The wraps of Roeselare are booming. No less than 6 million wraps roll off the conveyor belt every day at Paulig, the largest Tex-Mex factory in Europe. And it's running smoothly as their turnover grows by around 5 percent annually, currently accounting for 500 million euros. Olé!
On the rise
The name 'Paulig' might not immediately sound familiar as, even though it is the largest in its niche, Paulig mainly produces wraps and chips for other (private) label brands. The demand is high: every day, the company produces 6 million wraps and thousands of bags of tortilla chips. In short, the factory's success may be below the radar, but it is undeniable.
On the conveyor
Paulig’s team operates like a well-oiled machine with 850 employees smoothly running the production. The chips are made of corn flour, sourced from the surrounding countries. Next, they undergo an automated transformation: passing on the conveyor belt, along the fryer and by quality control. The journey ends in a cardboard box in the warehouse.
The wraps follow a unique route as well. Small balls of dough roll from the large divider to a proofing chamber. Next, they are flattened into wraps and sent through an oven all the way to the packaging department, ready for their final destination. Both innovative production processes are partly powered by green energy, generated on-site. In 2022, Paulig invested in a wind turbine and installed more than 5,500 solar panels.
In your hands
Did you know that tortilla chips contain 30 percent less fat than potato chips? This explains their success. Consumers also consider wraps a healthy alternative, which is why their popularity continues to grow. Moreover, Paulig is experimenting with new flavors and compositions: "Thanks to research, we've been able to remove E-numbers from the ingredients list. Nowadays, we also make wraps made of beetroot and carrots," says Bjorn Boon, Communication Manager at Paulig.