MEAT+POULTRY - March 2015 - 50

D R Y- C U R E D M E AT R E P O R T

VERSATILE AND TALENTED

Photo courtesy of Tala Drzewiecki

"Our machinery
aids production,
but our most
important
machines are
our people."

50

La Quercia introduced the US to its first
Prosciutto Varietals - dry, cured ham made
from specific sources with specific breeding
and husbandry specifications. Its products are
sold at high-end supermarkets throughout the
US, including Whole Foods, and at some of
the best-known specialty stores and high-end
restaurants in the country. Product is also sold
on the websites of several customers - and
in Canada. "Our [retail and foodservice]
customers really care about the quality of
meat, where the animals come from and how
they're raised - and they want to enjoy a good
eating experience every time," Herb says.
Trends driving La Quercia's business
include the continuing growth and popularity
of upscale, Italian-style deli meat; the
increasing demand for more hand-made
American food products; the continuing
growth of natural products; and increasing
disposable income among US consumers.
La Quercia's newest product is Salami
Americano, a 2 ¼-inch-diameter salami. "We
use all the parts of the pig and trim to make
various salamis," Kathy says.
Using co-packers is not an option. "I'm in
favor of developing the American, premiumquality, cured-meats industry, but you can't pay
attention to all the details when you co-pack,"
Herb says.

MEAT+ POULTRY | 03.15 | www.meatpoultry.com

Attached to the company's recently remodeled
and expanded corporate office is a versatile,
10-year-old, 30,000-sq.-ft. production plant.
Thirty-nine people staff the plant, which
operates one production shift and one
sanitation shift per day, five days per week.
At present, the company buys approximately
3 million lbs. of pork annually to produce its
growing range and number of products.
Herb and Kathy work on the production
floor about nine hours per week handling
different jobs. "Working in production
shows our employees how seriously we take
production and how important it is working
with them on shifts," Kathy says.
Sustainability is key to continuing
success. La Quercia's production facility,
which opened in February 2005, was
built with energy efficient materials and
it even uses an environmentally friendly
refrigerant. New curing space added in
2009 incorporates high-density, non-ozone
depleting polyurethane foam; Freon R404A;
heat recovery from the refrigeration
compressors provide most of the heating;
and computer-optimized compressors
minimize horsepower on-line. High-efficiency
fluorescent lighting was installed and ondemand hot-water heaters reduce electricity
and gas use.
Smoking is the only process not done
at the plant; a local smokehouse naturally
wood-smokes their meats. "We considered
installing a smoker," Kathy says, "but
the strong, pervasive, smoky odor would
permeate everything."
Flexible is the word that best describes
the production plant. "Lines and operations
[much of the equipment is portable and
not fixed] differ on any given day," says
Sebastian Beumer, plant manager. "We have
a salami line operating today.
"Everything started with a table top,"
Beumer adds. "We're now looking to conveyors
and auto lifters to bring products to our
people. We strive to make everything more
ergonomic for our workers. We're also taking
LEAN systems. We're working to reduce
wasted motions in processes. We're working to
streamline everything possible to get the most
from our people through good organization."
http://www.meatpoultry.com
MEAT+POULTRY - March 2015

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