Company History 5 The Van Drunen family emigrated from the Netherlands to South Holland, Illinois in the mid 1800's. The first farm crops grown by early Van Drunen settlers were potatoes, onions, peas, beans, cabbage, and carrots. In the early 1900's onions, onion sets, and potatoes became the main crops. In the late 1960's chives became of interest and were planted, harvested, and sold fresh to the Chicago market or frozen for use by dairies. During this time freeze-drying technology began to have an impact on the food industry. Some of the frozen chives were sent to various freeze-drying companies for custom drying. Freeze-dried chives became popular due to the quality of the freeze-dried product and the ease of product use. Van Drunen Farms eventually became one of the largest producers of chives. In order to better integrate production and to gain more control of the entire process, eight freeze-drying chambers were purchased in 1985. Installation began immediately on four of the chambers, which were operating by 1986. The freeze-drying plant was constructed in Momence, Illinois close to the family-owned farms where the chives were being grown. To better centralize all facets of production, all operations were moved from South Holland, Illinois, to Momence, Illinois, in 1987. The four additional freeze-dryers were installed in 1988. This allowed for the introduction of both freezedried fruits and vegetables. In addition, a line of IQF (Individually Quick Frozen) herbs was introduced. These herbs, which were grown locally by Van Drunen Farms, were marketed for use in wet applications as an alternative to fresh air-dried herbs. Another expansion took place in 1991 with the purchase of an additional facility and eleven more freezedrying chambers. The new installation opened for full production in September of 1992. In April of 1994, construction and installation of a double cylinder drum dryer was completed. This new system allowed Van Drunen Farms to produce low cost vegetable, fruit, and bean flakes. In 1996-1999 Van Drunen Farms continued to grow. A production line was added to produce sugar-infused fruits, two additional drum-dryers were installed, and a fire roasting line was added for the production of roasted IQF vegetables. The demand for Drum Dry products expanded quickly and in 1998, a new facility was purchased as a dedicated Drum Drying facility. In addition, a 170,000 square foot warehouse was added as a central warehouse and shipping location. By the year 2007, the drum dry facility added another 50,000 square feet of processing and three more drum dryers. Also in 2007 the main freeze dry facility saw a doubling in size and increased drying capacity by another nine freeze dryers. In the years of 2011 and 2012, an additional six freeze dryers were added to the ever increasing drying capacity of the Tuthill facility. Although the business has changed its operations and focus over the years, it is still owned and operated by the Van Drunen family and continues to grow and change to meet customer and market demands. This HACCP plan is fully endorsed by the management team*: Kevin Van Drunen, President Jeff Van Drunen, Operations Manager Deb Dobben, Financial *Signed copy is included with master copy of HACCP plan.
6 Description of Products Freeze Dried The Process: In the freeze-drying process, frozen food products are placed in a vacuum system so that the ice in the product can be turned directly into water vapor. Since the product remains frozen during the process, the product's cell structure is not disturbed. This method retains the color, shape, flavor and nutritional value better than other drying methods and allows the finished product to be quickly rehydrated when used in applications. Applications: Freeze-Dried products are available in whole, piece, and powder. A full line of herbs, fruits and vegetables are produced for sale to the industrial food ingredient market. Packaging and Storage: The primary contact packaging of freeze dried product is heat sealed 6 mil blue poly liners inside of corrugated cartons. Freeze dried products should be stored in a sealed container at ambient temperatures. Vegetables: Artichoke Asparagus Beans, Green Beet Broccoli Brussels Spouts Cabbage, Green Carrots Cauliflower Celery* Corn, Super Sweet, Gold and Jubilee Collard Greens Cucumber Edamame* Garlic Freeze-Dried Product List Kale Leek Mushrooms Mustard Greens Okra Olives, Black Olives, Green Onions, Green, Red Onions, White Onions, Yellow Peas, Garden Peas, Split Pepper, Gr. Bell Pepper, Gr. Chile Pepper, Jalapeno Pepper, Red Bell Pepper, Yellow Bell Peppercorns, Pink and Green Potato Shallots Soybeans* Soy Nuts* Spinach Squash, Yellow Squash, Butternut Squash, Zucchini Sweet Potato Tomato Turnip Fruits: Acai Apple Apricot Aronia (Chokeberry) Banana Bilberry Blackberry Blueberry Boysenberry Camu Camu Cantaloupe Cherry Cranberry Currants, Black Dragon Fruit Elderberry Goji Grapes Grapefruit Lemon Kiwi Lime Mango Mangosteen Nectarine Noni Orange Papaya Passion Fruit Peach
7 Pear Pineapple Plum Pomegranate Raisins Raspberry Rose hips Strawberry Tangerine Freeze-Dried Product List Herbs: Basil Chives Cilantro Dill Beans: Adzuki Black Garbanzo Other: Alfalfa Sprout Barley* Broccoli Sprout Powder Buckwheat Sprout Cheese* Chía Chlorella Clove Coffeeberry Dandelion Root Powder Eggs* Gingko Biloba Marjoram Oregano Parsley Kidney Lentils Lima Fo-Ti Root Powder Ginseng Ginger Green Tea Powder Ice Cream * Kamut* Kelp Powder Melts, Fruit and Veggie Miso* Oat Grass Powder Pumpkin Seeds Nettles Sage Thyme Navy Pau d Arco Powder Rice Quínoa Rhodiola Rosea Sesame Seeds* Spirulina Tofu* Turmeric Wheatgrass Wheatgrass Sprout Yogurt* Low Moisture Fruits The Process: Fruits are saturated with a liquid base sugar, then lightly dried to offer a flavor packed product that keeps its original size with a chewy texture. Applications: Low moisture fruits are available in whole or piece form. Outstanding flavor makes low moisture fruits ideal for cereals, mixes and bakery goods. Packaging and Storage: The primary contact packaging of low moisture products is 3 mil blue poly liners folded over in corrugated cartons. The average expected shelf life for low moisture products is 18 months. Low moisture products should be stored in a sealed container at ambient temperatures.
