Indonesian IQF Vegetables Custom Blends: Complete 2025 Guide

A practical spec-and-QC blueprint from the Indonesia‑Vegetables Team. Learn how to set ratio tolerances, match cut sizes and densities, pick the right glazing percentage, prevent segregation in transit, and verify blends with a sampling plan that actually works.

If you’ve ever opened a bag of mixed vegetables and found all the heavy pieces piled at the bottom, you know why a tight IQF vegetable blend specification matters. We’ve cut ratio claims by more than half in 90 days for several buyers using the exact process below. It comes down to writing the spec so it can be executed on the line, then verifying it with simple, repeatable tests.

The 3 pillars of reliable IQF blends

1. Harmonized cut size and density. A blend behaves like a pile of sand. Large, heavy pieces roll down. Small, light pieces float and migrate. We group items by similar piece geometry and bulk density. In practice that means pairing 8–12 mm dice with 8–12 mm kernels or slices, and avoiding big wedges with tiny peas. For example, our Frozen Mixed Vegetables standard 30/30/20/20 works because carrots are diced similar to peas and corn kernels. When buyers want color pop, we add Frozen Paprika (Bell Peppers) as a 10 mm dice rather than strips. Strips segregate faster.

2. Ratios with realistic tolerances. We specify pack‑out targets and acceptance bands separately. At the blender, we aim tight. At incoming inspection, we allow for glazing, sampling and handling variance. More on numbers below.

3. Process control for glazing and handling. Glaze protects color and texture. Too little and you get dehydration. Too much and you mask ratio errors. We use controlled spray glaze with in‑line checks, then minimize drop heights and free fall to reduce segregation before sealing.

Takeaway. If your spec nails these three, you’ll prevent 80 percent of complaints before they start.

Weeks 1–2: Draft the spec and validate assumptions

Here’s the supplier brief template we use for custom IQF blends in Indonesia. Copy it and tweak for your product.

• Product name and intended use. Retail, foodservice, or industrial. Ready meals need tighter size control than soups.
• Components and ratios by weight. Example: Corn 30%, Carrot 30%, Peas 20%, Green beans 20%. List scientific names if you sell into markets that require it.
• Ratio tolerances. Pack‑out tolerance ±1.5% absolute for any component ≥25%. ±1.0% for minors under 25%. Incoming acceptance can widen to ±3% for majors and ±2% for minors.
• Cut size and piece size tolerance. Specify target geometry and tolerance. Carrot dice 10×10 mm ±2 mm. Green bean cuts 15 mm ±3 mm. Bell pepper dice 10×10 mm ±2 mm. Okra slices 10–15 mm. Avoid mixing shoestring Premium Frozen Potatoes with 10 mm dices. If you need potato in a veg blend, choose 10–12 mm cubes.
• Component preparation. De‑seeded and diced for bell peppers, de‑stringed green beans, trimmed ends. If edamame is included, choose shelled Premium Frozen Edamame only. Pods don’t blend well.
• Glazing percentage and method. 5–8% spray glaze for export cartons. 2–4% for retail where transparency matters. Specify that declared net weight excludes glaze and that glaze is verified by thaw‑and‑drain method.
• Food safety and physical controls. Foreign matter zero tolerance. Metal detection Fe 2.0 mm, Non‑Fe 2.5 mm, SS 3.0 mm. Core temp at packing ≤ −18°C.
• Packaging. Bag size and film. Common: 1 kg retail, 2.5 kg or 10 kg foodservice. Specify fill headspace under 15% to limit movement. Carton spec and pallet pattern for full container loads.
• Label and legal. Ingredient order by weight, country of origin Indonesia, allergen statement none. If you supply to the EU, state each component’s QUID.
• Process checks. Ratio checks every 30 minutes at pack‑out. Glaze checks hourly. Temperature checks every hour.

We recommend choosing components already in our frozen range so you can skip development time. For example, Premium Frozen Sweet Corn, Premium Frozen Okra, and Frozen Paprika are common building blocks. Want a sanity check on your draft spec or a quick ratio simulation? Need help with your specific situation? Contact us on whatsapp.

Practical validation. Before you finalize, run a beaker test. Mix 300 g total by hand with your chosen cut sizes. Shake the container 30 times to simulate transport. Pour gently and check if components stratify. If they do, move sizes closer or change geometry.

Weeks 3–6: Pilot run, homogeneity testing, and ship test

Pilot run. We like a 500–1,000 kg pilot to prove the spec. Indonesian MOQ for customs blends is typically 5–10 MT per formulation per run. A small pilot clears risk.

Homogeneity testing. We measure blend uniformity with coefficient of variation. Here’s the method that has worked best for us.

• Take eight random grab samples of 250 g each from across the line. Rinse glaze quickly if present, then surface dry.
• Sort and weigh each component in each sample. Calculate each component’s percentage. Compute coefficient of variation for each component. Target CV ≤ 10% for majors. ≤ 12% for minors.
• If CV is high, check feeder stability, mixing time, or cut size mismatch.

Ratio verification method. Always verify by weight, not piece count. Weight reflects value and labeling. The only exception is when one component is extremely light compared to others and pieces vary widely. In that case, run both tests and correlate.

