PACMOORE Manufacturing Brochure

Serving CuStomerS with integrity, effiCienCy and innovation

PacMoore is unique as a contract-manufacturing partner. More than an outsource, we’re innovative problem solvers who deliver solutions to your specific production issues. Our goal is to become a seamless extension of your own operation. Our customers agree that we set the standard in the industry especially differentiating ourselves in the following ways:

peopleOur experienced workforce, with access to ongoing training and educational programs, pride themselves on production and service excellence. PacMoore will always value people above profits.

protectionOur customers sleep well at night. Quality processes, redundant capabilities, financial stability, and secure intellectual property and formulations are just some of the ways we help provide sweet dreams.

problem solvingPacMoore’s product expertise and technical know-how combined with dependable and flexible equipment enable us to deliver the results you require. Our pilot equipment and creative ability are available to meet your product development needs.

Company Overview

contact us to experience the pacmoore difference866-231-7575 i www.pacmoore.com

oUr vAlUes

commitment to people

©2011 PacMoore Corporation

Call uS today for all of your external manufaCturing needS866-231-7575 | www.pacmoore.com

mAnAgement teAm

William J. Moore President and CEO B.S. Chemical Engineering University of Wisconsin

Chris BekermeierVice President, Sales & Marketing B.S. Business Management Eastern Illinois University M.B.A. University of Chicago

Brent Ness Vice President, Engineering B.S. Chemical Engineering University of Wisconsin

Scott ReidVice President, Operations B.A. Chemistry Augustana College M.S. Health Systems Rush University

Giri VeeramuthuVice President, Quality Assurance M.S. Biological Science St. Johns University Ph.D. Food Science Texas A&M University

Lee Randall Corporate Controller B.A. Business Administration Cedarville University M.B.A., Wesleyan University

Tony Weber National Sales Manager B.S. Business, Depaul University

Bill McClure Corporate Chaplain B.A. Human Relations Salem College Th.M., Dallas Theological Seminary

FAiTh: We devote our work to the Creator’s purpose.

FAMiLy: Our employees are encouraged to put their families first.

iNTEGRiTy: Employees will always be truthful and stay accountable for their words and actions, even when the cost is high.

RESPECT: We speak with respect, resolve disagreements fairly and refrain from personal criticism.

ExCELLENCE: We strive to work confidently, minimize errors and serve customers with our best.

• Dedicated to paying living wages

• Highly impactful work and life skills training

• Chaplains on staff

• Goal to create 5,000 jobs by 2020

• Customers benefit by having trained, experienced, and loyal employees working on their products

• Founded in 1992 by William J. Moore in a 50,000 square-foot Chicago facility

• headquartered now at our 200,000 square-foot facility in hammond, indiana

• Construction of a new 110,000 square foot facility in Mooresville, indiana was completed in 2006

• Over 200 employees across both plants

• Over 150 million pounds of ingredients processed annually

• Annual sales over $20 million

A History of Innovation

external manufaCturing SolutionS that Stand apart

From highly trained people to high-performance equipment to audit-ready facilities that meet tough food certifications, PacMoore can deliver the processing, packaging and dry-ingredients you need. We’re known for providing the highest quality solutions possible, and we do it with fast turnaround times and high security, thanks to our two plants with broad, duplicated capabilities. Our expert engineers, operators and customer-service teams always work toward one goal – manufacturing your products with the strictest quality and confidentiality controls.

that’s the pacmoore difference – let us put it to work for you.

Capabilities Overview


two FAcilities• Hammond, IN, one hour SE of Chicago

• Mooresville, IN, 30 minutes SW of Indianapolis

• Operating 24 hours per day, five to six days to per week

pAckAging• Both plants can package into or from poly bags, multi-wall bags, drums, totes, bag-in-box, super sacks, bulk trucks or rail

• Multiple consumer packaging options at Hammond plant

• Rail service capacity at Mooresville allows for up to 22 railcars (8 indoors)

• Rail service capacity at Hammond allows for up to 5 railcars


eqUipment cApAbilities Hammond

• Dry blending - Ribbon blenders

- Plow blenders – equipped with chopper blades

• Consumer packaging - Hayssen vertical form, fill and seal

- Langen cartoner

- Bartelt horizontal form, fill and seal–equipped with auger, cup fillers and combi scale

