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Step 1. Harvesting and Cleaning.
Traditional divers hand-collect ripe lotus seeds from Bihar pond beds. These prized “black diamonds” undergo thorough washing to eliminate mud and impurities completely.
Step 2. Natural Sun Drying Method
Raw seeds spread evenly on drying mats reduce moisture content to around 30-32%. Final cleaning removes stones, immature seeds, and debris for pure processing ahead.
Step 3. Precision Size Sorting
Vibrio grader machines or calibrated sieves separate seeds into 5-7 uniform categories. Consistent sizing ensures perfect roasting results for premium Puffzen™ quality.
Step 4. Thermal Pre-Treatment Phase
Initial Roasting: Cast iron kadhais heat seeds at 250-300°C for 5-6 minutes.
Resting Period: 2-3 days controlled cooling (“sweating”) naturally loosens tough outer shells.
Step 5. Expert Popping Technique
Tempered seeds get final high-heat roast (290-340°C). Perfect crackling signals thappi mallet strike – releasing snow-white puffed kernels instantly with golden perfection.
Step 6. Finishing & Quality Sorting
Bright Polishing: Bamboo baskets or polishers buff away shell remnants for sparkling white finish.
Premium Grading: Lawa (perfect pops), Thurri (semi), Chipta (flat) – only Lawa makes Puffzen™ grade
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