FAQ's - Co-Packing, CoPacking - Alaga Products, Alaga Syrup, Whitfield Foods Inc.

Copacking

Our minimum runs will vary based on package type, case count, expected line efficiency, labor costs, and utility costs. As a general rule we need to schedule a complete day of production. A complete day of production will vary depending on the production line used and the product packaging. However, the following guidelines may help answer your question:

These case amounts will vary depending on bottles per minute at the filler and bottles per case.

Tolling fee calculation can only be accomplished once all blending, processing, packaging and business evaluation questions are answered (see our manufacturing evaluation form for help in answering these questions). As a general rule we must be able to make a certain amount of money on each production line per day in order to justify running the line. Different blending, processing, and packaging requirements can affect our margin because they may add costs for labor, materials, and utilities or impact line efficiency. Therefore all these areas must be taken into consideration prior to tolling fee calculation. Finally, the business review will determine the volume and frequency of production runs. Larger volume and single flavor runs will help reduce tolling fees because these longer runs will improve line efficiency and case output per day.

We are a hot fill co-packer which means we pasteurize liquid products in a temperature range from 185-205 degrees Fahrenheit by means of a heat exchanger using the high temperature short time (HTST) process. Hot fill products are bottled at approximately 180 degrees Fahrenheit and the container and cap are kept at this temperature for up to 120 seconds before they are drenched cooled in a spray cooling tunnel. After 30 minutes in the cooling tunnel most products are less than 100 degrees Fahrenheit upon exit at which point they are labeled, packed, and palletized.
We are also an ambient fill co-packer which means we are able to fill liquid products in a temperature range of 80-90 degrees Fahrenheit. These products are specially formulated so they do not need heat treatment (pasteurization) to make them shelf stable. This formulation includes specific ingredients and product attributes that prevent micro growth (i.e., spoilage). Additionally, this type of filling requires equipment that has met stringent cleaning standards.

We are not a process authority and cannot provide you with the proper processing requirements for your product. Product attributes such as pH, TA, & brix along with the product ingredients will determine what processing temperatures are required to make your food shelf stable and safe for consumption. Competent process authorities are available from several professional organizations and we can provide contact information to you for these different services.

We receive quarterly audits from both the County and State Health Departments
We receive annual audits from the U.S. Food & Drug Administration
We receive annual audits from third party auditors such as AIB and Cook & Thurber

We may have the capability to run a particular package if we already have the change parts needed. However, in the event that our existing change parts will not fit your package, we would expect the customer to pay for the parts needed.

Our standard terms for co-packing are that the customer provides the packaging materials and ingredients. We provide pallet stretch wrap, treated water, product filtration, coder ink, label and box glue, limited refrigerated ingredient storage, and finished goods storage for a limited time.