Review our 11-step production process

Estate Selection

Carefully vetting and identifying our plantations.

As a vertically integrated manufacturer, we source our conventional coconuts both from our partner estate Noorani and from other registered farms in the area. For organic production, we source from select certified organic estates. All the estates are located in the Sri Lankan Coconut Triangle which is globally recognized for having the most ideal soil and climatic conditions for nutrient-rich coconut growing.

All our product batches offer traceability back to the origin.

Dehusking

Patiently waiting and removing the husks.

After plucking the fully developed coconuts from the trees, coconuts are allowed to mature between 4-6 weeks before dehusking. This process creates a space between the shell and the kernel, which is critical for the coconut processing industry. Before 24-48 hours of processing, the coconuts are dehusked and then delivered to our factory premises with the shell intact.

Sorting

Calmly identifying and sorting our coconuts.

We only allow fresh coconuts into the production process. Rotten coconuts are rejected and set aside for copra coconut buyers. This process is critical so as to not allow the contamination of the batch with a spoilt coconut.

Deshelling

Expertly holding and deshelling the shells.

Our trained deshellers remove the shells carefully using a hatchet and make sure the kernels are kept intact. It is important at this stage that the desheller retains as much of the kernel as possible so as to not have high levels of wastage. If the desheller is untrained or inexperienced, it is probable that a significant amount of the kernel will be discarded with the shell.

Peeling

Gently holding and peeling the testa

Our trained peelers remove the brown testa around the whole kernel, leaving only the white kernel intact. It is important at this stage that the thickness of the testa is no wider than 1.5mm. If the testa is above 1.5mm in width, too much of the white kernel has been peeled alongwith the testa, and this will lead to a yield reduction.

Crushing & Cutting

Immediately crushing and cutting the coconut kernel

We crush/cut the wet white kernel using a stainless steel industrial crusher/cutter with the blade drum adjusted to the required size.

Drying

Correctly drying and reducing the moisture of the desiccated coconut

We then send the wet desiccated coconut through our continuous dryer at or below 60 centigrade celsius / 140 faranheit until the moisture level is reduced to our target levels. As a cold-pressed extra virgin coconut oil manufacturer, this is a critical control point which we closely monitor. It is vital that the temperature does not exceed 60 celsius centigrade / 140 fahrenheit during the drying process in order to retain the natural aroma, taste and the nutrient properties of our extra virgin coconut oil.

Then, we keep the dried desiccated coconut (DC) inside food grade liner bags overnight for the heat to settle.

Expelling

Neatly expelling and separating the oil and the oil cake

We expel the dried DC using a stainless steel expeller. Even at this stage, we monitor the expelling temperature and make sure that the temperature does not exceed 60 celsius centigrade / 140 fahrenheit in order to retain the natural properties of the virgin coconut oil and to obtain non-burnt oil cake.

During this stage, we obtain both unfiltered extra virgin coconut oil and virgin oil cake.

Filtration

Carefully filtering and removing all sediments from the oil.

At this stage, we filter the extra virgin coconut oil using two filtration machines - a casting press and a polypropylene press. As a cold-pressed extra virgin coconut oil manufacturer, this is a critical control point which we closely monitor. It is vital that all sediments are removed from the final product since sediments have a higher propensity to build mould and aflatoxin.

Storage

Neatly storing the coconut oil

The virgin coconut oil is stored inside stainless steel storage tanks prior to the packaging process.

Filling & Bottling

Passionately bottling and pasting the labels

The last step of our production process includes packaging. The bottle and the lid are cleaned and sterilised, the bottle is filled with oil, the net weight is verified, the lid is tightly shut and the shrink sleeve is placed around the lid. As the final steps of the process, the artwork label is placed on the bottle, and the batch code is dominod on the lid.

We export our coconut oil bottles in 5 ply cartons.