Facility

After over 2 year of planning, preparation and building, our state of the art facility encompassing all of the service areas below, opened it’s doors in Spring 2015.

The building is an evolution and embodiment of all the experience and knowledge that we’ve gained over the last 20 plus years, in which time we have had several manufacturing sites. This means that all the process flows and efficiencies from production and admin, to product development and cleaning have been optimised and matched to todays rigorous standards and requirements on both the regulatory and quality side to the commercial side.

With further room on site for expansion in the future, we can increase capacity and add further capabilities again in the future with minimal disruption.

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Laboratory

We have a large, spacious and well equipped lab and test kitchen that is used for both product development work and quality testing and checking of finished products. Part of the development process for new products involves customers visiting for tasting sessions in the lab which is well suited for a comfortable day of trials and taste panels. All of the production processes we carry out at Calleva can be replicated on a small scale in order to accurately test products and ensure compatibility prior to increasing volumes to full production size batches. Organoleptic, physical and some chemical testing is also carried out in house in our laboratory and we have close relationships with some chosen external partners for microbiological, nutritional, banned substance, accelerated shelf life and other specialist testing services.

Powder Blending

Calleva’s powder production facility incorporates several pharmaceutical-grade blenders designed to mix a wide range of powdered ingredients gently and efficiently, while offering flexibility across different blend volumes. All powder production lines also include integrated sieving and metal detection, providing complete confidence in product quality and safety. Our processes are supported by a centralised batch control system, ensuring full traceability of raw materials and consistent production managed by our highly trained and dedicated team.

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Liquid Processing

Our bespoke liquid mixing and heat treatment plant is designed for small to medium sized production runs of specialist liquid products. Rather than large-scale beverage production, our facility is dedicated to producing sports gels, syrups and other specialist liquid ingredients. The plant features full CIP capability and supports both hot and cold filling into bulk containers. As with our powder production, every ingredient and finished product is tightly controlled through our batch management system to ensure quality, consistency and full traceability.

Packing and Filling

Our filling lines are housed in dedicated production rooms designed to reduce risk of cross contamination and maintain extremely high levels of hygiene whilst being comfortable and efficient to work in. We have multiple state of the art production lines consisting of horizontal form fill and seal (FFS) machines for powder sachets, a fully automatic, high output, powder doy pouch line and vertical liquid stick pack FFS machines.

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Warehouse and Storage

Raw material ingredients are stored in our large, clean internal warehouse, with space maximised through use of high bay racking. We have separate areas for the storage of finished products, allergens (milk and soya as Calleva are a nut free site), and organic products in accordance with our BRC accreditation and internal quality management system. Once ingredients are opened for use in production we also have a dedicated area for secure storage of any partially used bags that adjoins our dispensary room for easy point of use access during subsequent weighings.

Packaging items and consumables are stored separately to all raw materials and finished products, for both cleanliness and product safety.

Offices

Our modern and spacious offices create a hub for all of the support services necessary to back up our business, from sales, purchasing and quality, to maintenance and management. In addition we have a board room for large meetings and presentations and a range of options for smaller meetings, even including a completely private office for customer use during extended lab trial days or longer meetings.

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