Walnut Processing

From 1963 until 2000, Carriere Family Farms was a grower of walnuts. In 2000, all that changed. Borges Spain was intent on having a processing presence in California. In addition, Borges wanted to control the flow and guarantee a supply of inshell walnuts early in the season. The Carriere Family viewed this as an opportunity to vertically integrate without the risk. After much discussion and urging from the Borges group in Spain, we found ourselves at an auction in Hollister, Calif., bidding on an inshell bleach line. That day, we were the high bidder and immediately became a handler of inshell walnuts.

After many design changes and construction delays, the inshell plant processed and shipped our entire 2000/01 Hartley crop. That year, we shipped a total of 11 loads. Each container took a full day to load. Since then, each year, we have substantially increased the amount of inshell walnuts we process, pack and ship. From 10 loads in 2000 to 150 loads today, the growth has been dramatic in a very short amount of time. In the beginning, Gus Lohse and his son Matt Lohse managed the plant and were instrumental in getting the inshell plant built and up-and-running. This was no small task as we bought the equipment in July, started construction on the building in August and started processing walnuts in mid-September.

During the next 5 years, we learned a lot about the processing, marketing and sales of walnuts. In 2006, we decided to take what we learned and add to it. That year, we decided to add a shelling line to round out our processing operation. Seeing the need to add depth and expertise to the management team, we hired Ron Bryant to oversee all plant operations. Ron came to us with 30 years experience in the nut industry. Ron had experience in building and running a walnut sheller and was a very valuable asset when it came to making decisions on equipment and staffing. Later that same year, Jeni Carriere joined the team to work for Ron running the laser and shelling line.

The sheller added a whole new dimension to our operation. The inshell market is all about speed. Getting product packed and shipped before November 1st is necessary to meet the inshell market needs in Europe. The shelling market is a much more spread-out process that keeps us shelling and packing most of the year... For a processing company that used to be done by mid-November, this took a little getting used to. In addition to the processing challenges, the sales and marketing of the walnuts proved just as challenging. In the inshell market, everything is booked in September and shipped over the next 3 months. In the shelling market, product is sold and shipped throughout the year. In 2006, Matt Doyle took over the full-time role of Sales. Matt is able to focus on strategic direction and provide overall guidance on marketing and sales of walnuts to both the domestic and international markets.

After getting a late start, the 2006/07 crop season was a huge success. With Ron at the helm, the plant performed very well under pressure and was able to process and ship the entire crop on schedule. Utilizing proven technologies, good manufacturing practices, HACCP controls from the point of receiving grower product to shipping finished goods, and the addition of a new 180 load concrete storage building, we will be able to provided our customers with a high quality product for years to come.

With these vital practices in place, the production volume of the sheller has grown from 60 loads in 2006 to 130 loads today. This is equivalent to processing of 14,000,000 lbs of inshell to shelled product.. As with any plant, there are always modifications and additions. Ron has added the items and technology needed to process a high quality product. For example, the shelling line utilizes aspiration to remove shell fragments and meal at the time the walnuts are cracked and sized. We have 2 BEST laser sorters that ensure anything that got past the aspirators is caught and removed prior to packing. Additional aspirators are used going into and coming out of the packing room to give us another chance to remove shell and meal. The material passes over a magnet and then through a metal detector before being palletized and prepared for shipment.

Having an inshell and shelling plant has made Borges of California and Carriere Family Farms a one-stop shop when it comes to handling customer's walnut needs. We can ship year-around and in many different sizes to meet the customer's needs.