Each week, Gills Onions undertakes the monumental task of processing millions of pounds of onions, delivering them to restaurants, grocery stores, and beyond across the United States and Canada. As with any fresh product, time is of the essence, but have you ever wondered how we streamline the packaging process for our freshly processed product?
At Gills Onions, we understand that our customers value not just the quality of our pre-diced, sliced, and peeled products, but also the convenience factor. To jump deeper into the behind-the-scenes workings of our packaging process, we sat down with Juan Francisco Pastrana, one of our all-star employees who serves as a diced equipment technician lead here at Gills Onions. He shared with us his own personal journey of how he got where he is today and elaborated on the role he plays in getting our product into the hands of our customers.
All Hands on Deck
At Gills Onions, we take pride in offering our customers the highest quality products that meet their diverse needs. Our bagged products typically come in a standard 5-pound bag, providing convenience and value for our customers. However, we also understand the importance of flexibility, which is why we offer special orders in a 3-pound option, catering to unique preferences and requirements.
As the product journeys through our facility, it eventually reaches our diced equipment. Within this system, the product enters the flume, where it undergoes a thorough washing process, followed by the removal of excess water through a spin cycle. Next up, the product is weighed before it’s carefully placed into the bag and sealed using a zipper.
At the helm of our packaging operations is Juan, our dedicated equipment technician lead. Leading a team of over 20 individuals, Juan oversees operations with meticulous attention to detail. From ensuring the correct amount of product is bagged based on orders to upholding stringent quality standards, Juan ensures every bag leaving our facility is sealed to perfection.
Two years ago, we revolutionized our packaging process with the introduction of a state-of-the-art machine, and since day one, Juan has been at the forefront of its operation. For him, a major key to our success lies in the machine being dismantled effortlessly for daily sanitation. At the end of each shift, he carefully disassembles the pacman, ensuring our sanitation team is able to thoroughly clean it in preparation for the next shift.
A Whole New World
With the weight of his family’s financial security on his shoulders, Juan left his home state of Guerrero – located along Mexico’s Pacific Coast – at the age of 17. Making the trip alone to the United States, he wasted no time in finding a job and quickly found work planting in local strawberry fields.
But it wasn’t long before Juan found his place at Gills Onions, joining our team around the age of 21. Starting as a packer and forklift driver, he has steadily worked his way up to his current role. However, Juan’s roots trace back to working on his own family’s farm producing sesame seeds and watermelon.
It was his involvement in his family’s fishing enterprise that truly captured Juan’s heart, though. “Even at the age of five, I was learning the ropes of swimming and being safe around the water,” Juan recounted. “We owned all our fishing gear, ventured out onto the waters, and hauled in whatever fish was in season, selling our catch at the local fish market. Although my clearest memories are from ages 14 to 16, I know I started even earlier than that.”
The work ethic ingrained in him from his experiences working in the sesame and watermelon fields back home, to his days spent fishing out on the open sea, is what truly defines him as a leader here at Gills. Coupled with the profound sense of responsibility he undertook when he left home to provide financial security for his family, his leadership shines daily.
Embracing the Latest Technology
As someone drawn to mechanics, Juan’s journey has been one of continuous evolution and discovery. Reflecting on his own experiences, Juan emphasizes the spirit of relentless improvement embodied by Gills Onions. He’s witnessed firsthand how the pursuit of excellence never settles, even when perfection seems within reach. With each technological advancement, he often finds himself energized by the prospect of refining processes and embracing innovative solutions alongside his coworkers.
“I’ve seen a lot of changes, but what I like is when we’re doing something good, they [Gills Onions] doesn’t just stop there – we find a way to still do it better,” said Juan. “There’s room for improvement even if it looks perfect. There’s always new technology coming in to do it better.”
At Gills Onions, excellence isn’t just a goal – it’s our standard. Juan and his team epitomize this commitment, ensuring that every package leaving our facility exceeds our customers’ expectations. As we continue to innovate and refine our processes, we remain steadfast in our commitment to uphold the highest standards of excellence, ensuring that every package leaving our facility represents the highest level of quality and satisfaction. This dedication to quality and customer satisfaction is ingrained in every aspect of our operations, reflecting our approach to growing onions “The Gills Way.”