8 Low Moisture Product List: Banana Blackberry Blueberries Cranberries Cherries Lemon Peel Orange Peel Peach Strawberries * Allergen/Sensitivities ** Based upon scientific and historical data on the raw materials listed, Listeria and Salmonella are considered to be the microbiological hazards on all risk assessments contained in this plan. *** Individual risk assessments for raw materials, packaging and ingredients are available for each process upon request. See VDF documents HACCP-2010 through HACCP-2065 Ingredient List: Tuthill: 10 strain probiotic blend Acai Flavor Acerola extract Aloe Amberex Ammonium Carbonate Ammonium Hydroxide Antifoam Emulsion Apple Extract Apple Pectin Aronia Ascorbic Acid Banana Natural Flavor Beet Juice Clarified Beta Carotene Bilberry Extract Bilberry Wild Extract BioPure GMP Black Currant Extract Blackberry Flavor Liquid (Natural) Black Radish Powder Black Soybean Hull Extract Blueberry Liquid Concentrate Blueberry Flavoring Blue Corn Extract Boric Acid Brown Rice Protein Buckwheat Flour Butter, Salted* Calcium Acetate Calcium Carbonate Powder Calcium Chloride Calcium Lactate Cane Sugar, Granulated Cane Sugar, Liquid (Organic) Canola Oil Capsicum Cellulose Chromium Chloride Hexahydrate Cinnamon Citric Acid Cocoa Powder Coconut Oil RBD Concord Grape Juice Concentrate Corn Flour Non-GMO Corn Flour (Organic) Corn Syrup Cumin (Organic) Cranberry Flavor, Natural Cranbiotic Cultures Crystaline Fructose Dextrose D-Mannose Elderberry Natural Flavor Egg Whites Powdered Enzyme Blend NSA Evaporated Cane Juice Fibersol 2 Flax Seed Powder Glacial Acetic Acid
Glycerine Grape Seed Extract Green Tea Extract Gum Acaia (Organic), Fibergum Hydro-Dri AFA Powder Inostitol Powder Inulin Agave Inulin Jerusalem Artichoke Iron amino Acid Chelate L. Acidophilus L-Arginine Base L-Carnitine Base L-Carosine L-Cystein Hydrochloride L-Histidine Base L-Lysine Monohydrochloride Malic Acid Maltodextrin Maltodextrin (Organic) Millet Flour Monk Fruit Extract Nicotinic Acid Novoshape Nu-Rice Oat Beta Glucans Oat Flour Olive Extract Onion Extract Quercetin Palm Oil Pea Protein Powder Peach Flavor (Natural) Pineapple Flavor Pine Bark Extract Pomegranate Extract Potassium Carbonate Potassium Sorbate Probiotics Puree Carrot Juice Concentrate Quercetin Anhydrous Raspberry Flavor (Natural) Red Color FD&C #40, powder Reservatol Rice Bran Risolubles Rice Flour (white) Rice Maltodextrin (Organic) Royal Jelly Powder Safflower Oil Sea Salt Silica (Amorphous) Silicon Dioxide Sodium Benzoate Sodium Bicarbonate Soy Concentrate Standard Dye Reactive Blue #4 Stevia Strawberry Flavor Liquid Strawberry Flavor Powder Sugar Beet Fiber Sugar Cane Juice Evaporated Sunflower Lethicin Super Multi Enzyme Blend Supernat Sweet Whey Powder* Tangerine Juice Powder Tapioca Maltodextrin Tartaric Acid Taurine Tutti Fruitti Flavor Vanilla, Natural Vitamin E Powder Vitamin K1 Vitamin Mineral Premix Wild Yam Powder Xylitol Yeast Extract Powder (Organic) Yumberry Powder 9