Precision At Every Stage
One Process, Engineered For Control
Healthy Foods Egypt processes its crops at a single factory in Egypt, close to the cultivation areas it draws from. Dedicated lines for dehydration, for cutting and granulation, and for herbs and spices processing are kept physically separate to prevent cross-contamination. Running every stage in-house means one supplier covers the full particle-size range with a single, documented chain of custody.
The lines are built around food-contact surfaces in stainless steel type 304, and from dehydration through to sealed packaging the product is conveyed without the touch of human hands. The forms each line can produce are listed on the products hub, and the controls that govern the whole operation are described on the quality hub. Below, the process is shown first as 5 narrative stages, then as the full 14-step flow.
5 Stages, 14 Process Steps
Every batch follows the same documented flow, organised as five main stages that together cover all fourteen monitored process steps.
Sourcing & Receiving
Steps 1-2: Agricultural sourcing, receiving and inspection
Every batch begins in the field. We select crops field-side from the cultivation areas near our facility in Egypt, then inspect each intake at receiving before it enters the line. Agricultural sourcing and receiving inspection together confirm that only sound, fully traceable raw material moves forward.
Cleaning & Preparation
Steps 3-4: Washing and preparation, air separation
Raw material is washed in pure water with no additives, then passed through air separation to lift away dust, skins, and lightweight foreign matter. Washing, preparation, and air separation leave the product clean and uniform before any sizing or sorting begins.
Sorting & Detection
Steps 5-8: Screening and sieving, laser and colour sorting, manual sorting, metal detection
Cleaned product moves through a sequence of quality and safety gates: screening and sieving to grade by size, laser and colour sorting to remove off-colour pieces, a manual sorting check by trained staff, and metal detection calibrated to strict ferrous, non-ferrous, and stainless thresholds. These four steps are where consistency and food safety are proven rather than assumed.
Sizing & Milling
Steps 9-10: Granulation, milling
Product is then cut to the exact particle profile a buyer specifies. Granulation and milling produce everything from bold cuts and kibbled grades through to fine granules and powders, all on dedicated equipment that keeps each output profile repeatable batch after batch.
Packaging & Dispatch
Steps 11-14: Packaging, warehousing, laboratory testing, export and distribution
Finished product is packed in a sealed double-bag system straight off the line, warehoused under controlled conditions, and released only after laboratory testing confirms it meets specification. From there it is loaded for export and distribution to buyers across Europe, North America, and Asia-Pacific.
Every stage of production is monitored through controlled processing systems designed to maintain product integrity, consistency, and food safety.
Specified Machinery, Measurable Safeguards
The dehydration line is built around a 3-stage belt dryer supplied by National Aeroglide, and the herbs and spices line uses sieving, separation, and metal-detection equipment from Allagier of Germany. The choice of named, industrial equipment is deliberate: it makes capacity and performance predictable, and it gives buyers something concrete to audit.
Foreign-body control is one of the most important safeguards on a dried-food line, so it is measured rather than assumed. Across the dehydration line, metal detection is held to defined rejection thresholds and a powerful magnet removes ferrous fragments, as set out in the table. These checkpoints sit inside the HACCP framework described on the quality hub.
| Ferrous | 0.8 mm |
|---|---|
| Non-ferrous | 1.1 mm |
| Stainless steel | 1.2 mm |
| Magnet strength | 12,000 G |
| Food-contact surfaces | Stainless steel 304 |
Built On Dedicated Equipment
Lines are physically separated to prevent cross-contamination between alliums, herbs, and seeds, each engineered for a specific output profile.
Production line
Dehydration
Receiving, washing, slicing, and 3-stage belt drying, engineered to preserve colour, odour, and taste while meeting EU and US import specifications.
Dedicated line, in-house lab tested
Line detail
Production line
Cutting & Granulation
Chopped, minced, granules, ground, and powdered output on dedicated cutting, granulation, and milling equipment, each engineered for a repeatable particle profile.
Dedicated line, in-house lab tested
Line detail
Production line
Herbs & Spices Processing
A complete automated line for herbs, spices, and aromatic seeds, with sterilisation options including ETO, steam, and IRR.
Dedicated line, in-house lab tested
Line detailSee The Lines In Operation
Buyers in active sourcing evaluation are welcome at the Beni Suef facility. Schedule a visit through sales and we'll arrange the audit window around your team's calendar.