Brazil nuts are a delicious and nutritious snack that many of us enjoy. But have you ever wondered how they are shelled commercially?
In this article, we will take a closer look at the process of shelling Brazil nuts, from the moment they arrive at the factory to the moment they are packed into cartons ready for export.
Join us on this journey through the Amazon forest and discover the fascinating world of Brazil nut processing.
How Do They Shell Brazil Nuts Commercially
The journey of a Brazil nut from the forest to your plate is a long and complex one. After weeks of hard work collecting the nuts, they arrive in Riberalta by truck or riverboat barges. Once they reach the factories, the raw in-shell nuts are received in large sacks with a high humidity level.
The first step in shelling Brazil nuts commercially is to calibrate them into tiny, midget, medium, and large sizes, which is the international sizing format for Brazil nuts. Once calibrated, the nuts are sent to the Autoclave, a large heated cylinder that begins the drying process and helps to separate the protective nut shell from the nut kernel.
Traditionally, most processing factories have used the hand cracking method. However, more recently, several plants have converted to a mechanical cracking system to remove the individual nut shells from the kernels. Hand cracking is a significant source of employment for many families in the town, with each family unit employed and rotating on shifts to crack the nuts and earn an income.
Mechanical cracking systems provide increased throughput in the factory and save on labor costs in the long term. However, hand-cracked nuts are seen by many as being of better quality because they result in less damage to the kernel when compared to mechanically cracked nuts.
Once cracked, the kernel materials pass through several quality control lines where teams of women work to hand-select out ‘chias’ – rotten or damaged nuts. The majority of factory employees are women as men tend to be out collecting the nuts in the forest.
The kernel materials also pass under aflatoxin lights. Aflatoxin is a bacteria mold that can grow on nuts when there is prolonged exposure to wet conditions. These conditions are characteristic of the forest floor of the Amazon, so it is important that collectors recover the nut pods from the forest at the right time. This is a critical part of the production process because to allow export and import of Brazil nut materials, aflatoxin levels need to be within a specified range.
Next, the kernels are dried in metal trays for anywhere between 15 to 20 hours at high temperatures to take the humidity level down to a moisture level of about 4.5%. After another check for kernels with defects and one more aflatoxin check, the goods come off the production belt and enter the packing room.
Kernels are packed into 44LB cartons, ready for export. The export journey begins in Riberalta where trucks full of finished goods travel the 3 to 4 day “good weather” journey to La Paz to be warehoused in El Alto, a natural cool store at 4800 meters. La Paz is the export hub where all documents are prepared before the containers leave to travel to the port of Arica in Chile.
Introduction To Brazil Nuts And Their Harvesting
Brazil nuts are a type of nut that comes from the Brazil nut tree, which produces fruit almost exclusively in pristine forests. Large-bodied bees are the only ones capable of pollinating the tree’s flowers, making it difficult to harvest the nuts from disturbed forests. The fruit takes 14 months to mature after pollination, and it is a large capsule resembling a coconut endocarp in size and weighing up to 2 kilograms. The capsule contains eight to 24 wedge-shaped seeds packed like the segments of an orange, known as Brazil nuts. The seeds are planted by large rodents like agoutis in caches during the wet season, and young saplings may have to wait years for sunlight to reach them before they start growing again. Capuchin monkeys have also been reported to open Brazil nuts using a stone as an anvil.
The harvesting process for Brazil nuts is a long and complex one. After many weeks of hard work collecting the nuts from the forest, they arrive in Riberalta by truck or riverboat barges. Once they reach the factories, the raw in-shell nuts are received in large sacks with a high humidity level. The nuts are then calibrated into tiny, midget, medium, and large sizes before being sent to the Autoclave to begin the drying process and separate the protective nut shell from the nut kernel.
The traditional method of shelling Brazil nuts is hand cracking, which is a significant source of employment for many families in the town. However, more recently, several plants have converted to a mechanical cracking system to remove the individual nut shells from the kernels. Once cracked, the kernel materials pass through several quality control lines where teams of women work to hand-select out rotten or damaged nuts.
The harvesting process also involves checking for aflatoxin levels, which is a bacteria mold that can grow on nuts when there is prolonged exposure to wet conditions. As such, it is critical that collectors recover the nut pods from the forest at the right time. Once the kernels are dried, they are packed into cartons ready for export, with the export journey beginning in Riberalta and ending in the port of Arica in Chile.
Sorting And Cleaning The Brazil Nuts
Sorting and cleaning the Brazil nuts is a crucial step in the commercial shelling process. After the nuts are cracked, they go through several quality control lines where teams of women work to hand-select out ‘chias,’ which are rotten or damaged nuts. This meticulous process ensures that only the best quality nuts make it to the next stage.
The majority of factory employees are women, as men tend to be out collecting the nuts in the forest. These women work diligently to remove any damaged nuts and ensure that only the best quality kernels move on to the next stage.