• Repacking

• Sifting

• Bulk loading and unloading

eqUipment cApAbilitiesMooresville

• Dry blending - Ribbon blender

- Plow blender – equipped with chopper blades

• Spray drying - Niro FS4 spray dryer

- GEA Bowen design full scale spray dryer – equipped with rotary or nozzle atomization and fluid bed dryer

• Repacking

• Sifting

• Bulk loading and unloading

DevelopmentAl Ability• Pilot equipment - Blenders (ribbon and plow)

- Spray dryer

- Gluten-free bakery

• highly experienced staff

• Emphasis on innovation


paCkaging produCtS for the retail Shelf

PacMoore can package food into custom consumer packaging to get your product ready for the retail shelf. We can utilize your ingredients and packaging or provide turnkey manufacturing by procuring these items for you before processing and packaging your product.

Our vertical form, fill, and seal equipment, horizontal form, fill, and seal equipment, and cartoner equipment, enable us to package for retail in a variety of forms, sizes, and configurations according to our customers desire.

Custom Retail Packaging


HAyssen verticAl Form, Fill & seAl (vFFs)

• Able to fill powders, candy, snacks, nuts, and many other food granules, grains or pieces

• Fill options include auger and multi-bucket combi scale

• Stainless steel product contact

• Metal detection

• Tight product measurement

• Check weigher

• Efficient speeds

• Smallest Bag – 2 1/8" x 3" (W x H)

• Largest Bag – 12" x 16" (W x H)

• All types of poly-laminate film

• Printed, clear, or color film

• Registered or non-registered film

• Bag registration in one bag length

• Tear notch ability

• Code dates on film

• Clean, consistent seals


Acs bArtelt HorizontAl Form, Fill & seAl (HFFs)

• Able to fill powders, candy, snacks, nuts, and many other food granules, grains or pieces

• Fill options include auger, cup fillers, and multi-bucket combi scale – multiple drop ability

• Stainless steel product contact

• Metal detection

• Tight product measurement

• Check weigher

• Efficient speeds

• Smallest Bag – 3" x 3" (W x H)

• Largest Bag – 7 3/4" x 9" (W x H)

• All types of poly-laminate film

• Printed, clear, or color film

• Registered or non-registered film

• Gusseted pouch ability

• Tear notch ability

• Hole punch ability

• Zipper addition ability

• Code dates on film

• Clean, consistent seals

lAngen b1 HorizontAl cArtoner

• Able to fill cartons with product in self contained bags (VFFS or HFFS)

• Able to fill multiple components including promotional inserts

• Smallest Carton – 1 3/4" x 1/2" x 3 3/4" (L x W x D)

• Largest Carton – 12" x 6" x 14" (L x W x D)

• Code dates on carton

• Tuck or glue closure


dediCated to being the moSt reliable link in your Supply Chain

Quality assurance is PacMoore’s top priority. It drives everything we do, from ensuring food safety through contamination prevention policies to providing consistently smooth, homogenous blends to meeting food certification standards. We know that when it comes to you and your customers, too much is at stake to let food safety and quality be anything less than our number one goal.

Quality/Food Standards Certification


brc (gFsi)• Both PacMoore plants certified

with A ratings from the BRC for compliance with the Global Standards for Food Safety Initiative

HAccp• Fully functioning plan at both

plants includes screens, magnets, and metal detection

proDUct testing• internal - Sieve testing, viscosity, bulk density, salt titration, pH, moisture and color

• External - Micro testing, and a wide variety of physical or chemical characteristics


kosHer• Both facilities approved to

process Kosher products

• Orthodox Union (OU)

glUten-Free• Both facilities approved to

process Gluten Free products

• Gluten-Free Certification Organization (GFCO)

grADe A DAiry • Mooresville facility approved

to process Grade A dry dairy products for the U.S. and select EU countries

• Indiana State Board of Animal Health – Dairy Division (BOAH)

orgAnic• Mooresville facility approved to

process Organic products for the U.S. and entire EU

• Quality Assurance International (QAI)

HAlAl• Both facilities approved

to process Halal products

• Islamic Food and Nutrition Council of America (IFANCA)


our highly Skilled workerS deliver produCt exCellenCe

Even the most sophisticated equipment can only perform as well as the people operating it. That’s just one reason why PacMoore provides ongoing learning programs designed to be a standard in our industry. Auditors of our operations including many Fortune 500 companies consistently highlight PacMoore’s training as a prominent area of differentiation. Our training success has been acknowledged by the State of Indiana and featured in Indiana Business magazine.

