Carla’s Pasta: The Production Facility of the Future

Carla’s Pasta is setting new standards in the food safety industry. Its new production facility is designed around a high hygiene, BRC+ concept, and the only ready-to-eat filled pasta company in the U.S. establishing this level of excellence for food safety.
This new state-of-the-art production facility is purposefully designed with a three-zone hygiene system, requiring employees and equipment designated to each zone to remain within their respective area. This prevents pathogens from ever entering food prep areas. The facility features 21-inch stainless steel concrete filled baseboards to eliminate harborage collecting cavities, stainless steel curbs to block moisture collection, and ¼-inch thick antimicrobial coated concrete floors for a chemical and slip resistant surface.

The use of multi-zoned, stainless-steel air ducts in high hygiene areas create positive air pressure to prevent outside air from ever entering, minimizing any risk of foreign airborne contaminants. The ultraviolet lighting and HEPA filtration systems disinfect and filter out foreign matter from the air.

Underneath the facility, an isolated multi-zone draining system carries wastewater away from each zone independently, so the plant is never at risk for contamination if a backup were ever to occur. Drain pipes in the building are bound together by a process called electrofusion, which provides a seamless, welded seal between sections of pipe, preventing any opportunity for pathogens to propagate.
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An Environmental Monitoring Program (EMP) is also strictly enforced throughout the building, to seek out any traces of pathogens. Before the start of production, and each day, allergen and ATP swabs (measuring actively growing microorganisms) are conducted throughout the facility. Case Level 10 testing on all finished product is also completed regularly to ensure maximum confidence in food safety. Every night, 40,000 gallons of hot, pressurized water is heated to 130 degrees Fahrenheit and used for a complete facility wash-down, including the blanchers and spiral freezers.

With the facility of the future now a reality, Carla’s Pasta continues to lead the industry with an unprecedented level of food safety practices. This facility totals 90,000 square feet, bringing the entire production capacity to just shy of 200,000 square feet.

Carla’s Pasta is the largest specialty filled pasta company in the U.S., woman owned and family operated since 1978 and proud to be recognized and part of NWBOC.