A practical, field-tested IQF frozen vegetables quality checklist from the Indonesia‑Vegetables Team. Use this step‑by‑step pre‑shipment and on‑arrival process to verify export quality, read COAs, set microbiological specs, check glaze and net weight, apply AQL sampling, and prove cold‑chain integrity with temperature loggers.
If you buy IQF vegetables, you know one rejected container can wipe out months of margin. We’ve prevented that more times than we can count using a simple, disciplined checklist. Below is the same process we run at Indonesia‑Vegetables when we ship our frozen lines like Premium Frozen Sweet Corn, Frozen Mixed Vegetables, Premium Frozen Edamame, Premium Frozen Okra, and Frozen Paprika (Bell Peppers).
The 3 pillars of export‑quality assurance
- Supplier and documentation. Confirm certifications, specs, and hazard controls on paper before you wire a deposit.
- Product and process verification. Validate weight, glaze, defects, microbiology, pesticide residues, and metal detection through sampling and simple on‑site tests.
- Cold‑chain proof. Lock in reefer settings and data loggers so you can prove the cargo stayed at −18°C from loading to arrival.
Here’s how we sequence it across your first order so you get predictable quality without playing detective at the destination.
Week 1–2: Lock the specs and verify the supplier
We start by aligning on what “export quality” means for your market. In our experience, ambiguity at this stage creates 80% of later disputes.
- Certifications to request. HACCP and one of BRCGS Food Safety (Grade A or better) or FSSC 22000. ISO 22000 is common, but buyers in EU/US typically prefer BRCGS or FSSC. For GCC, ask for Halal MUI. If you plan US retail, request a documented allergen control and FSMA readiness.
- Factory pack and process controls. Ask for the process flow, CCPs, metal detector specs (we use typical sensitivities around 2.0 mm Fe, 2.5 mm non‑Fe, 3.0 mm SS for retail packs), sanitation SOPs, water analysis, and pest control records.
- Product specification sheet. Size ranges, cut style, color tolerance, defects definitions, glaze target (usually 5–10%), target blanch, and net content declarations. Example: for Frozen Mixed Vegetables, lock the ratio (e.g., 30% corn, 30% carrot, 20% beans, 20% peas) and permitted deviation (±2–3%).
- COA expectations. Agree up front what a COA will show per lot: microbiology, chemical (salt if seasoned, Brix for corn if relevant), net weight results, and metal detector verification. For pesticide residue, many EU buyers require a full screen to EU MRLs (Reg. 396/2005) at least per new season or supplier change. For US, align to EPA tolerances; for GCC, match destination MRLs or default to EU for stricter coverage.
- Micro specs. We see most buyers set: Salmonella not detected in 25 g. Listeria monocytogenes not detected in 25 g for RTE items or <100 cfu/g for non‑RTE. E. coli <10–100 cfu/g. APC/TPC ≤1×10^5 cfu/g. Yeasts and molds ≤1×10^3 cfu/g. If your brand is RTE or “ready to eat,” insist on ND in 25 g for Listeria. After recent market scrutiny, many retailers require this even for “cook before eating.”
Practical takeaway. Don’t just collect documents. Write a one‑page quality agreement that restates the spec, micro limits, glaze target, AQL levels, reefer setpoints, logger placement, and dispute protocol. Have both sides sign it before deposit. Need a quick sanity check on your draft? If you want a second set of eyes, Contact us on whatsapp.
Week 3–6: Pre‑shipment validation and AQL sampling
This is where we verify that what’s on paper shows up in the carton.
- Third‑party inspection. For Indonesia, we’ve used and seen solid work from SGS, Intertek, Bureau Veritas, Cotecna, TUV Rheinland, and local state‑owned firms like Sucofindo and Surveyor Indonesia. Book them for a pre‑shipment inspection when the goods are staged but before loading.
- Sampling plan. Use ANSI/ASQ Z1.4, General Level II. A common setup is AQL 2.5 for major defects, 4.0 for minor, and 0 for critical. For example, for a medium lot, inspectors often pull 125 retail packs. Acceptance might be 0 critical, 7 major, 10 minor. For bulk, sample at least 20 kg distributed across the lot.
- Defects definitions and typical tolerances. Critical: any foreign matter (metal, glass, hard plastic) and hard extraneous vegetable matter. Acceptable: 0. Major: insect fragments, severe blemish/discoloration, decay. Minor: size out of spec, slight blemish. We usually target total defects ≤5%, with major ≤2%. Extraneous vegetable material ≤0.5%. Foreign matter 0.
How do I check real net weight when products are glazed?
Glaze protects against dehydration, but it can hide underfill. Here’s the simple check we use for corn, mixed veg, peppers, and edamame.
- Pull 5 retail packs per SKU from different cartons. Keep them frozen.
- Weigh each pack immediately out of the freezer. Record glazed weight Wg.
- Quickly de‑glaze by dipping contents in cold running water for 30–60 seconds to remove surface ice only. Drain for 2 minutes and gently blot. Weigh to get net product weight Wn.
- Glaze percentage = (Wg − Wn) ÷ Wg × 100.
