory name and the original lab reports. To arrange an audit, ask for a free sourcing review.