Annual Production Capacity
Product
| Factory | Wet Konjac Noodles & Rice | Dry Konjac Noodles & Rice | Microwave-ready Konjac Meals |
| Area | 8,000 sqm | 12,000sqm | 100,000sqm |
| Production Lines | 6 lines | 12 lines | 2 lines |
| Annual Capacity | 15,000 tons/year | 18,000 tons/year | 70 million boxes/year |
| Total Manufacturing Base | 120,000sqm | 20 lines | 33,000+ tons + 70M boxes |
Production Process of Dried Konjac Rice
1. Raw Material Intake & Unpacking
All incoming raw materials undergo strict quality control inspections for compliance, safety, and integrity. Once approved, qualified materials are transferred to the clean production area, where outer packaging is carefully removed to prevent contamination prior to processing.
2. Material Crushing & Ingredient Mixing
Dry ingredients (such as rice) are automatically fed into a crushing system and ground into uniform particle sizes. They are then combined with konjac powder, dietary fiber, starch, and other ingredients according to the formula, along with controlled amounts of water, and thoroughly mixed to create a homogeneous mixture for optimal extrusion.
3. Extrusion Molding
The mixed material is fed into the extrusion machine. Different molds are installed according to product specifications. Temperature, pressure, and screw speed are precisely controlled throughout the extrusion process to produce uniformly shaped konjac rice grains.
4. Two-Stage Drying Process
Extruded konjac rice undergoes a precise two-stage drying process to achieve optimal stability and shelf life. The first stage uses low-temperature drying (around 35°C) to gently remove surface moisture while maintaining structural integrity. The second stage gradually elevates temperatures (50–100°C) to further reduce moisture to target finished-product levels.
5. Cooling
After drying, the konjac rice is naturally or mechanically cooled to room temperature before packaging. This prevents condensation inside the package and helps maintain product quality.
6. Packaging Disinfection & Inner Packing
All packaging materials undergo strict sanitation before use to minimize microbial contamination. The cooled konjac rice is then automatically weighed, filled into individual packages per specifications, printed with key details (batch number, dates, shelf life), and securely sealed to guarantee freshness and food safety.
7. Outer Packing
Individual packages are packed into cartons according to customer requirements. Finished products undergo final quality inspection, including packaging appearance, labeling, weight verification, and carton sealing. Qualified products are palletized and transferred to the finished goods warehouse for storage and shipment.
Production Process of Wet Konjac Noodles/Rice
1. Personal Hygiene & Garment Preparation
Before entering the Shirataki Konjac production workshop, all personnel-including staff and visitors-must wear clean, compliant protective outerwear. Hands must be thoroughly washed, sanitized, and blown dry. Hair must be completely secured inside hairnets, and all personal belongings or items unrelated to food production are strictly prohibited in the facility.
2. Air Shower & Hygiene Barrier
Next, everyone must pass through the air shower prior to stepping onto the production floor. This hygiene barrier serves to:
- Prevent cross-contamination between distinct operational zones.
- Ensure strict adherence to food safety standards and regulatory requirements.
- Maintain an ultra-clean, sanitary environment required for high-quality food manufacturing.
3. Mixing, Shaping & pH Adjustment
In this section, high-grade konjac flour is blended with hot water to hydrate and refine the mixture. It is then extruded into specified shapes-such as shirataki noodles or rice-cut to precise lengths, and submerged in soaking tanks to optimize and balance the pH levels.
4. Manual Weighing & Automated Packaging
The product is then weighed to exact customer specifications before entering the automated packaging line. To ensure continuous quality control, our QA team conducts hourly random inspections, verifying net weights and confirming 100% seal integrity on every package.
5. Metal Detection & Pasteurization
Following metal detection, all packaged konjac products undergo high-temperature sterilization on our state-of-the-art pasteurization line. Once pasteurized, the sealed bags are thoroughly rinsed with running water and automatically air-dried.
6. Specialty Crafting: Hand-Tied Konjac Knots
In the hand-knotting workshop, skilled technicians manually tie and weigh each konjac knot into its signature shape before packaging. Konjac knots are exceptionally popular across Asian markets-particularly in China and Japan-where they are a staple ingredient in hot pot dishes.
7. Light Inspection & Secondary Packaging
After the sealed packages are dried, every bag undergoes a visual light-inspection to ensure it is completely free of foreign particles. Workers then assemble the final product, combining the shirataki noodles with sauce packets according to specific order requirements. Specialized packing teams handle different flavors and kit configurations.
8. Warehousing, Final QA & Shipping
Finally, boxed products are transferred to the finished-goods warehouse, where they undergo a mandatory 48-hour quarantine period to monitor for seal integrity or quality defects. Prior to dispatch, our QA team performs a final audit before the products are loaded and shipped to our global clients.
Production Process of Instant Multigrain Noodles
1. Raw Material Inspection & Preparation
Incoming raw materials are inspected and approved, then accurately weighed according to the formula, thoroughly blended into a uniform dry mixture, and fed into the production equipment.
2. Cooking / Gelatinization
The mixed ingredients undergo controlled heating under precise temperature and moisture conditions to improve their processing properties. During this stage, starches gelatinize, while proteins and fibers are fully hydrated, forming a structure suitable for extrusion or molding.
3. Extrusion Forming
The cooked mixture enters the extruder, where it is forced through specially designed dies under mechanical pressure to form noodle strands. By utilizing different molds, noodles of various shapes and diameters can be produced.
4. Hanging / Noodle Arrangement
Freshly formed noodles are arranged and hung on rods or racks. This step maintains the desired noodle shape, prevents deformation or clumping, and improves overall drying efficiency.
5. Drying & Cutting
The formed noodles undergo controlled drying to reduce moisture content and extend shelf life. Once dried, they are precisely cut into specified lengths (e.g., 9cm, 10cm, 13cm, 15cm, or 20cm).
6. Packaging & Storage
Finished noodles are automatically packed using automated equipment and then transferred to the finished goods warehouse.
