OSI doubles chicken production capacity at Spain plant
State-of-the-art production line added, enabling facility to produce 24,000 tons annually
OSI Food Solutions Spain has added a high capacity production line to its existing operation in Toledo, Spain. The EUR17 million (US$20.5 million) investment was completed earlier in 2017 and has increased the production capacity of processed chicken products from 12,000 tons to 24,000 tons annually.
With this latest expansion, the OSI operation in Toledo has reached a total production capacity of more than 45,000 tons of quality beef, pork and chicken products. The entire project, including production lines and related services, will add 20 new jobs to the existing workforce of 140 people, including the recently created position of product development manager. This new role will continue to ensure skilled and dedicated leadership for both new product development and continuous improvement of existing products.
"This plant extension is in response to the fast-growing demand for chicken products in Spain and Portugal,” said José María del Río, managing director of OSI Spain. “Demand for chicken items in this area has seen more than 6 percent average annual growth over the last decade and 8 percent average annual growth for the last three years. We are anticipating continued growth of this demand, and we are ready for it.”
The building addition of 2,100 square meters (22,600 square feet) included a new production hall, shipping and receiving areas, facility supplies storage, refrigerated rooms for waste container storage, service areas for oil, hot water and nitrogen tanks, and a social area for employees. The project also included a product development kitchen to better service the changing needs of clients and consumers.
"This expansion strategy will allow us to add new products to our portfolio, grow with new foodservice and retail key accounts, and support the growth of our long-standing customers,” said OSI President and Chief Operating Officer David McDonald. “We are excited to be adding capacity and creating new jobs.”
Special features at plant
The company’s food defense system was enhanced by the installation of a new perimeter access control surveillance system, which was further complemented by the addition of indoor cameras. An advanced firefighting system was also installed.
Special attention was given to sustainable elements to meet the company’s high standards for sustainability. The new equipment has already reduced electricity consumption by about 20 percent. Heat recovery from the cogeneration system and the refrigeration unit, which are used to heat and store 200m3 of water used every night during the cleaning shift, will further improve the operation’s energy efficiency.
The regional government recognized OSI Spain’s commitment to agricultural development, employment, and sustainability and granted the project EUR1.5 million (US$1.77 million) from the European Agricultural Guarantee Fund. In February 2016, OSI Food Solutions Spain received an award from the local Chamber of Commerce for its commitment to employment.
OSI Spain’s management system is certified according to Food Safety Standard FSSC 22000, ISO 22000:2005, ISO/TS 22002-1, Environmental Standard ISO 14001, the EU Eco-Management and Audit Scheme (EMAS), and Social Responsibility Standard SA 8000:2014.