At Biosabor our premises are carefully designed and built using the latest innovations in technology aimed at achieving maximum production whilst, more importantly, looking after the well-being of our staff.
The new packaging centre was opened on the 18th December 2015 and is built on a plot measuring 45,000m2. The actual operating area measures 10,200m2 and is divided into two parts; the main operating area and a handling area which measures 5,200m2, with dimensions of 80 x 65. There are offices on both floors measuring 4,50m2, a total of 900m2. The cardboard supply area measure about 2,500m2.
The total cost of building these fruit and vegetable farming facilities required an investment of 6 million euros, including the cost of the actual building and the production line machinery which use the latest technology and adhere to strict safety standards.
These facilities have been carefully and evaluated by the technical team and by the president who have brought together their wide experience as well as the staff and other companies who were involved in the construction of the facilities.
During the construction the following guidelines were established which clearly set out a series of objectives:
The wellfare of our staff:
This is the main objective of our company which is why our facilities are focussed on providing the optimum working conditions for our staff in terms of light, heat and health standards. Our facilities make the most out of natural light, creating a friendly working environment where staff feel comfortable which inevitably have a positive effect on their mood which in turn increases their output. As we are a company which produces ecological products, mainly tomatoes, many of our production processes are manual, so we really depend on our workforce of 300 staff.
In tune with our ecological philosophy, we´ve made every effort to ensure that our premises are in accordance with our respect for natural resources by designing the most sustainable and energy efficient building possible.
We made an in-depth study of structural solutions for the outside covering of the building before finally opting for a ventilated façade, a covering with insulated panels and a false roof, thus creating an air chamber which keeps the heat in better and skylights made of multicellular polycarbonate.
A healthy and hygienic interior:
Of prime concern to us in the food handling business is the interior finish of the building. We looked for a clean, free-standing elements which could be taken down to avoid the accumulation of dirt and dust. Completely smooth walls and a sealing treatment for the tiny holes in the floors to avoid dirt becoming encrusted.
Biosabor has 200 hectares of its own production facilities. About 30% of them are new constructions made in the Multitunnel structure which use the highest technology as far as structure, irrigation, and climate are concerned.
The rest are traditional RASPA –AMAGADO greenhouses found in Almeria but with improved structures, climate control and exhaustive irrigation controls.
During the last few years we have developed new operating facilities to cover production during summertime these are crops grown outside or with minimal protection from anti-insect netting.
In the multi-tunnel greenhouses we employ the highest technology to maintain strict control over the climatic conditions using fully automated ceiling and side ventilation systems (about 35% of the surface area uses ceiling ventilation).
The hermetic nature of the structures enables humidity and temperature control inside the greenhouse, which are important to keep the plants in optimum growing conditions. In these production plants we grow the most sensitive and demanding varieties as they have a higher value-added factor due to their unique flavour and the difficulty involved in growing them.
Practically half of the surface area of the greenhouses have heating during the winter months, enabling us to maintain levels of output and high quality even in the coldest and dampest months of the year.
Our RASPA – AMAGADO greenhouses are high specification structures which have opening and closing systems to maintain the hermetic nature of the greenhouse in order to achieve strict control over the inside temperature. Between 6 and 12% of the area is ceiling ventilated – an important advance, as traditionally these structures have only had ventilation in 3 -5%. Of their surface area.
All our greenhouses have automated irrigation systems which constantly monitor the quality of the soil. We work towards responsible consumption of water by administering the correct amount of water a plant needs. We´ve completely reduced the amount of leachate and we´ve managed to cultivate with 30-40% less water than we used in previous years.
Right from the start, we carefully considered the location of our production facilities in order to take advantage of each of the micro-climates in south-eastern Spain in order to benefit from the special conditions each one has for growing different crops at different times of the year. When choosing locations we always keep in mind isolated areas, providing this is possible.
The company has production plants in various areas in the municipality of Nijar; la Cañada, Retamar, Cabo de Gata Natural Park and on the coast of Murcia.
Every year, in all of our production facilities, we install double-cavity coverings These not only protect our plants from condensation from the surrounding covering but also maintain the hermetic nature of the environment and reduce atmospheric dampness – all important advantages to reduce the proliferation of fungicidal disease. After 5 years of trial and error, our theory has been proven right. This has lead us to find the right kind of film for these temporary coverings which we started to use only in winter but even today we use them for half of the growing season due to their distinct advantages.
In summertime we grow crops in the open air with anti-insect netting. Our production is located in isolated areas in Sierra Alhamilla and Sierra Nevada, between 600 and 1000 metres above sea level. Like this we can grow crops taking advantage of the big difference in temperature between the day and night which doesn´t occur at lower altitudes. Whether they are grown completely in the open air or with an anti-insect netting we grow the same crops as we do in the greenhouses without having to suffer the limiting consequence of high temperatures.
We are on the right track in the area of ecological production due to the tools we use and the measures we take to protect our crops. But the success and efficiency of our production is also due to the knowledgeable handling which we carry out plant by plant. It is a specialised and delicate job which requires handlers to be in a pleasant working environment. As well as the tidiness and cleanliness of the work areas as the design and management of the tasks make the working day more enjoyable.
All our production facilities have accommodation for the field staff. The families who live in this type of accommodation have more time to spend at home doing household tasks and looking after their families as they don´t have to commute to work. At the same time they feel as though they are part of the production unit. For the staff who live off-site, there are designated rest areas, canteens, toilets and showers. All of these comforts make staff feel involved and committed to the company, and with each passing day efficiency and output improve.