Objective: To ensure beans retain peak aroma, moisture, and marketability.
Final Quality Assessment:
Beans should be uniformly dark, slightly oily, and flexible.
Check for any signs of mould or uneven curing.
Grading & Sorting:
Beans are graded based on length, appearance, aroma, and moisture content.
Premium Grade A: <18cm long, plump, highly aromatic, and 35% moisture.
Grade B: Between 14-18 cm long, Slightly drier, thinner (can include beans <18cm long that do not meet A grade quality standards)
C-Grade/Industrial Use: Short, curly or broken beans, used to make extract and paste
Packaging:
Store in zip lock bags with air removed. Label with harvest year, weight and grade of beans
Vacuum-sealed bags for long-term storage*
Storage Conditions: (Aging)
Store in a cool, dark, and dry environment (16-20°C).
Avoid exposure to direct sunlight and excessive heat.
Beans can be aged for many years, improving their complexity and richness.
*Other storage options include; Glass Tubes, jars or wooden boxes for premium retail presentation or Wax paper wraps: allows slow aging and prevents excessive drying.
The packaging phase represents the final critical control point in vanilla processing, encompassing the classification, conditioning, and encapsulation of cured pods for commercial distribution. This process involves precise grading, moisture stabilization, and protective enclosure designed to preserve organoleptic qualities and extend commercial viability.
Standard grading protocols incorporate the following evaluation criteria:
Morphological assessment:
Length categorization: Prime (>15 cm), First (12-15 cm), Second (10-12 cm), Cuts (<10 cm)
Diameter evaluation: Bold (>8 mm), Medium (5-8 mm), Slender (<5 mm)
Structural integrity: Split percentage, tip condition, physical damage quantification
Moisture content verification:
Standard range: 25-30% (optimal commercial parameters)
Premium specialty: 30-35% (enhanced aromatic profile with reduced shelf stability)
Extended storage: 20-25% (maximized shelf life with compromised aromatic complexity)
Organoleptic evaluation:
Aromatic profile categorization
Vanillin crystallization assessment ("givre" or "frost" development)
Flexibility and texture analysis
Pre-packaging conditioning includes:
Final moisture equilibration: 24-48 hour stabilization under controlled humidity (50-60% RH)
Bundle configuration: Organization into standardized units (typically 250g or 500g) bound with specific tying patterns indicating origin and grade
Surface treatment considerations:
Traditional methods: Light application of vegetable oils (typically castor oil) to prevent excessive desiccation
Contemporary approaches: Application of food-grade wax emulsions or specialized coating formulations
Premium/organic protocols: No surface treatment to maintain organoleptic purity
Primary packaging systems include:
Traditional methodologies:
Waxed paper wrapping: Double-layer waxed paper with specific folding patterns
Tin containers: Hermetically sealed metal containers with desiccant inclusion
Vacuum-sealed foil: Aluminum laminate pouches with partial vacuum application
Contemporary approaches:
Modified atmosphere packaging: Nitrogen-flushed high-barrier films
Oxygen scavenger integration: Active packaging incorporating oxygen absorption technologies
Humidity-regulating systems: Bidirectional moisture control materials
Secondary packaging considerations:
Temperature stability provision
Light protection systems
Physical protection methodologies
Tamper-evident mechanisms
Optimal preservation conditions include:
Temperature specifications: Maintenance of 15-20°C with minimal fluctuation
Relative humidity parameters: 45-55% RH to prevent both desiccation and microbial proliferation
Light exposure limitations: Complete protection from UV and visible spectrum radiation
Aromatic isolation: Segregation from other aromatic materials to prevent cross-contamination
Terminal quality verification includes:
Vanillin quantification: Analytical determination of vanillin concentration (typically 1.5-3.0%)
Moisture stability verification: Confirmation of moisture content stability through storage simulation testing
Microbial analysis: Verification of acceptable microbial population parameters:
Total plate count: <10,000 CFU/g
Yeast and mold: <1,000 CFU/g
Absence of specific pathogenic microorganisms
Sensory evaluation: Final organoleptic assessment against established standards
Packaging variations exist based on destination markets:
Culinary professional packaging: Simplified access designs with minimal opening frequency
Retail consumer packaging: Enhanced visual presentation with educational components
Industrial extraction packaging: Bulk configurations optimized for extraction efficiency
Specialty/premium packaging: Gift-appropriate presentations with enhanced aesthetic considerations
The packaging phase represents not merely a logistical consideration but a critical extension of the curing process, as improper packaging commonly results in quality degradation through inappropriate moisture migration, aromatic compound volatilization, or oxidative deterioration. Contemporary vanilla packaging increasingly incorporates active and intelligent packaging technologies to extend effective commercial viability while preserving the complex aromatic profiles developed during the extended processing cycle.