Processing Plant Description

The largest single investment at BAL has been the construction of a processing plant considered to be one of the leading high tech plants in the world. The plant was constructed under the tight rules of the Codex Alimentarus and with the involvement of well known international equipment manufacturers Cabinplant, York , Ruland-ATM, Reid, etc.. BAL understands the importance of quality and traceability, and therefore has been certified by the NQA and BAHA for HACCP approval and will be ISO 9001:2000 certified by the third quarter of 2005.

The processing plant was designed to handle 60,000 lbs. of shrimp in a normal eight (8) hour shift and can produce a variety of value-added presentations. However, the key to being able to produce a quality finished product requires an input of high quality raw product. To ensure that the very freshest product is delivered to the processing plant three key critical factors are followed, Harvest Method, Temperature, and Time.

BAL developed a harvest method that is fast paced making certain that the absolute freshest product is delivered to the processing plant. A typical harvest at BAL is completed within three hours. During the harvest, the shrimp are continually delivered to the processing plant, and processing begins before the harvest is completed. The shrimp are harvested directly into slush ice to lower the body temperature. The slush ice completely envelopes the entire shrimp body, quickly lowering the body temperature to 1 ° C (33.8 ° F). These three factors allow for BAL shrimp to spend less than twelve (12) hours from time of harvest to processing completion.

Inside the processing plant strict guidelines are followed. The BAL Quality Assurance Team monitors all parameters that can affect the quality of the shrimp. Incoming fresh water is continually monitored against the World Health Organization's standards, chlorine levels are monitored and kept below 5 ppm, and the core temperature of the shrimp is checked at key points every fifteen (15) minutes. Additionally, no chemicals are used or needed, that can adulterate the quality of the shrimp. The ingredients list on a box of BAL shrimp only has one item listed Shrimp.

BAL utilizes the best freezing methods in the industry. DSI Plate Freezers, with a ninety (90) minute freezing time, are used for the Block Product. For IQF product a Frigoscandia Spiral Freezer with a twelve (12) minute freezing time is employed. Adding to the presentation of the IQF product is a water glaze, which prevents the product from developing freezer burn, and can be applied as per the customer specifications. Then the glazed IQF shrimp pass through a Frigoscandia Freezer after to harden the glaze shell and remove any snow that may have accumulated during the glazing process. Our fast freezing methods and strict quality assurance program guarantees the quality of the finished product.