Walsh Mushrooms - Production & Packhouses


	Mushrooms are predominately sourced from our grower base in Ireland, and is supplemented by grower partnerships in the UK and Holland. In Ireland we operate a satellite system with a base of 40/50 growers with whom we work very closely. Growing was predominately in bags but as growers have invested in new growing techniques, shelves of bulk and blocks are now the main methods of production made possible by the availability of Phase III compost from our state of the art production facilities at Custom Compost Ltd. in Gorey.
	We have a strong partnership built up over the years with a major Dutch producer from whom we take deliveries into Evesham on a daily basis.	View larger version of image
	All our supply base is carefully managed by our own Technical Advisors who are constantly monitoring growers. This is further enhanced by An Bord Glas (an independent monitoring body), who audit every farm in Ireland three times per annum and awards are presented to the top growers to continually encourage improvements.
	Every grower complies with the codes of practice laid down by Walsh Mushrooms, the UK Retailers and An Bord Glas.
	Because these farms are privately owned the attention to quality is very strong. All the harvesting is done under the watchful eye of the owner manager, which guarantees the quality and enhances the shelf life of the mushrooms.
	Mushrooms are harvested on a daily basis aiming for our '30 minute rule' and no longer before they enter the chill chain. Our own fleet of chilled vehicles collects from the farms, arriving back at our packhouses for early afternoon.	View larger version of image
	Through growers investing in their farms and new growing techniques being introduced, we envisage continued expansion of our grower base. Availability will be further enhanced through the demand for Phase III compost, leading to greater throughput. The average growing units throughput will increase by 60% with these new technologies allowing growers to improve their profitability in a market place that is experiencing severe price pressure.
	PACKHOUSES The packhouses liaise with every grower on a daily basis controlling production and ensuring every order is packed fresh and complete every day. Our packhouses are all up to date facilities employing the most advanced automated packing lines. Advanced grading systems and rapid cooling equipment are also utilised. The mushrooms arrive at the packhouse from noon onwards for grading, packing and shipping that day.	View larger version of image
	All produce is carefully checked for quality and weight, checks are recorded. The packing operation takes place throughout the afternoon. All mushrooms are vacuum cooled prior to final despatch to obtain optimum temperature and enhance shelf life. Produce is loaded onto dedicated vehicles and shipped over night to arrive in the UK in the early hours of the next morning.
	Gorey Packhouse Gorey was the company's first packhouse when we acquired the Creagh site in 1985. This has been extended and extensively upgraded over the intervening years. Some of the earliest growers who started 20 years ago are still supplying mushrooms into the Gorey packhouse today. It packs a high proportion of prepack which is supplied from 10/12 growers in the South East area of Ireland and is ISO 9002 accredited.	View larger version of image
	Athlone Packhouse We first took over a small packhouse in 1992 servicing growers in the area. In 1999 from a green field site we built a 14,000sqf state of the art packing facility. Throughput is currently 250,000lbs of mushrooms per week expected to reach 300,000lbs in the near future.	View larger version of image
	Armagh Packhouse Armagh was acquired in 2000 serving growers in the Border Counties, it is now well established in this historically strong mushroom growing area. Throughput is currently at 80,000lbs per week.
	Evesham Packhouse Construction was completed in August 2000. Investment in high speed packing lines makes this the most up to date packing facility handling product from our UK supply base. A new concept which has developed, is to collect mushrooms from large commercial growers and proceed directly to the Vale Park Depot bypassing out Irish Packhouse facilities. Similar services to those supplied by the Irish Packhouses are provided in Evesham, but it allows the larger growers to bypass the Irish Packhouses which helps to take costs out of the system	View larger version of image