Current Layout of Factory
The factory has a total area of 10,884 m2, which is divided in separated areas, with independent entrances, to avoid the risk of microbiological contamination of either air born, people or packing introduced bacteria being introduced into any area.
The cutting area is located in an independent space area of 2,725 m2, with independent entrances for personnel, raw material and waste. The processing or blanching area, with 989 m2, is located in a closed environment with a positive air system, and an independence entrance from the cutting area, and leading towards the packing room. Between processing and packing room there is an airlock separation, as well as between the packing room and the final storage facility for packed product. To enter the packing room, personnel has to pass 2 specially designated filters, were disinfection, hair retrieval and correct uniform usage is closely inspected. The original packing area has 876 m2 and the new additional area for packing has 528m2. Packing material is stored in a specially designated room that has an independent entrance and a controlled environment to avoid bacterial or foreign material contamination. There is a special filtered area to deliver the packing material to the packing room.
The raw storage room, receives the raw material that comes from the fields and is initially stored in a cooled room at 7-9 C after is sampled and approved. It is clearly identified to continue the traceability process through the factory. It is later placed in transportation belts, were it is selected and cut by hand by our personnel. After cutting the broccoli florets, is stored in another cold room at 7C, to maintain freshness of the product before being placed in the processing belts. In the processing room, it is placed on the belt lines, were it is washed, blanched, precooled and frozen in our IQF tunnels and transported by belts to be packed in bulk and stored in the freezing rooms at -18 C.