Discover the Protocols of

Plantation, Production & Hygiene Protocols

STEP 1

Organic Farming Compliance

Organic farming ensures agricultural activities promote and enhance biodiversity. The main objective is to give the best produce to the consumer.

PIJ Manufacturing Sdn Bhd practices stringent organic farming protocols by efficiently managing :

  • Climate and growth area
  • Cultivation method
  • Transport usage in the farm
  • Drainage and irrigation system
  • Offshoots replanting
  • Productivity schedule
  • Periodical soil check
  • Plant nutrient level

STEP 2

Eco Friendly Harvesting Technique

Harvesting is usually done by hand with a knife, which a small incision made to the bottom of the leaves.

The harvested leaves are processed the same day latest within 24 hours to ensure the optimum presence of the enzymes.
Depending on the growth of the plants, it may be possible to harvest around 3 to 5 times per year.

The optimal number of harvests per year is dependent on various local factors but only the mature plants and largest leaves are cut during harvesting.
STEP 1
Only selected mature leaves are harvested 		STEP 2
A small incision is made to separate the leaf from the plant 		STEP 3
The harvested leaves are ready for collection
     
     
 STEP 4
Leaves then placed in a basket and gathered at collection point		  STEP 5
Baskets of leaves are loaded to the truck		  STEP 6
Leaves transported to the weighing area.




         
 STEP 7
Each basket weight is recorded prior leaving the farm		        

STEP 3

Green Approach Disinfectant Method

When the leaves reached the factory, it is crucial to abide to the strict procedures for cleaning and disinfecting. Green approach disinfectant method is used to prevent harm to the workers as well as the environment.

The harvested leaves first must be washed thoroughly one by one to ensure they are free from soil and dirt. These leaves later will be cut at the stem and soaked in a disinfectant solution.
STEP 1
Arrange the leaves for cleaning process 		STEP 2
Antimicrobial soaking treatment 		STEP 3
Clean the leaves
 
STEP 4
Brush the leaves 		STEP 5
Cut the bottom of the leaf		 STEP 6
Soak the leaves again

STEP 4

Aloin Bleeding & Removal Procedures

Subsequent to Step 3, the leaves must undergo an aloin bleeding and removal process. Aloin is a purple substance of Aloe Vera that has a laxative effect and taste bitter which is undesirable in the end product. Therefore, it is important to have it removed. The removal process involves cutting the underside of the leaves and straining them for about an hour.

STEP 5

Leaves Cutting Prior AGS Machine

After bleeding and removal, the leaves undergo another cutting process to remove the spiky sides, top and bottom of the leaves. This ensures the unwanted parts are removed prior to extraction.

STEP 6

AGS Machine Solid Gel Separation Phase

PIJ Manufacturing Sdn Bhd is privileged to be equipped with state of the art Aloe Gel Separator (AGS) machine from Holland.

The machine embodies cutting edge technology and has proven to be efficient, reliable and capable of producing the best grade for food, beverage, cosmetic and pharmaceutical applications product.

Our company is ranked 6th in the world for companies adopting the technology and is the 4th Generation of its kind. It is highly efficient and able to extract up to 47% pure gel from matured leaves.

STEP 1
Leaves are inserted into the AGS to extract the aloe gel 		STEP 2
The unwanted skins are separated from the gel 		STEP 3
AGS ensures the leaves are properly pressed
     
 
STEP 4
The luxury thick gel appears 		STEP 5
AGS extracts up to 47% gel from a mature leaf		  

STEP 7

Sterilization and Preservation Process

Sterilization and Preservation processes are paramount to eradicate the risk of bacteria, viruses and cross-infection. Failing to follow these steps can ruin the end product quality. Every piece of equipment that comes in contact with the concentrate must go through these stringent processes.



STEP 8

Advanced Filtration Technology

The next important phase is filtration. The initial step is course filtration to remove lumps that are still intact in the gel. Next is the floatation separation process which separates the unwanted coarser fibres from the smaller ones.

 The phase continues with colloid filtration to remove microfibers and colloid. This is the final filtration to ensure the end product is free from impurities and unwanted sediments.

STEP 9

Quality Control and Assurance

At all times, Quality Control and Assurance is the company’s utmost priority. End products from every individual batch will be thoroughly inspected, examined and tested in our in-house lab. Samples are also sent for external laboratory analysis to ensure only safe products are transported out from the factory.

STEP 10

Bottling, Packing & Storage

Ready Product for Sale.

Once the products pass quality control, they are ready for the buyers. These products are stored at room temperature to ensure they met the quoted shelf life.