- Labeling rule of thumb. “Net weight” on the bag should refer to product excluding glaze. So Wn should meet or exceed the declared net weight, within legal tolerances. If the label declares “gross weight” and glaze percent, verify both.
Typical targets we run: 5–8% glaze depending on product. Under real retail conditions, anything above 10% raises eyebrows (and complaints).
What’s a simple drip loss test at 20°C?
Drip loss shows how the product behaves after thawing and signals blanch quality.
- Weigh frozen product Wf (e.g., 1,000 g) and place on a sieve over a pan at 20°C for 2 hours.
- After thawing and draining, weigh the drained product Wd.
- Drip loss % = (Wf − Wd) ÷ Wf × 100.
Our benchmarks: sweet corn and peas 1–3%. Mixed veg blends 2–4%. Okra can be higher; for Premium Frozen Okra we keep it within 3–5% for slices and lower for whole pods.
- Ratio and size checks. For Frozen Mixed Vegetables, count or weigh component percentages and confirm the spec ratio within ±2–3%. For Premium Frozen Sweet Corn, Brix 9–13 and uniform kernel size make a big difference in perceived sweetness and cook time.
- Metal detection and sieving. Verify detector challenge tests each shift. For diced products like Frozen Paprika (Bell Peppers), insist on documented screen integrity checks if the line uses sieves.
Practical takeaway. Photograph everything. Keep a one‑page field record for weight/glaze, drip, defect counts, and any non‑conformances with corrective actions. This becomes your defense if there’s a claim later.
Week 7–12: Cold‑chain proof and on‑arrival QC
Containers don’t reject themselves. Temperature excursions and poor loading do.
- Reefer settings to lock. Setpoint −18°C cargo temperature. Supply air often at −20 to −22°C to maintain product core. Require pre‑cooling of the reefer and product at −18°C or colder before loading. For large dices and edamame, we like to see −20°C product core.
- Logger placement. Use at least two independent temperature loggers: one in the top third of the load near the air return and one mid‑pallet in the middle of the container. For high‑value loads, add a third near the doors. Start all loggers before loading and set to 30‑minute intervals.
- Loading pattern. Leave air channels. Don’t block T‑bars or the air return. We’ve seen perfect product get frosted edges just because the first row was jammed against the bulkhead.
How can I prove the reefer stayed at −18°C during transit?
- Download logger data on arrival and compare with the shipping line’s telemetry (most lines can export a voyage temperature report). If both match, you have robust evidence.
- Acceptable variation? Short spikes during defrost cycles are normal. What we care about is product core. If your loggers show ambient inside the container rising but still below −12°C and returning to target quickly, the cargo is often fine. Above −12°C for extended periods raises risk of texture loss and drip.
On‑arrival QC checklist. Pull temperature on 10% of pallets. Re‑check net weight and glaze on a few packs. Quick sensory check for texture and aroma after cooking. If something’s off, quarantine and escalate with your evidence package.
Microbiological specs you can actually use
We’ve found the following limits work well for EU, US, and GCC buyers when paired with a “cook before eating” instruction. If you position your product as ready‑to‑eat, tighten to Listeria ND in 25 g and consider more frequent lot testing.
- Salmonella: Not detected in 25 g (n=5, c=0).
- Listeria monocytogenes: Not detected in 25 g for RTE, otherwise <100 cfu/g with environmental monitoring in place.
- E. coli: <10–100 cfu/g depending on market.
- APC/TPC: ≤1×10^5 cfu/g.
- Yeasts and molds: ≤1×10^3 cfu/g.
- Bacillus cereus: ≤1×10^3 cfu/g for starchy items like corn or potatoes.
COA interpretation tips.
- Check lot traceability, production date, and that sampling time matches your goods. For corn, a Brix of 9–13 indicates the sweet profile most retail buyers expect. For mixed veg, verify ratio results and defect counts mirror your spec. If you’re new to Indonesian supply, consider an independent lab like Intertek or Sucofindo to cross‑check the first shipment’s micro panel and pesticide screen.
The 5 biggest mistakes that kill frozen veg shipments
- Vague specs. “Export quality” isn’t a spec. Write defects, glaze, size, micro, and AQLs in plain language.
- Ignoring glaze. Over‑glaze hides underfill and triggers retailer fines. Always de‑glaze and weigh.
- No logger data. Without it, temperature disputes devolve into finger‑pointing. Use at least two.
- Weak sampling. Counting defects on three pretty bags tells you nothing. Use a proper Z1.4 plan.
- Skipping pesticide screens on first loads. Season changes can swing residues. Do an initial full MRL screen, then move to risk‑based frequency.
Resources and next steps
Apply this checklist to any Indonesian IQF line. We follow it on every batch of Premium Frozen Edamame, Frozen Mixed Vegetables, Premium Frozen Sweet Corn, Frozen Paprika (Bell Peppers), and others so you don’t have to learn the hard way. If you want sample specs or a template quality agreement for your next PO, Call us. Or browse what we currently run through our IQF lines and fresh program: View our products.
Key takeaway. Pre‑shipment quality isn’t luck. It’s structure. When you lock the spec, verify the product with simple field tests, and prove the cold chain with data, you cut rejection risk to near zero and ship confidently, every time.