Dry Roasted Hazelnuts

Introduction:

From rich savory flavor to plentiful health benefits, dry roasted hazelnuts are a versatile flavor addition to any meal. How do these wonder-nuts make their way from the farm to a dinner plate? Here we’ll detangle the process of dry roasting hazelnuts, from harvest to ready-to-eat snack. We’ll offer an overview of how hazelnuts are harvested, cleaned, descaled, shelled, dry roasted, packaged, and distributed on their way to a dinner plate.

Harvesting Hazelnuts:

Hazelnuts, also known as filbert nuts, are the sweet and flavorful fruit of the hazel tree (Corylus Avellana). They are generally harvested either with a machine or by hand. During the harvest, the machine shakes the trees to drop the nuts. This can damage the nuts and the trees, so careful management and an experienced hand ensure the highest-quality nuts get to the market. Careful selection is paramount: nuts that are too ripe or too immature must be discarded. Handpicking is slightly gentler and produces fewer damaged and defective nuts, but the process is more labor-intensive than using a machine.

Once the nuts are harvested, they must be picked up and sorted for processing. During this stage, the quality of the nut is assessed—cracked nuts, unusually shaped, or shriveled nuts are rejected. Modern sorting machines utilize optical-sorting tips, size profiles, and software to prepare hazelnuts for processing.

Cleaning and Prepping Hazelnuts For Processing:

Once the nuts are harvested and sorted, they must then be washed, dried, and stored properly for processing. Cleaning and preparing hazelnuts comprises two processes: descaling and shelling.

Descaling is the process of removing the thin outer layer from the hazelnuts. For industrial processing, there are several methods to descale hazelnuts. Boiling and vibrating are two traditional methods that have been largely replaced by more efficient systems such as jets of air and hot-air cabinets. Descaling is important because it makes the nuts easier to shell, removes any dirt or detritus, and makes them easier to roast evenly.

The second step of prepping hazelnuts is shelling, which involves the physical removal of the nut’s outer membranes. Certain nuts, like smaller varieties, are difficult to remove with traditional hand shelling techniques. Therefore, mechanical cracking is used to ensure consistency across large batches.

Industrial Dry Roasting:

Once prepared, hazelnuts can be dry roasted. Dry roasting is a low-moisture method where heat is used to cook the nut to bring out the nutty characteristics and make the nut easily edible. Dry roasting generally takes place in either a drum roaster or a conveyor-belt roaster; depending on the size of the batch, companies may utilize a combination of both.

Dry roasting can take anywhere from 10 minutes (for wetter, timber varieties) to 40 minutes (for drier, burgeon varieties). As the nuts cook, they release an aroma that tells if the batch has been overcooked or if the flavor has reached its desired profile.

Cooling the Roasted Hazelnuts:

One of the most important aspects of any dry-roasting process is the proper timing of cooling. Once the roasting temperature is reached, the nuts are spread out in a single layer, allowing them to cool quickly and evenly. If the nuts are allowed to cool too slowly, it can induce overheating and yield an undesirably bitter flavor.

Packaging:

Once cooled, the dry roasted hazelnuts are put into packaging for distribution. There are a variety of different packaging methods. Prepackaged bags are popular for in-store sales and one-way distribution, while bulk packages are better suited for applications like gift boxes or large restaurant orders. Manufacturers typically supplement their packages with oxygen absorbers to help maintain freshness.

Distribution and Delivery:

This is where the finished product is ready to be shipped out. Hazelnuts can be shipped via freight or in food-grade plastic bulk containers. Because of their high protein and omega-3 fat content, hazelnuts are a potentially hazardous food, so they must be kept cooled to an acceptable temperature during transit to prevent spoilage.

On the dining table:

Dry roasted hazelnuts are the perfect addition to a variety of recipes. They can be tossed into salads, added to roasted vegetables, or used as a fragrant topper for desserts. Crushed hazelnuts can be incorporated into muffin batters and stirred into ice cream for a crunchy twist. Their sweet and creamy flavor, combined with a subtle nuttiness, makes them a favorite among cooks.

Conclusion:

Dry roasted hazelnuts are a delicious, healthy snack with a range of culinary uses. In order for these exquisite morsels to make it to the dinner plate, they must first pass through a carefully managed process of harvesting, cleaning, descaling, shelling, dry roasting, packaging, and distributed. This complex journey, along with the unique flavor and abundant nutritional benefits it brings, is just one of the reasons why the humble hazelnut has become a dietary staple.