Starting research on sauce packing business, co-packing

Good day!

Note: If the mods feel this is inappropriate or too business related, please let me know; move or delete as required.

My wife and I have decided to go down a new road and chapter in our life which entails opening up a small co-packing business. Along with cooking, packing and labeling our own line of sauces, and in order to make ends meet we will do packing for other people as well. Our focus is on the small guy, someone who doesn't need 250 cases of product, (we can do that), but say 40 cases, maybe fewer. Print labels (digital) and all.

A lot to consider! One thing I am truly seeking comment on from anyone who might be in the know or been around other co-packers, is a floor plan for the cooking, packing and labeling area. Generally this cooking area would be a clean room within an industrial style building with plastic air curtains and the like. I also realize that AZ has possibly some specific rules, but I am trying to get a general idea of where say a hand washing sink would be located in relationship to dual stainless sinks for the cooking and cleaning of the kettles and etc. and just general thoughts from you all on how this would best be laid out. And what should be contained outside of this clean room. I.E., should bottles be laid out outside this clean room and conveyored in with labeling done outside as well?

I know this is pretty generic and a very broad question, but I feel certain that someone may have some good thoughts on such.

Thanks a bunch for any thoughts, insight, ideas, or whatever.

John

Thanks everyone for your comments! In Arizona it is the Arizona Department of Health who regulates food manufacturers and packers with primary enforcement duties held by county health departments. So far I have to start with county, get through that then go to the state then the FDA.

@Southern_Home_Boy. Our ancillary services will be 'farmed out' to laboratories. Recipes will be scaled up or down, usually up, via computer program/math AND the customer being present for the first batch/run and any tweaks added/not added during a larger batch run. Without a doubt, no matter how accurately you ramp up or multiply a recipe for gallons instead of a few quarts, things may taste different. In my belief, the customer is right and he will decide on his product, flavor profiles and etc. As for dsitributors, I have been in touch with several for my products and would be more than happy to assist our customers in expanding their product availability.

I have a lot of hurdles ahead!

I was hoping for some ideas to have so i wouldn't go in to my HD with a total blank sheet of paper, but maybe that would be best to get their input from the "git go". Industrial space where I live is inexpensive, but fitting them with clean room for packing and cooking with water and drainage is going to be one of the biggest hurdles.

@BigButzBBQ... I do fear success to a big degree. We all want success. But I guess we can take on as much as we want to handle so if it is successful we won't tend to be too greedy. As far as customers expecting this and that from us, one thing I have learned from dealing with several co-packers in this past year is to ensure a good statement of understanding as part of the confidentiality agreement. One guy, by the way in Ixonia WI, was really going to put it to me without me fully knowing it as far as quantities. That rep got fired for some reason right in the middle of working with them. That's when the facts came out.

Still open for more feedback and ideas! And sorry for being long winded

@bbqpitstop. I have already encountered pretty high shipping costs as they have gone through the roof. Truck shipment has been by for more economical but for a couple cases.. that's problematic.

@Jacked_Up_BBQ. THANKS! I've got a loooong way to go and so far it has been a challenge. But I do know a guy in Alabama who is helping me out and is in the process of getting a plant running again catering to the smaller guys. He is further along in the process but still several months out. Check with Dave at Kalahari Pepper Company, kalaharipepper.com. He is a bit closer.

In looking at some industrial warehouse office space, to retrofit will be pricey! Gas on the wrong side, water on the wrong side, no drains..... That's why I'm doing research first and found a ton more on the Internet last night about misc 'stuff'. The old saying of "there's no such thing as free lunch" sure is a fact!

John