Category Archives: Food Industry

Food manufacturing, processing, and cold storage. Seafood, produce, poultry, beef/poultry, meals/meal kits, and food ingredients intended for grocery stores, restaurants, institutions, and consumers. Facilities with freezers, coolers, USDA processing areas, bakeries, floor drains, food safety testing labs, and wastewater interceptors.

Slaughterhouse Scarcity

A New York Times article describes some of the challenges of local-food movements across the country: a lack of slaughterhouses.

...growing problem for small farmers here and across the nation: too few slaughterhouses to meet the growing demand for locally raised meat."  Los Angeles has only a handful of live animal processing plants, when decades ago there were dozens.

In what could be a major setback for America’s local-food movement, championed by so-called locavores, independent farmers around the country say they are forced to make slaughter appointments before animals are born and to drive hundreds of miles to facilities, adding to their costs and causing stress to livestock.

As a result, they are scaling back on plans to expand their farms because local processors cannot handle any more animals.

The LA Times recently posted this article “One of L.A. County’s last slaughterhouses could go on the chopping block.”  Neighbors and city zoning codes pose serious challenges to any type of animal processing plant here in Southern California.

I represent one of the last slaughterhouses in the City of Los Angeles. The company is thriving with hearty demand for their product.

Grease Interceptor (Clarifier) for Food Processing Buildings

Grease fat waste interceptor clarifierFor most industrial food processing facilities, the minimum required pretreatment of water containing solids or fats (grease) consists of a three-compartment, gravity separation interceptor (clarifier) and a sampling box.  These water clarifiers can be found commonly  in the yard area outside of the food prep area for operations such as seafood processing, poultry deboning, beef cutting, produce packing, commercial kitchens, commissaries, etc…  The goal of these interceptors is to prevent dirty water containing solids from entering the sewer system.    They are designed specifically for the sanitary removal of solid waste from food processing operations and smaller versions are commonly called grease traps in restaurants.

Vernon Livestock Rendering Plant

Animal Fat Recycling Plant, Food Processing, Vernon, CaliforniaLos Angeles Magazine has written a lengthy article about Baker Commodities, a livestock rendering plant based in the City of Vernon, California, near Downtown Los Angeles.  It is the oldest rendering business in L.A. and the largest on the West Coast.  In 2008, some 250 U.S. rendering plants like Baker took in 54 billion pounds of killed livestock—blood, bone, guts, legs, hide, muscle, and head, the detritus of slaughter—warmed the raw material in cookers, and squeezed out a clear liquid called tallow.

Baker seizes on fat wherever it can: dairy cows that have died in the heat of the Central Valley, the trimmings left over from the purchase of a Niman Ranch roast at Whole Foods, steaks and chickens whose shelf life at Pavilions has expired. The company retrieves grease from deep fryers at McDonald’s and the drippings of ribs in the Vons hot section. Rendering is the most elemental form of recycling, the regeneration of the dead into soap and scented creams. It has existed for millennia in societies, and its reach in modern America is staggering. We live in a vast cycle of fat reclamation, one that stretches from the killing floors of the Midwest to our medicine cabinets, making a stop along the way at the local Burger King.

Every restaurant and fast-food stand in L.A. has a fat reservoir called a grease trap, usually secreted under the parking lot. A trap may strain as much as 15,000 gallons of liquid fat from a kitchen’s drains, though the speed at which it fills depends on what’s cooking upstairs. A Burger King trap can take three months to fill, while an El Pollo Loco trap might need to be emptied in weeks. There are tens of thousands of grease traps citywide, each a promising revenue source for rendering companies. Baker taps around 8,000 of them.

Biodiesel!  About 40 pounds of good ground beef heated to 250 degrees will produce enough tallow to make a gallon of biodiesel. The process is insanely wasteful if cattle are raised for it alone; you’d need to boil an entire cow to fill your Chevy Volt. Yet there’s no shortage of cow remnants in slaughterhouses, and U.S. production of biodiesel from renderers has grown from 78,000 metric tons in 2007 to 400,000 metric tons in 2008.

Full article.

Real Mex Food Expands Food Processing Plant

Real Mex Foods expanded food processing plant in Vernon, CaliforniaReal Mex Foods supplies more than 200 restaurants as the distribution branch of Real Mex Restaurants, Cypress, Calif., including Chevy’s, El Torito and Acapulco restaurant concepts located in Arizona, California, Nevada, Oregon and Washington.  In addition, Real Mex Foods has branched into broader frozen foods processing for foodservice, co-pack and retail channels serving clients such as Sysco Distributors, El Pollo Loco, Carl’s Jr.-Green Burrito, Albertson’s and U.S. Foods.

In February, Real Mex closed its 32,000-square-foot manufacturing plant in Santa Fe Springs, Calif., and moved into a 100,000-square-foot space in Vernon, California. The city of Vernon and a developer came to us and proposed a deal where we got a 100,000-square-foot building retrofitted to a state-of-the-art USDA manufacturing plant, Angulo explains.  It was an opportunistic deal.   They got us into 100,000 square feet at the cost that we would have gotten a build-to-suit 65,000-square-foot building.

Food safety also was a major priority for Real Mex in building out the new plant. The company built an in-house lab and hired a complete quality assurance team. Other food safety precautions include a triple boiler system, floor foamers, centralized sanitation system, in-house chlorination system for vegetables and a full quality assurance staff.

The developer invested $10 million in the build out, while Real Mex spent about $4 million on equipment. The completely refurbished plant quadrupled the company’s previous capacity and allowed it to more than double the number of kettles, tumble chillers and blast freezers. www.realmexfoods.com

Major Bakery Closing Locations – Reducing Food Processing Footprint

Interstate Bakeries Hostess Bakery

Interstate Bakeries Corp., the maker of the iconic Wonder Bread and other baked goods, said Tuesday it will no longer make or sell bread in Southern Califonia, closing its bakeries in San Diego, Los Angeles, Pomona and Glendale.

The San Diego bakery employs about 80 workers and makes buns and rolls under the Millwood brand. Interstate also said it will close 17 distribution centers and 19 outlet stores, including five locations in San Diego County. In total, some 1,300 workers will be affected throughout Southern California. The company plans to deliver bread products until Oct. 20. Other brands affected include Home Pride Bread, Baker’s Inn and Roman Meal.

IBC, which also makes Ding Dongs and Twinkies, said it plans to continue selling its line of Hostess and Dolly Madison snack cakes in the area.

The closing of the company’s bread operations in Southern California comes as IBC continues to struggle to improve its business, which has been hurt by declining sales and higher costs. The Kansas City company filed for bankruptcy in 2004. For the fiscal year ended June 2, IBC reported a net loss of $128.5 million on sales of $2.92 billion.

Craig Jung, chief executive of IBC, said the decision was difficult but necessary as the Southern California bread business continued to be a drag on the company. Among the competitive pressures, he said, were the growth of low-cost, non-union rivals as well as changing consumers demands. Compounding the problem, Jung added, was the high cost of doing business in California including what he called the “excessive” workers’ compensation insurance costs and a confrontational relationship with one of the company’s main unions.