Wow, this is a really exciting behind the scenes post! This is the first ever feature of a lettuce harvesting machine and processing operation that I have been able to show. That means that you get to see the entire process of how salad mixes are created! All of this footage was taken at Babé Farms, growing operations, as well as at their processing facility (Fresh Venture Foods) in Santa Maria, California.
Table of Contents
Growing Spring Mix and Sweet Lettuce Mixes
At Babé Farms, they have Spring Mixes and Sweet Mixes that are made up of multiple lettuce types. As you can see by how the fields are planted (below), there are different leafy greens planted per row and those are what get harvested to make up the mix. The different cultivars that make up each mixture are planted at the same time in order to be able to harvest all of the lettuce types that make up each mixture at the same time. The lettuce harvesting machine shown below is used to harvest multiple different lettuce varieties.
Harvesting Lettuce Using a Lettuce Harvesting Machine
The lettuce harvesting machine essentially acts as a large mower. The blocks are grown to fit within the bounds of the harvesting machine. A huge benefit to the grower when using these machines is the efficiency of use and the ability to use four workers instead of an entire harvest crew. In this set-up, there is one driver, two workers on the harvesting machine and one worker on the adjacent trailer.
- The driver maneuvers the harvesting machine throughout the rows.
- The two workers that work on top of the machine make sure the harvested lettuce makes it into the bins
- Once each bin has been filled, it is passed off to the worker in the adjacent trailer.
After a trailer has been filled, the harvested bins of leafy greens are transported to the nearby processing plant. Since these leafy greens are being packed as ready-to-eat lettuce mixes, they are washed three times at the processing facility and packed into containers. (You can see more of that process here.)
Harvesting Salad Mixes Using a Lettuce Harvesting Machine Video
To see an overview of the entire process and see what it is like to ride on the lettuce harvesting machine, check out the video below!
What Lettuce is in Spring Mix?
Although we are accustomed to the name “spring mix”, all companies use their own unique mixture to create their specific mix. For Babé Farms, they create multiple different types of lettuce mixtures. In the picture below, you can see how they dictate what types of lettuce are included into each mix.
Mixing, Washing & Packing Spring Mix
- Mixing the Spring Mix – This is a manual process, where the workers take the bins of harvested lettuce varieties and pour them out onto a conveyor line. Each bin is poured out throughout the line in order to be mixed in evenly with the other varieties of lettuce that are already laid out on the line.
- Conveyor – After all of the lettuce has been poured out and mixed manually, the lettuce mixture moves into the next room and proceeds on the conveyor line.
- Sorting – The lettuce passes through an optical sorting machine and then through a manual visual inspection. Any lettuce with issues, such as discoloration or the presence of foreign materials, is redirected from the line.
- Washing – The lettuce continues through a three part wash step step, where it is washed with sanitized water.
- Drying – The washed lettuce then goes into bins and workers take the bins and place the lettuce into spin-dryers, which act as a centrifuge, to dry the lettuce.
- Conveyor – After the lettuce has been dried, the lettuce is transferred in those same type of bins back to another conveyor belt, where they are transferred up to a multi head weighing machine.
- Weighing Machine – The multi head weighing machine is located on the second level of the processing facility and once it weighs out the product, it is dropped down to the automated packing machine on the first level.
- Automated Packing – Workers place the plastic containers onto the packing line of the automated packing machine and the weighed out lettuce mixture drops into the containers. A mechanical hand on the machine then pushes the lettuce down, a quality assurance worker completes a second step of pushing the product down and then the machine places the lids onto the containers.
- Final Packing – The packed spring mix containers pass through a metal detector, get labeled with a labeling machine and are packed into boxes. The packed boxes are then placed onto pallets to prepare for shipment.
Salad Processing Video
You can see a complete step-by-step view of how spring mix is created in the video below.
Food Safety Considerations
For this type of operation, some of the main food safety concerns are:
- Glove policy – Since gloves are required, there needs to be a glove policy enforced. This means that the gloves are controlled by the company, and that they are either disposable or able to be washed, and are changed out appropriately. If the gloves are washed, the company needs to control the cleaning of the gloves.
- Cleaning and Sanitation of the harvesting machine, wash line and packing machine – Every piece of harvested product touches the conveyor line between being harvested and sent to the bins, as well as the wash line, packing line, and all other equipment involved, so it all needs to be cleaned and sanitized to prevent any potential cross-contamination issues to the product.
- Sanitation of the harvesting bins – Cleaning and sanitizing of the bins needs to occur on a regular and frequent basis.
- Testing and changing of the wash water – The leafy greens are exposed to water during the packing process. There needs to be frequent water testing and an implemented policy in place to follow for changing out the wash water.
With less actual hands on the product, there is a greater focus on the cleaning and sanitation of the machinery. There are many more items to be taken into consideration, but this is just a brief list to get you thinking about it!
Postharvest Considerations
The most important thing when it comes to leafy greens is temperature management. Maintaining the product as close to 32°F/0°C, as well as maintaining the relative humidity (think of misters at the grocery store), is what will provide the greens with the longest shelf-life.
Featured Grower Information
I would like to thank Babé Farms and Fresh Venture Foods for the tour and for allowing the gathered content to be shared. Babé Farms is located in Santa Maria, California, and specializes in growing “baby” vegetables. They have been featured on the blog many times previously and you can check out their other harvesting operations by clicking on the following links: kale, blonde frisée, baby romaine, carrots, and radishes.
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Do you know what chemicals or gases are used to fill the packaged containers of the spring mixed lettuce for commercial restaurant use. I have noticed that something in them can not sit well with some people and it only happens when they eat at certain restaurants that use the prepackaged commercial packaged products.