Our employees are not only given extensive work skill training through our proprietary Target Talk program but also communication skills including English as a Second Language, education skills including GED preparation, and life skills including leadership, marriage, and financial training. These programs have combined to create a “culture of learning” which has brought continuous improvement to our work processes, multiple facets of growth in our employees, and improved delivery of service for our customers.

Training and Education


sAFe orientAtion trAining

• SAFE (Stop, Analyze, Fix, Educate) teaches employees to recognize, highlight, and correct problems in the workplace

• 4 key areas of awareness

- Hazardous conditions

- Personal Safety

- Food Safety

- GMPs

• Testing confirms learning and retention

on tHe Job trAining

• Specific to work environments

• Focus on SOPs

• Ongoing training and coaching

• Buddy system matches new employees with experienced employees

• Certifications allow increased responsibility



tArget tAlk trAining

• Proprietary PacMoore developed program

• Engaging and interactive

• Teaches key components of PacMoore operations

• Continual rotation for constant reinforcement


• Target Talk training areas:

- Personal Safety

- Food Safety

- HACCP

- GMPs

- Sanitation

- Metal Detection

- Equipment Safety

- Electricity

- Tools

- Motors

esl AnD geD

• 16 week educational sessions

• Improves language and communication skills

• Develops math skills and prepares for higher education

• Strengthens teams and builds a positive work environment

• Improves safety


• Enhances not only work skills but promotes cultural and community assimilation to positively impact our employees’ quality of life outside of work


people you Can Count on at every level

With PacMoore, you’re choosing much more than a co-manufacturer. You’re also selecting a partnership team who listens in order to understand your needs and respond with expert solutions. PacMoore’s renowned responsiveness is possible only because of the people who comprise our company at all levels. They’re our most valuable asset, and through training, expertise, innovative thinking and unwavering commitment to customers, we’re always leveraging that value to give you our best.

“ �When�push�comes�to�shove,�you�can�deal�with�anyone�—�but�I�prefer�PacMoore.”

People



oUr cUltUre oF cAre pAys oFF

PacMoore not only believes strongly in high quality job-skills training, we are committed to life skills training as well. We fund training that allows our employees to become fluent in English and to obtain their GEDs where needed, so they can achieve more and experience more, not only on the job but also in their homes and communities. Three of our recent GED graduates are moving on to higher education. We have been gratified to see their life experiences and potential expand because of the success of our programs. Even more importantly from our perspective, we also offer spiritual support and encouragement to help employees cultivate this aspect of life as desired, with chaplains assigned to each of our plants.

responsiveness in Action

One major international Fortune 100 food company relies on PacMoore for re-packaging and blending some of its major ingredients into sizes and configurations that work best for the efficiency of its plant. Because this customer has a constantly changing production schedule, a lean supply chain and shifting demand, they consistently praise PacMoore’s ability to accommodate changes whenever possible. At PacMoore, we employ people who recognize that our success depends on our customers’ success. Let us know how we can add to your success, as well.


A few examples of PacMoore’s people at work:

leArning yielDs continUoUs solUtions

When a competitor of ours suddenly went out of business, their customers were affected by the unforeseen loss of supply. Due to the closure, one customer stood to lose an important piece of business if they could not re-source production within six weeks. Thanks to our training and ability to respond in new situations, PacMoore was positioned to help. We tested and produced a blend unlike anything we had produced before, sourced and ran packaging equipment we had not utilized before, and shipped product in five weeks, saving the customer’s business. The only reason our management accepted this sizeable challenge was the confidence they had in our trained employees – and they delivered!


we never Stop looking for wayS to help you improve

With PacMoore, you get much more than a co-manufacturer – you get an expert partner who works closely with you to deliver solutions that address your needs. Whether you want to streamline your manufacturing process, improve blend consistency, upgrade packaging, integrate challenging ingredients or explore new products, PacMoore can deliver. We continually innovate for customers, helping them resolve production issues, take advantage of market opportunities or simply reduce costs. If you are still searching for the right solution, you haven’t asked PacMoore yet.

