When it comes to meat products, the MANE Group’s flagship manufacturing site is in Rubí, Spain, combining a production plant, R&D centre, and prototyping unit.
In 2014, the MANE Group unveiled a new facility in Rubí, near Barcelona, that specialised in texturising products for the meat industry and had recently been acquired from the Cargill Group. Today, the site comprises a production plant, an R&D centre for meat and charcuterie products, and a prototyping unit for new offerings. It also has two flavour application laboratories for sweet and savoury.
“Rubí is the Group’s main production centre for the EMEA region for charcuterie products,” says Erwann Chabot, CEO of MANE Iberia and Industrial Director for the French sites at Quéven and Sablé-sur-Sarthe too. “We’re also the main R&D platform for the meat market in EMEA.” Rubí’s clients operate in more than 20 countries around the world and although most are involved in the meat industry, some are also active in the snacks sector.
Production lines and powders
Rubí is the Group’s largest manufacturer of savoury powders by weight, with more than 10,000 tons a year rolling off its four production lines - which can provide four different mixtures at the same time. “Our expertise is in mixing powders to offer a complete solution for making the final products,” says Erwann Chabot, adding: “The secret is in the formulation…”
In terms of product types, Rubí specialises in both flavouring and functional powders, which provide both texture and a specific lifetime for a product. “Our focus is on taste and flavour,” explains Erwann Chabot. “Our flavourings provide taste, while our other ingredients give texture, and we consider them a separate group of products. We do not have any functionality other than taste in our flavourings.”
An R&D centre that drives innovation
Rubí’s R&D teams are constantly working on innovations in areas such as:
- elimination of nitrites
- reduction of salt, sugar and phosphates
- development of juice-based flavourings (used in stock)
- transition to vegan diets
- clarification in terms of labelling (clear label products).
Located within the R&D centre, the prototyping unit is designed to meet the needs of customers seeking to develop new technologies or new products. Consumers in Spain are true connoisseurs when it comes to the spices used in products such as chorizo, ham, sausages and the Catalan speciality, fuet.
Quality, a shared commitment
Another key role is carried out by Rubí’s quality team, which ensures that the Group’s customers benefit from the highest possible standards of food safety. To deliver products that are 100% compliant with regulations, the team operates an extensive laboratory area where a range of tests can be carried out every day, including:
- organoleptic analyses (observations of different aspects)
- microbiological analyses (for hygiene issues)
- granulometric analyses (to ascertain the size of particles)
All raw materials arriving on-site are tested, as are the finished products prior to dispatch. “The quality control team checks for allergens and any potential cross-contamination,” adds Erwann Chabot. “Nothing leaves Rubí without quality being involved.”
Certifications and environmental efforts
To meet the needs of a wide range of consumers, the site is approved for specific labelling regimes, such as halal, along with certification standards:
- FSSC 22000, based on the ISO 22000 standard, it meets the requirements of distributors and industrial companies for food safety management;
- ISO 14001, an environmental management system focused on reducing energy intensity;
- GEEIS (Gender Equality European and International Standard), a label that promotes gender equality in the workplace;
- SMETA (Sedex Members Ethical Trade Audit), an ethical audit methodology that encompasses all aspects of responsible business practice.
When it comes to environmental commitments, the site uses 100% renewable electricity and efforts are also being made to reduce its energy consumption as far as possible. All statutory requirements are being met for the management of wastewater, with water consumption per ton of manufactured product being reduced every day.
Proximity, trust and transmission
More than 100 employees work at Rubí, where the atmosphere is more like a family and the average length of service is more than 18 years. “Employees help each other, and the senior managers work closely with their teams,” says Erwann Chabot. “Everybody has access to the top executives and the production department, which means that people can easily share their ideas with the rest of the team.”
Knowledge and experience are passed on from one generation to another, with employees coming up for retirement playing their part in training the new recruits for up to 7 or 8 months. “In general, the newcomers enjoy learning from the people around them,” concludes Erwann Chabot. “It’s easier for them to communicate and to see their long-term future here. There’s a genuine transfer of knowledge and it’s done in a way that also builds trust.”