OSI Group, LLC, Aurora, Ill., announced that OSI Food Solutions Spain added a high-capacity production line to its existing operation in Toledo, Spain. The €17 million investment was completed earlier this year, and has increased the production capacity of processed chicken products from 12,000 tons to 24,000 tons annually.

With this latest expansion, OSI Food Solutions Spain has reached a total production capacity of more than 45,000 tons of 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.

"This plant extension is in response to the fast-growing demand for chicken products in Spain and Portugal,” says José María del Río, managing director of OSI Spain. “Demand for chicken items in this area has seen more than 6% average annual growth over the last decade and 8% average annual growth for the last three years. We are anticipating continued growth of this demand, and we are ready for it.”

The 22,600-square-foot building addition 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,” says David McDonald, OSI president and COO. “We are excited to be adding capacity and creating new jobs.”

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 and an advanced firefighting system. 

Plus, the new equipment has already reduced electricity consumption by about 20%. 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.