In an industry driven by mass production and global distribution, Hertel Meats Ltd. stands apart as a proudly independent, family-owned processor committed to doing things differently.

Based in Port Alberni on Vancouver Island, Hertel Meats has spent over 60 years building a reputation for all-natural, preservative-free pork products that reflect a deep commitment to quality, transparency and community.

What began in 1963 as a small, locally focused operation run by founders Thomas and Helena Hertel has grown into one of British Columbia’s most trusted names in pork processing.

It is known especially for its traditional smoked sausages, nitrate-free bacon, and MSG-free seasonings.

In addition to establishing itself as a highly reputable wholesaler of fresh pork chops and other popular cuts for leading grocery retailers on Vancouver Island and British Columbia’s Lower Mainland region, the company’s flagship Hertel’s brand of sausages, bacon, ham and artisanal salamis also gained strong traction among the region’s health-conscious consumers for their all-natural processing and composition.

While developing a new line of fresh sausages processed without wheat gluten, lactose (milk) products or artificial preservatives, Tom Hertel also created a line of naturally smoked bacon cured without the use of sodium nitrite, nitrate or other chemical preservatives, as well as pioneering the production of products seasoned without the use of MSG (monosodium glutamate).

These products have found a very receptive and loyal audience among the region’s leading grocery retailers and health-savvy consumers, according to Hertel Meats general manager Jay Jayawarna.

Today, Hertel Meats continues to serve a loyal customer base that values authenticity, ethical sourcing, and the kind of hands-on service that only a family-run business can provide.

Jayawarna notes that the company has remained committed to meeting evolving consumer expectations.

“Hertel Meats is well-known for its traditional, high-quality and preservative-free products,” he says.

“We specialize in high-quality ham, bacon, smoked sausages, and fresh sausages made using our unique processing methods that prioritize natural ingredients,” Jayawarna adds.

“We’ve built a strong reputation on Vancouver Island and beyond for our naturally smoked, locally-sourced pork products.”

“Being a small, family-run business really is our strength,” Jayawarna states. “People connect with that.

“There is a high level of trust that comes from knowing who’s behind the product: it means we’re hands-on with everything we do, and that we genuinely care about what goes out the door.”

Jayawarna speaks with gratitude about the community that has supported Hertel over the decades.

“Vancouver Island shoppers are incredibly loyal,” he says. “We’ve built real relationships with families and local businesses, some of them have been with us for generations.”

The company actively supports its community-focused brand through regular in-store tastings, product sampling, and promotional events.

“In today’s market, consumers expect brand interaction,” Jayawarna points out. “Experiential marketing, like in-store tastings, is key to boosting sales.

“Transparency and traceability are also increasingly important,” he adds. “Customers want ethically-sourced, locally made products they can trust.”

Employing around 50 people working one shift, five days a week, the Port Alberni plant houses two production lines and two packaging lines.

Production is adjusted to meet the peak demand periods in the run-up to Easter, Christmas, and Thanksgiving holidays, as well as during the busy BBQ season in the summer months.

To meet increasing demand, Hertel Meats recently invested in two state-of-the-art thermoforming packaging machines, models R 105 and R 126, manufactured by the renowned German company MULTIVAC, and distributed in Canada by MULTIVAC Canada Inc., with locations in Brampton, Ont., and Richmond, B.C.

Featuring a compact design and modular construction for optimal flexibility, the MULTIVAC thermoforming packaging machines are designed to provide maximum productivity and highly efficient solutions for vacuum packaging, modified atmosphere packaging (MAP), or skin packaging.

Notably, the MULTIVAC thermoforming packaging machines are characterized by:

• High production output and pack quality;
• Robust and durable stainless-steel construction;
• Proprietary Hygienic Design for maximum hygiene and easy cleaning;
• Safe and ergonomic operation;
• IPC control with HMI 3.0 graphic user interface; and
• Efficient use of film and energy.

“We wanted to get the best packaging solution we could find,” Jayawarna says, “and our market research revealed that MULTIVAC had a reputation for having the best packaging solutions for processing multiple products, in different SKUs (stock-keeping units), and in many different formats.

“The name MULTIVAC describes their machines perfectly!

“These machines have helped us significantly increase our packaging efficiency,” Jayawarna says. “They’ve also allowed us to reduce our plastic usage dramatically.”

Initially using semi-rigid MAP (modified atmosphere packaging) tray-packs, the company worked with MULTIVAC Canada’s regional sales manager for B.C., Sam Nosek, to transition to 100 per cent flexible film vacuum-packs in late 2023.

“One of MULTIVAC’s biggest strengths is providing ongoing support for the life of the equipment we manufacture,” says Nosek. “We can retrofit or modify MULTIVAC machines to help customers adapt to changing needs.

“In Hertel’s case, we helped them shift from rigid film (MAP) packaging to flexible film vacuum packaging,” says Nosek, noting the switch facilitated a more efficient use of materials, a longer shelf-life, and new branding opportunities.

A major advancement in the Hertel Meats project was the integration of Bell-Mark’s EasyPrint MLP thermal-transfer printers onto both machines.

These printers allowed Hertel Meats to move away from manual labeling to printing key variable product information directly onto pre-printed top film, also supplied by MULTIVAC.

As Nosek explains, the new set-up allows for quick and easy printing of variable data like:

• product name;
• ingredients;
• weight;
• certification logos;
• nutritional data; and
• date/lot codes.

Patrick McCarthy, MULTIVAC’s Film & Materials sales manager for Western Canada, adds: “This solution not only enhanced Hertel’s branding, but also prepared them for evolving labeling needs like front-of-pack (FOP) requirements and QR (quick response) codes for consumer engagement.”

Says McCarthy: The combination of the MULTIVAC thermoformers, MLP printers and MULTIVAC-certified film provided an effective solution for Hertel Meats to reduce packaging costs, reduce operational complexity, and elevate the brand value for their extensive line of market-trusted, emerging and innovative food products.”

According to Jayawarna, the packaging upgrades reduced plastics use by 69 per cent, increased throughput by 50 per cent, and lowered labour costs by 40 per cent, largely thanks to eliminating manual labeling.

“We’ve reduced packaging costs while delivering a more attractive product for our retail customers,” Jayawarna says, also citing notable improvement in the products’ shelf-life.

“Having all our packaging equipment, materials and expertise provided by a single partner like MULTIVAC has been a real advantage,” Jayawarna states. “Their support during installation and training was exceptional.

“We haven’t had any downtime with the machines so far, but even if we did, their service team is outstanding,” he says. “They’ll be here the next day.”

As Jayawarna concludes, “To succeed as an innovative food producer, you need a strong partner for processing and packaging, and for us, MULTIVAC Canada is that perfect partner for the long run.”