FORGE
Field to Frozen in Under Four Hours
IQF Processing · Private Label · Co-Pack · Cold Chain
Scroll to trace the journey
The Journey
Six Stages.
Zero Shortcuts.
Every product that leaves our dock has passed through the same uncompromising sequence — from contracted soil to sealed carton. Trace it below.
Contracted at the Root
Every harvest begins with a multi-year grower contract. Our agronomists walk fields 90 days before harvest, locking Brix levels, moisture content, and pick windows to within 6-hour tolerances. No spot-market purchasing — ever.
Stage 01 — Sourcing
Triple-Stage Sanitation
Incoming loads hit a three-stage flume wash — pre-rinse, ozone-treated soak, final potable rinse — within 20 minutes of dock arrival. Pathogen testing at every stage. No product advances until ATP swab scores clear 10 RLU.
Stage 02 — Washing
Precision at 180,000 lbs/day
Six processing lines run in parallel — slicing, dicing, blanching, portioning. Each line is dedicated to a single product category to eliminate cross-contamination risk. Vision-inspection cameras reject off-spec pieces at 400 frames per second.
Stage 03 — Processing
Minus Forty. Every Time.
Product enters the blast tunnel within 90 minutes of processing. Cryogenic IQF tunnels drop core temperature to −40°F in under 8 minutes — locking cellular structure, color, and flavor before ice crystals can form. This is the four-hour promise.
Stage 04 — Flash Freezing
Your Label. Our Precision.
Robotic pick-and-place fills retail bags, club packs, and food-service cases to ±0.5% weight tolerance. Private-label artwork is pre-loaded for each SKU. A single changeover takes under 12 minutes — critical for multi-SKU runs.
Stage 05 — Packaging
Three Time Zones. One Temperature.
Two million square feet of −10°F blast-hold storage. Dedicated dock lanes for LTL, FTL, and intermodal. EDI integration with all major 3PL networks. Your product leaves our dock with a continuous cold-chain record — timestamped to the pallet.
Stage 06 — Distribution
Operational Scale
The Numbers
Don't Lie.
Third-party audited. Publicly verifiable. These are the operational realities behind every co-pack proposal we send.
Maximum time from harvest to IQF blast tunnel — the core of our quality lock
6 dedicated processing lines
SQF Edition 9 — last independent audit
All 12 IQF tunnels
Blast-hold −10°F, 24/7
Across 14 growing states
Multi-SKU private-label runs
Certifications & Compliance
Seen enough to
start the conversation?
Our co-pack team responds within one business day. Share your volume estimate and product category — we'll come back with a preliminary capacity window and pricing range.
No commitment required. Proposal delivered in 3–5 business days.
Partner Voices
The Operators
Who Depend on Us.
"We moved our private-label frozen vegetable line to Forge 18 months ago. Our shrink rate dropped from 3.2% to 0.4%, and we've had zero FSMA holds. That's the kind of operational discipline that protects a category manager's career."
"We spec protein portions for 1,400 QSR locations. Forge hits our ±0.3 oz weight tolerance on every pallet — not most pallets, every pallet. One supplier doing that. It's them."
"Cold-chain gaps are a distributor's nightmare. Forge's continuous temperature logging with pallet-level timestamps means I can close any audit question in under two minutes. That's a competitive moat for my customers."
Start the Conversation
Ready to Lock In
Your Volume?
Share your requirements below. Our co-pack team will respond within one business day with a preliminary capacity window and pricing range — no commitment required.
Request a Co-Pack Proposal
For national accounts, QSR operators, and food-service distributors.
Download Our Capabilities Deck
Not ready to talk volume yet? Get the full operational overview — certifications, capacity specs, product categories, and case studies.
- Full facility specs & floor plan
- GFSI / SQF audit documentation summary
- Private-label case studies (3 categories)
- Capacity windows & lead times by season
- Cold-chain traceability overview
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