Glaze verification. We prefer the thaw‑and‑drain method. Weigh frozen sample Wf. Rinse glaze for 30 seconds in cold water or thaw in a sieve under refrigerated conditions until surface ice is gone. Pat dry. Weigh net Wn. Glaze % = (Wf − Wn) ÷ Wf × 100. Your spec should state that invoices and labels refer to Wn.

Transit test. Fill finished bags. Stack as per container loading. Vibrate or drive them for a realistic distance. We aim for no visible segregation and no measurable ratio drift beyond half your incoming tolerance.

Weeks 7–12: Scale up and lock the SOP

Equipment and line settings.

• Feeding. Loss‑in‑weight feeders give the best control for 3–6 component blends. If you do batch tumble mixing, keep batch sizes small and mixing time short. Over‑mixing damages edges and increases fines that segregate.
• Drop heights and transfer. Keep free fall under 40 cm where possible. Use soft transfers and short chutes. Fit baffles to slow velocity.
• Glazing. Spray glaze is more consistent than immersion for blends. Verify nozzle flow and temperature. Keep glaze water under 1°C.

In‑process checks. Ratio every 30 minutes with a 500 g sample. Glaze hourly. Bag weight 100% checked by checkweigher. Core temperature hourly. Record corrective actions, not just numbers.

Lead times and logistics. For Indonesian suppliers, custom IQF blends run in 2–4 weeks when all components are already in stock. New cut sizes or new crops may extend to 4–6 weeks. Book reefer space early. In the last six months we’ve seen some route volatility on trans‑shipment lanes, so allow a buffer week for vessel schedules.

The 5 biggest mistakes that kill blend consistency

• Mixing incompatible geometries. Peas with long pepper strips will segregate. Match dice with dice. Match slices with slices.
• Vague glazing instructions. “Light glaze” means nothing. Write 2–4% for retail clarity or 5–8% for export protection. State method of calculation.
• Sampling too small. A single 100 g scoop is noisy. Use 500 g or 1 kg for ratio checks and at least five bags per lot at incoming.
• Verifying by piece count only. You’ll pass a visual check and fail a label audit. Use weight as the truth.
• No acceptance band. Your pack‑out can be tight and still fail incoming if you don’t account for glaze and handling variance. Set both.

Quick answers we get every week

What ratio tolerance is acceptable for each component in a custom IQF vegetable blend?

At pack‑out we target ±1.5% absolute for components ≥25% of the blend and ±1.0% for minors. For incoming acceptance, widen to ±3% for majors and ±2% for minors. For a 30/30/20/20 blend, you’d accept corn 27–33%, carrot 27–33%, peas 18–22%, beans 18–22%.

How do I keep heavier vegetables from settling to the bottom of bags in frozen blends?

Match cut size and density. Keep bulk densities within roughly 10–15% of each other and choose similar geometries. Minimize free fall and vibration post‑mix. Reduce headspace in bags. And avoid long, thin shapes that behave like “needles” in a blend.

Which cut sizes pair best to prevent segregation in mixed IQF vegetables?

Reliable pairs. Carrot 10×10 mm dice with corn kernels and peas. Green beans cut 12–18 mm match well with 10 mm dice. Bell pepper 10×10 mm dice stays mixed better than strips. Okra 10–15 mm slices mix well with 10 mm dice. If you add potato, use 10–12 mm cubes from Premium Frozen Potatoes, not wedges.

How much glazing should I specify for an IQF vegetable blend?

Retail or transparent packs. 2–4% to keep visibility while preventing dehydration. Export cartons or long voyages. 5–8% to protect color and texture. Always specify that net weight excludes glaze and define glaze verification by the thaw‑and‑drain method.

What MOQ and lead times do Indonesian suppliers require for custom blends?

Typical MOQ is 5–10 MT per blend per production run. Lead time is 2–4 weeks if all components exist in the supplier’s range. New cut sizes or crops need 4–6 weeks. We can often schedule a 500–1,000 kg pilot inside the first two weeks.

Should I verify blend ratios by weight or by piece count for IQF vegetables?

By weight. It correlates with labeling, nutrition and cost. Use piece count only as a secondary visual control when pieces vary wildly in mass, and document the correlation to weight.

How do I sample incoming IQF blends to confirm the specified ratios?

Use a simple plan. For each lot up to 20 MT, pull five bags at random. From each, take a 1 kg sample. Thaw and remove glaze, then sort and weigh components. Compare to your acceptance band. If any component is out in two or more bags, hold the lot for investigation. If everything passes, record the data and release. Include temperature at receipt (≤ −18°C), bag integrity, and organoleptic checks.

Resources and next steps

If you want a working spec fast, start with our building blocks like Premium Frozen Sweet Corn, Frozen Paprika, Premium Frozen Okra, and Premium Frozen Edamame. You can browse typical cut sizes and applications here. View our products. Questions about your project or need a pilot booked? Call us.

In our experience, most blend problems aren’t solved on the line. They’re solved on the spec page. Get the geometry right, set realistic tolerances, control glazing, and verify with a consistent sampling plan. Do that and your 2025 custom blends will be boring in the best possible way. And your claims folder will stay light.