The kernel materials also pass under aflatoxin lights, which detect bacteria mold that can grow on nuts when there is prolonged exposure to wet conditions. These lights are a critical part of the production process because they ensure that Brazil nut materials meet the necessary aflatoxin levels for export and import.
Once sorted and cleaned, the kernels are dried in metal trays for up to 20 hours at high temperatures to reduce the humidity level to about 4.5%. This ensures that the nuts are safe for consumption and can be stored for longer periods without spoiling.
After another check for kernels with defects and one more aflatoxin check, the goods come off the production belt and enter the packing room. The kernels are packed into 44LB cartons, ready for export. The export journey begins in Riberalta, where trucks full of finished goods travel the 3-4 day “good weather” journey to La Paz to be warehoused in El Alto, a natural cool store at 4800 meters. La Paz is the export hub where all documents are prepared before the containers leave to travel to the port of Arica in Chile.
Preparing The Nuts For Shelling
Before Brazil nuts can be shelled commercially, they must first be removed from their outer husks. The nuts are then placed in a machine that uses a large rotating wheel to crack them open.
However, before they can be cracked, the nuts must be soaked in water for 24 hours to soften the shell. After soaking, the nuts are then immersed in boiling water for five minutes, which further softens the shell and makes it easier to remove.
The shells can then be removed from the nut quite easily by either hand or machine. However, it is important to note that the shells of Brazil nuts contain high levels of aflatoxins, which are produced by molds and can cause liver damage and cancer if consumed.
Therefore, unshelled Brazil nuts should be kept in an airtight container in the refrigerator or freezer to prevent mold growth. It is also important to note that because of the high oil content of Brazil nuts, storing them for an extended period of time can cause them to become rancid.
The Shelling Process: Mechanical Vs Manual
The shelling process of Brazil nuts can be done either manually or mechanically. Traditionally, most processing factories have used the hand cracking method, which involves a whole family unit sitting at one cracking table where they rotate on shifts, each taking their turn to crack the nuts and earn an income for their families. Hand-cracked nuts are also seen by many as being of better quality because they result in less damage to the kernel when compared to mechanically cracked nuts.
However, more recently, several plants have converted to a mechanical cracking system to remove the individual nut shells from the kernels. This system provides increased throughput in the factory and saves on labor costs in the long term. The most common method is to use a machine that cracks the nuts open and then separates the shell from the kernel. Other methods include using a hand-held tool to crack the nuts open or using a hammer to break the nuts open.
Regardless of the method used, once cracked, the kernel materials pass through several quality control lines where teams of women work to hand-select out ‘chias’ – rotten or damaged nuts. The majority of factory employees are women as men tend to be out collecting the nuts in the forest.
It is important to note that regardless of the method used, shelling Brazil nuts commercially is a critical part of the production process because it helps to separate the protective nut shell from the nut kernel. This separation allows for further processing and quality control measures to ensure that only high-quality kernels are packed into 44LB cartons, ready for export.
Removing The Inner Skin And Sorting The Kernels
After the Brazil nuts have been cracked and sorted, the next step in the shelling process is to remove the inner skin from the kernels. This is done to enhance the nut’s flavor and texture. The inner skin is a thin, papery layer that covers each kernel.
To remove the inner skin, the kernels are first soaked in warm water for several hours. This softens the skin and makes it easier to remove. Once soaked, the kernels are then placed onto a conveyor belt that passes under a series of rotating brushes. The brushes gently scrub away the inner skin, leaving behind a smooth and shiny kernel.
After the inner skin has been removed, the kernels are sorted once again to ensure that only high-quality nuts are packed for export. This sorting process is done by hand, with teams of women carefully checking each kernel for any defects or imperfections. Any damaged or discolored kernels are removed from the batch.
Once sorted, the kernels are ready to be packed into 44LB cartons for export. The packing process is done carefully to ensure that the nuts are not damaged during transportation. The cartons are then loaded onto trucks and transported to La Paz for export.
Packaging And Exporting The Brazil Nuts
After the kernels have been dried and checked for quality, they are packed into 44LB cartons, ready for export. The packaging process is crucial to ensure that the Brazil nuts remain fresh and intact during transportation. The cartons are made of sturdy materials to protect the nuts from damage and are sealed tightly to prevent moisture from getting in.
The export journey begins in Riberalta, where trucks full of finished goods travel the 3 to 4 day “good weather” journey to La Paz. The nuts are warehoused in El Alto, a natural cool store at 4800 meters, which helps to maintain their freshness. La Paz is the export hub where all documents are prepared before the containers leave to travel to the port of Arica in Chile.
Once the containers arrive at the port of Arica, they are loaded onto ships and transported to their final destination. Brazil nuts are exported all over the world, with the largest importers being the United States and Europe. The demand for Brazil nuts is high due to their unique flavor and nutritional value.
In conclusion, packaging and exporting Brazil nuts is a crucial part of the production process, as it ensures that the nuts remain fresh and intact during transportation. The journey from the forest to your plate is a long one, but it is worth it for the delicious and nutritious Brazil nuts that we enjoy.