On-site Planning
Installation & Commissioning
Automated & Energy Efficient
Client Name: V****H Group – Snack Foods Division
Country: Socialist Republic of Vietnam
Region: Duc Hoa, Long An Province – Western industrial corridor of Ho Chi Minh City, high-quality rice producing area in the Mekong Delta
Core Products: Garlic rice crust, chili shrimp flavor rice crust, coconut rice crust, barbecue flavor thick-cut rice crust
Equipment Configuration: Hadof custom twin-screw extrusion forming + fully automatic oil bath frying line (capacity 500kg/h, including continuous seasoning drum and pre-made bag packaging integration)
Commissioning Date: Q1 2024
Vietnam is the world's second-largest rice exporter, and Long An Province, as the gateway to the Mekong Delta, boasts abundant high-quality indica rice resources. V****H Group is one of the largest agricultural processing companies in southern Vietnam, long engaged in primary rice processing and export. In response to the government's policy of "deep processing of agricultural products," V****H decided to utilize its own broken rice raw materials to enter the snack food market, with rice crust being the flagship product. However, in exploring industrial production, they encountered challenges that traditional processes could not overcome:
Difficulty achieving both flavor and crispiness: Vietnamese consumers prefer rice crust with a strong rice aroma that is crispy without hurting the teeth. Traditional handmade rice crust is either too hard or absorbs too much oil, becoming greasy and softening quickly within the shelf life.
Inconsistent shape and high breakage rate: Traditional handmade pressing and slicing results in uneven thickness, leading to varying degrees of doneness during frying – thin pieces burn, thick pieces remain undercooked. Breakage rate during packaging and transportation once exceeded 15%.
Seasoning adhesion and flavor penetration: Popular Vietnamese flavors like shrimp and garlic require large amounts of seasoning powder, but the oil film on the surface of fried rice crust causes the powder to fall off, resulting in uneven flavor distribution and poor batch stability.
Variability in rice varieties: The amylose content of rice harvested in different seasons in the Mekong Delta fluctuates significantly. Fixed formulations resulted in dough that either fell apart or was too hard to fry through.
The technical director of V****H Group had visited several rice crust equipment manufacturers in China before ultimately choosing Hadof. We not only provided equipment but also stationed process engineers at the site for three weeks to test rice characteristics from different seasons, developing this industrial rice crust line specifically designed for "Vietnamese rice + Southeast Asian flavors."
1. Twin-Screw Extrusion + Three-Stage Temperature Controlled Gelatinization – Precise Control of Rice Aroma and Crispiness
To address the issue of amylose fluctuation, we designed a twin-screw extrusion system. By adjusting screw speed and barrel temperature (Zone 1 80°C, Zone 2 100°C, Zone 3 130°C), different batches of rice can be fully gelatinized. The extruded dough has a smooth surface and uniform density, completely eliminating the raw rice taste associated with traditional processes. After frying, the rice crust forms a uniform microporous structure internally, increasing crispiness by 60% without being harsh on the teeth.
2. Ultrasonic Cutter + Pneumatic Shaping – Regular Shape, Breakage Rate < 2%
Traditional mechanical cutters are prone to sticking and deformation. We introduced ultrasonic cutting technology, where the high-frequency vibrating blade creates a smooth cut without chipping, controlling thickness error within ±0.2mm. A pneumatic vibration shaping section before frying ensures each piece enters the fryer flat, achieving a finished product integrity rate of 98.5% and reducing breakage during packaging and transportation to below 2%.
3. Dual-Zone Variable Pressure Frying – Oil Content Reduced by 6%, Shelf Life Extended to 9 Months
Considering Vietnam's hot and humid climate, we designed the frying section with atmospheric pressure and micro-pressure zones: Zone 1 at atmospheric pressure 175°C for rapid shaping; Zone 2 at micro-pressure 0.02MPa 155°C for dehydration. This variable pressure process allows surface oil to be blown off by high-pressure steam before exiting the fryer, reducing oil content from 32% to 26%. Combined with subsequent intense cooling and dehumidification, the water activity of the rice crust drops below 0.35, maintaining crispiness for 9 months even during the Mekong Delta rainy season.
4. Vacuum Continuous Seasoning + Flavor Lock System – Rich, Long-Lasting Shrimp and Garlic Flavors
We configured a vacuum seasoning drum: under -0.06MPa negative pressure, seasoning powder penetrates into the micropores of the rice crust with the airflow, rather than just adhering to the surface. After seasoning, microwave sterilization instantly locks in the flavor, increasing flavor retention by two times. During the 2024 Vietnamese New Year peak season, V****H used this line to simultaneously produce garlic, shrimp, and barbecue flavor rice crusts, achieving a daily output of 12 tons with zero cross-contamination.
Capacity and Quality Leap
Daily capacity: From 1.5 tons/day on the pilot line to 10 tons/day on the automated line (two shifts), capable of running continuously for 25 days without quality fluctuations. Total production in the first half of 2024 exceeded 1,600 tons, with product qualification rate rising from 82% to 97%.
Channel Breakthrough
The low oil content and fully enclosed stainless steel production environment helped V****H rice crust successfully pass Vietnam's food safety certification and ASEAN Halal certification. "V****H Rice Crisps" are now available in Big C, Co.opMart, and other major supermarkets across 32 provinces in Vietnam, and are exported to Cambodia, Thailand, and Laos, becoming a leading Vietnamese rice crust export brand.
Economic Benefits
Return on Investment: The General Manager of V****H Group's Snack Foods Division stated: "The semi-automatic line required 18 people per shift; now this line needs only 4. We save over 2.5 billion Vietnamese dong annually in labor costs alone. Combined with lower oil consumption and higher yield, the actual payback period is under 14 months."
Product Premium: The industrial stability allows V****H rice crust to sell at a price 25% higher than similar products on the market, yet it remains in high demand, serving as a successful model for V****H Group's transformation from agricultural raw materials to high-value brands.
"Hadof's equipment showed us that the value of Vietnamese rice goes beyond exports. Now every piece of rice crust carries the aroma of Mekong Delta rice and the crispiness of modern technology. This is our confidence to enter the international market."
—— Tr?n V?n Hùng, Deputy General Manager, V****H Group