Problem Solving

“ �On�the�first�try,�PacMoore�was�able�to�solve�a�manufacturing�challenge�that�we�struggled�with�for�25�years.”

mAnUFActUring improvements

A major food manufacturer came to us after having poor experiences with several suppliers of outsourced spray drying. We invested in new equipment that would provide us with the full capability to resolve the issues and supply all of their needs. In addition, we also leveraged our spray-drying expertise and our equipment’s capabilities to increase the concentration of a key product component, which the customer had been trying to accomplish for 25 years. By truly listening to our customers’ needs, PacMoore can take your company and products further.

From cUstomer HeADAcHes to tUrnkey solUtions

One major CPG company had been producing a product component blend in their plant for years, knowing it was inefficient and out of the company’s core competency but also believing there were no other options. They then had to have it re-packed at a supplier who lacked the proper equipment. When they reached out to PacMoore, we provided the right solution. For year one, we provided a responsive re-pack solution, and for year two, we suggested blend adjustments, sourced ingredients, optimized equipment and delivered a turnkey solution.

A few examples of PacMoore’s problem solving at work:

solving ingreDient cHAllenges

One leading global candy manufacturer struggled for years to introduce a topical sweetener into one of their key lines of products. The problem not only affected the products but efficiency and worker safety as well. PacMoore was able to blend a product that created more consistent application, better product flow, higher yields, and reduced potential for injuries during production. We love to provide blending solutions but this was certainly one of our sweetest!



we take your buSineSSaS SeriouSly aS you do

At PacMoore, our goal is to serve as an extension of our clients’ manufacturing facilities, so the products we deliver always match your high expectations — and ours. With us, you get more than just a co-manufacturer – you get a partner whose processes are intentionally designed to protect your company, your consumers, your brands and your competitiveness in the market. Our plant certifications and audit readiness are only the beginning. To us, protection is a promise that extends through every level of every customer partnership.

Protection

“ �The�giants�of�the�food�world�are�their�customers.�And�since�they’ve�approved�PacMoore,�we�knew�they’d�already�be�at�the�level�we�need.”


conFiDentiAlity is key

PacMoore understands theabsolute necessity of confidentiality. Our high level of quality puts us in a small niche of top contract manufacturers. It’s only natural then that we work with many major food manufacturers, some of whom compete with one another. At PacMoore, we have great sensitivity to this and work with the utmost discretion for every client on every aspect of their business.

yoUr bUsiness comes First

PacMoore’s business is designed so that we succeed only when our customers do. As you grow, we grow. PacMoore’s top priority is your business. That is why we never compete with our customers. We never want you to worry about the security of your formulations, intellectual property, brands, customers or priority in our production schedule. Not only does our business model inherently protect you, but our values do, as well.

preventing contAminAtion

From receiving to processing to warehousing to shipping, PacMoore maintains strict adherence to our industry leading allergen control and segregation policies. We also have dedicated gluten free processing capabilities and are able to meet stringent food certification standards, including Kosher, Grade A, Organic and Halal.

protection For tHe FUtUre

Where will PacMoore be in the years to come? Right here, serving you. We have invested in our future strategically but also prudently, not putting our financial position at risk. Our experienced management team and succession planning ensures the stability of the company in case of any unexpected loss within our leadership or ownership. Even our plants have protection built in, with both of them featuring many redundant capabilities. You can sleep easy at night — we will be here.

A few examples of PacMoore’s protection at work:

ensUring proDUct AnD brAnD protection

Shortly after being awarded business that had previously been processed by another contract manufacturer, PacMoore’s HACCP plan proved worth the investment and focus. Our customer’s blend was used in a retail product that was part of a new launch for a highly regarded consumer brand. Early in production, PacMoore consistently identified that one component of our customer’s blend contained a low level of metal. Our customer was grateful for being alerted to the issue, which prompted them to change raw material suppliers. They have gained peace of mind from knowing that their brand’s quality remains intact and that its equity is protected by PacMoore.



PACMOORE Manufacturing Brochure

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