Build better. Operate smarter.
Designing a plant, starting one up or getting more out of the one you have takes someone who has done it, more than once, under USDA and FDA rules. Nacho has designed, opened and run food manufacturing facilities for over two decades.
You're planning a new facility or expansion and need a layout that will still work at twice the volume.
Product flow, equipment placement or bottlenecks are capping your output.
Your quality, sanitation or food safety programs are thin, informal or failing audits.
You're moving production from a kitchen or co-packer into your own plant.
Relevant experience
Nacho designed, opened and ran the Real Mex Foods plant, commissioned Everytable's 35,000 sq ft FDA facility, and has jump-started USDA and FDA facilities for Practical Solutions clients since 2015.
Everytable · 2020–2021
Vice President of Supply Chain, Manufacturing and R&D
Real Mex Foods · 1999–2010
Senior Vice President of Operations, Sales and Research & Development
Del Real Foods · 2010–2012
Vice President of Operations
Results achieved by Nacho Varela in executive roles.
Yes. Nacho has managed and started up both USDA- and FDA-regulated food manufacturing facilities.
Yes. The earlier the layout and equipment plan are involved, the fewer expensive changes you make later.
That's where most of the value is. We plan for being on the floor during commissioning, first production runs and team training.
Find the money hiding in your operation.
Labor scheduling, portion control, yields, KPIs and P&L discipline. The unglamorous work that turns a producing plant into a profitable one.
From recipe to production line.
Industrial formulation, batch sheets, COGS, nutritional analysis and packaging, so a recipe that works in the test kitchen works at production scale.
Support growth, not complexity.
Sourcing and contracting commodities, forecasting, warehousing, inventory control and production scheduling, set up to support growth instead of slowing it.
Share a few details about your operation and the outcome you need. We'll suggest the right starting point.
