Flavorcraft LLC
PARTNERS IN FOOD SOLUTIONS
QUALITY
The Flavorcraft team includes two HACCP-certified managers who ensure that our products maintain the quality and consistency that we are committed to providing to our customers. Our food scientist also serves as our director of research and development and quality assurance manager. She holds Better Process School certification in addition to HACCP certification.
SERVICES
Our facility offers a broad range of services to customers of many sizes, from a start-up wanting to manufacture 500 gallons of a product to monthly production by the thousands of cases. Our customer base ranges from small, privately-held mail-order companies and restaurants to gourmet foods retailers to national food service companies. We are able to assist with research and development in our onsite laboratory and ramp up production quickly based on company growth. We are generally about one month out on new orders of existing products, but the development phase can take several months to a year to realize.
CERTIFICATIONS
Flavorcraft is organic certified, and is registered with the FDA and permitted through the Commonwealth of Kentucky ‘s Cabinet for Health and Family Services as a food processing establishment. We are able to offer Kosher and Halal processing depending on customers’ requirements. We also hold the permits necessary to manufacture products with alcohol.
Flavorcraft LLC
Capabilities
Flavorcraft LLC is a leading manufacturing and co packing company based in Louisville KY, the main Louisville facility is approximately 35,000 square feet. 6 production lines consisting of:
Bulk Packing Line:
- 275 Gallon totes
- 55 Gallon Steel and Fiber Lined Aseptically Packed
- 5 Gallon Pails
Cup Lines:
- Flavorcraft has a total off 3 cup lines
- 60 mm and two 75 mm cup lines.
- Products includes Dip cups (Condiments and Wing Sauces), Jell-O Shots, Ice Shots, Thickened Water, Pudding and Nectar, Juices, Vitamin enriched products, puddings.
Pail Line:
- We are currently packing various condiments and products in HDPE pails.
- Pack sizes includes but are not limited to 1 gallon, 2.50 gallon and 5-gallon pails – Current capacity on this line is +/- 4.5 million pounds per annum.
A-Line:
- 2oz, 5oz, 10oz, 12oz,16oz 25.4oz,32oz, 1 liter, 1.75 Liter, ½ Gallon and 1 Gallon
- Product can be packed in Glass, PET, HDPE, PVC and Aluminum
- Products include but are not limited to BBQ Sauce, Salad Dressings, Marinades, Wing Sauces, Jams, Jellies, Cocktails Sauces, Dipping Sauces, Steak Sauce, Hot Sauces, Salsa’s, Curry Sauces and Dips
For Fill and Seal Line:
- A fully automatic form fill and seal line that can do pouches and or bags ranging from 2-inch x 3 inch to 6-inch x 12 inch.
- Packaging fill that can be used is PVC, Poly Laminates, Mylar Film etc.
- Products currently packed are Tahini Sause, Garlic Sauce, Pasta Sauce, Marinara Sauce Pizza Sauce etc.
Beverage Line:
- 100 ml, 200 ml, 12oz, 16oz, 20oz, 1 liter, 1.75-liter, Gallon
- Product can be packed in Glass, PET, PVC, HDPE, Aluminum, and others.
- Products include, Ready to Drink Teas, Flavored Waters, Energy Drinks, Alcoholic RTD’s, Margarita Mixes, Fruit Flavored Lemonades, Organic Teas . Coffee Syrups, Elixirs, Juice Concentrates, Smoothies, Vitamin Waters and Simple Syrups. Carbonated products, CBD Oils, Energy Drinks.
Bag In a Box Line:
- A fully integrated Bag in a Box Filling System aseptically packed.
Products that were packed include Drink Concentrates, - Beverage Syrup Concentrates, Ketchup, Mustard, Alcoholic Mixers.
Keg Line:
- A new addition to our capabilities was added in March 2021. Current capacity is set at 900 x 30-liter kegs per shift. Application for product is mainly in the restaurant and food service industry.
Drum and Tote:
- Flavorcraft is currently packing BBQ Sauces, Marinara Sauces, Pasta Sauces, and wine reduction sauces in 55-gallon drums and 275–300-gallon totes. This caters especially for larger industrial customers.
Flavorcraft can do dry blending.
- Current capacity is more than 2 500 000 pounds per year.
Flavorcraft plans to add the following lines that will enhance our capabilities and capacity:
- Vertical Form Fill and Seal Machine – 6 million gallons per year. This project will also include additional cooking and processing equipment
- Upgrade existing Jam, Jelly, Preserve and Mustard line. Additional equipment will include Steam Capper for 53-, 63-, 70- and 82-mm Caps, High Speed label machine
- Upgrade A-Line by adding a high-speed Capper and Versatile inline filler which will increase our capacity 120 %
- Additional Cup Machine to cater for increased demand of customers in portion control pack.
Flavorcraft has over the years formed strategic alliances with other copackers and give us the ability to offer a wide array of other packing capabilities and capacities. This includes the following:
- Beverage Canning 8.40oz, 12oz and 16 oz
- Tetra Pack drinks and fruit juices 177 ml and 200 ml
- Sachets ¼ oz to 3 oz
Flavorcraft LLC
Customer Base
Flavorcraft has provided services to a wide array of companies and end customers, including Kroger, Meijer, Publix, Trader Joe’s, Aldi, Maker’s Mark, Wild Turkey, Heaven Hill, Bourbon Country Products, Meyer Brothers, Smithfield Foods, Costco, Amazon, Fresh Market, Whole Foods, Ole Ray’s Sauces, and more. Flavorcraft is currently producing more than 4,000,000 pounds and completed over 400,000 cases of products in 2021.
Flavorcraft provides personalized service and custom production lines to meet specific needs in contract manufacturing, liquid and bottle filling, and blending and packaging services for a wide variety of food and beverage products.
Flavorcraft is dedicated to the success of our customers and their product needs. Whether it is a new product introduction, overflow capacity production or secondary packaging, our team is dedicated to help you succeed while supporting your processing and packaging needs.
What Makes
Flavorcraft Unique
Our capability to bring a product from concept to market is a big advantage over our competition. Our services includes research and development of new products, the adaptation of the same products to meet certain price points, matching of flavor and taste profiles, nutritional analyses, development of process control protocols, conducting shelf life studies, assisting with packaging development, and regulatory and statutory formula filings with authorities and process authorities.
Flavorcraft also prides itself in short turnaround times and going the extra mile for our customers. In normal circumstances, customers experience long lead times while being required to order large volumes. This is especially difficult and expensive for new companies and in the launching of new products.
The fact that Flavorcraft can do small batches attracts customers to test products before scaling up to larger production runs. We are very competitive with lower-volume orders of between 200 and 2,000 cases. We can also change production schedule on a relatively short notice to accommodate urgent production runs. This appeals to customers, especially in a rapidly changing marketplace.
Flavorcraft also prides itself in its logistical support services on behalf of customers. Our location is of vital importance, as about 65% of the country’s population is within a 600-mile radius. We are located on the I-64, I-65, and I-71 corridors, and I-75 is within 90 minutes of our facility. This is equally important to our supply chain for raw materials and packaging materials procurement on a just-in-time basis.