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Ever wondered where—and most importantly: how—does the magic at Shafi Gluco Chem happen? If you do, here is the where. Our state-of-the-art manufacturing facility is located in Hub, a small industrial town which is a 30 KM’s ride away from Karachi. At this facility, we make the highest-quality rice syrups and proteins for global transport.
Let us go about the how. Expanding over a series of six steps, our rice syrup is made from the finest ingredients, having undergone all necessary procedures.
We firmly believe in Quality Assurance as it runs the functionality of every business. We employ a completely automatic and bordered way of analysis during production, a periodic counter checker, and means of ensuring consistent quality of all our syrups and solids. Our core strength is in-house research and development. During manufacturing, our group of dedicated engineers and scientists remain continuously involved in R&D and development processes while also simultaneously coming up with ideation for product growth.
The first step is the milling of the rice. Brought from various locations nationally in the country over thousands of miles, the rice we use is of the finest descent and quality. Brought to our facility in trucks, is stored in our environment-friendly silos where it remains safe from any exterior intervention/pollutants and has the capability to last years.
Once an a-okay has been given for production to begin, a required amount of rice is transferred to our milling section not too far from storage. Through a series of conveyor belts, the rice then enters the milling machinery, a ceiling high facility made from a multitude of sub-machines. After rigorous grinding, this rice is turned into flour and sent ahead for step 2.
The rice flour, finely grinded, is then, through some tubes, brought inside glass cylinders with mixing fans at their base. There is, from before, weight of some determinedly cold water in these cylinders. It is with this water that the flour is thoroughly mixed to prepare slurry, which is a semi-liquid mixture that will later on form the base of the syrup.
A controlled, yet highly concentrated, amount of alpha-amylase enzyme is then introduced into the slurry so that all of the rice starch present in the solution is made to go through subsequent hydrolysis. This will prepare the solution for the steps ahead and our rice syrup will have climbed yet another step up.
Once completely liquefied, the slurry is pumped into a set of plate-and-flame filter presses. Here, the “protein cake” made from the previous process is retained. A series of rice solubles, more technically known as liquid effluent, is made to pass through the filter. A receiving tank, set adjacently, collects the entire solution.
The material required is filtered and that which is not needed is left in the first vessel. Filtration plays an important role in the making of rice syrup.
The filtration process gives you the base for forming the rice syrup. Once filtered, the contents are later sent to a boiling chamber of sorts. This forms the center of the entire machine that makes the rice syrup. With heat set to a specific centigrade, this energy efficient evaporation system, that despite the temperature, runs under very high vacuum conditions, concentrates the syrup completely.
Texture is key for rice tapioca. If messed up, it will not be able to give your resulting tapioca the right kind of needed texture. To ensure this, our concentration process is twice invested in than the rest. Once done, the contents of the syrup are sent away for the fifth and final stage.
Not entirely a step in the manufacturing process in its exactitude, packaging, as the name implies, is when the final version of the tapioca is pumped into a batch holding tank. This tank is equipped with agitation to ensure uniformity with the filling of tote bags and gallons that come ahead. From the pumps, through the conveyor belts, 275 Gallon IBC totes, which are placed in corrugated boxes, and 55 Gallon HDPE Drums. This is done intermittently, a tote after a gallon.
Next, we ship our syrup across borders, to our clients.
Shafi Gluco Chem’s syrup manufacturing process, as you read, is a penta-faceted process which ensures that the tapioca syrup obtained at the end of it all is of the finest quality and abides by all the standards that we promise you.
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