Sopakco Food Processing and Packaging Facility, USA

Sopakco is a leading producer of ready meals and one of the primary meal providers to the US Military.

On 12 November 2009, Sopakco opened a 200,000ft ² food processing and packaging facility in Mullins, South Carolina, US, its third plant in the State. The demand for shelf-stable heat-and-serve meals has been growing in the US. The new facility is a move to capitalise on this demand. Investment was approximately $10m.

Sopakco believes that its strength in providing turnkey solutions in recipe formulation, food processing, packaging and distribution will help it achieve quick market entry for the products manufactured at the plant.

Project

The plant employs 50 people, although this number is set to grow to 80 when the plant begins operating at full capacity. The plant employs food scientists, process engineers and packaging engineers.

The facility will design, prepare and package heat-and-serve meals. Packaging solutions include custom-made microwaveable meals in semi-rigid plastic bowls, trays and retort pouches.

Technology

The facility includes a state-of-the-art research and development lab. It also includes a test kitchen, pilot plant and automated batch and blending operations. The plant is equipped with volumetric filling and form/fill/seal equipment. The lines at the plant are high-speed bowl filling lines and automated packaging lines. The plant also features high-volume retort chambers.

Food safety is achieved through electronic digital inspection systems and magnetisers. Apart from this, in-line and end-of-line metal detectors and on-site USDA (United States Department of Agriculture) facilities also help in maintaining the safety standards.

The plant received a grant from the United States Department of Agriculture on 20 October 2009.

Products

The products that the company plans to produce in the facility range from beef pot roast and spaghetti and meatballs to gourmet selections such as pesto chicken with penne pasta. The food products require no refrigeration.

The food is prepared at the facility using various retort methods. This is done in order to maximise the flavour, safety and longevity of the food. The product is packaged in a special layered material in order for the freshness of the food to remain intact.