Meat&Poultry -- April 2014 - 47

The new facility includes four IQF
lines, two fresh-patty lines, a bulk
hamburger line and a chub line. Foodservice packaging is mostly corrugated boxes in various weights. At retail,
products are packaged in a variety of
polybag and box sizes and formats.
The new production facility operates
five days a week under two eight-hour
production shifts and one eight-hour
sanitation shift per day. Three-hundred twenty-five people work at the
new complex.
The grinding line is fully automated and computerized. "Our Food Processing Equipment Co. grinding system is the most advanced technology
at the new plant; it was custom-designed," Olivera says. "It's operated
by only four people. They plug in the
formulation they want, and the system
does everything else. Our main grind-

lifetime'

ing line handles mass production and
a secondary grinding line can process
10,000 lbs. per hour for miscellaneous
items for specialty clients. This gives
us more flexibility."
Five pre-blenders are on load cells.
"Once the meat in each blender is tested for fat, the results are entered into

million lbs. per year with about 150

Hamann Construction was the

the grinding panel view," Crivello

general contractor of the new complex,

says. "The operator enters in the de-

"We had to compromise a lot of

which was designed after lengthy and

sired final fat target and the system

the efficiencies and flexibility in or-

frequent discussions -which some-

does the rest by mathematical deduc-

der to increase our production at the

times escalated into debates, Olivera

tion. The current grinding line has the

Vista plant, which we did not like,"

says with a grin. "We decided we have

ability to grind 30,000 lbs. per hour."

adds Abel Olivera, chief operating of-

more expertise in-house so we took the

The four IQF lines combined pro-

ficer. "Our throughput capacity at the

challenge to design this building from

duce 18,000 lbs. of IQF burgers total

new facility is 110 million lbs. per year.

the ground up," he adds. "We focused

per hour; the two fresh-patty lines pro-

We're operating in 81,000 sq. ft., but

on employee flow and product flow."

duce 2,000 lbs. per hour per line; the

we're expandable to 150,000 sq. ft.

Departments at Jensen's new $30

bulk line processes 3,500 lbs. per hour;

and we have first-right of refusal for

million corporate/production com-

and the chub line produces 2,000 lbs.

this additional space. It's designed in

plex include customer service, mainte-

per hour for a grand production to-

a way we can mirror the image of our

nance, production, purchasing, qual-

tal of 27,500 lbs. of product per hour.

existing layout and get more capac-

ity assurance, sanitation plus shipping

Four forming machines provide max-

ity - but maintain our product flow."

and receiving and the corporate office.

imum flexibility to produce a wide

employees."

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Meat&Poultry -- April 2014

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