An Interview with Ashley Trunk, Quality Compliance and Continuous Improvement Specialist
In the competitive world of beverage manufacturing, innovation and efficiency aren’t just buzzwords—they’re essential ingredients for success. Our midwest facility in New Lenox, Illinois, represents a bold step forward in high-acid aseptic beverage manufacturing. I recently sat down with Ashley Trunk, our Quality Compliance and Continuous Improvement Specialist, to discuss what makes it a truly world-class facility.
Breaking Free from Constraints
“For years, we’ve manufactured products in existing facilities,” Ashley said. “While we’ve always produced great products, we’ve had to work within the confines of existing spaces.” This often meant making compromises and working around inherited inefficiencies. With our facility in New Lenox, everything changes.
“In existing facilities, we are confined to where we set up the equipment and machinery, we have limited options when trying to make additions or improvements, and we are forced to work within a blueprint that was not created for juice manufacturing,” Ashley said. “Since we opened the new plant, none of those issues exist. Each area is specifically designed for the tasks done there.”
Not only that, the new facility gives us space to grow. “It is designed specifically for efficiency, growth, and success from the ground up,” Ashley said.
First Impressions Matter
When asked about what stands out to visitors, Ashley’s enthusiasm is evident.
“Everything within the facility is gorgeous,” she said. “From the spacious break rooms with their elegant finishes and large communal tables to the immaculate bathrooms, every space has been designed with attention to detail.” But beyond the aesthetic appeal, it’s the state-of-the-art equipment that truly impresses visitors and employees alike.
Cutting-Edge Technology Driving Efficiency
The facility boasts several technological innovations that set it apart. A notable example is the double packing machine, capable of running two lines simultaneously—a significant upgrade from previous capabilities. The facility also features an advanced automated palletizer system, which Ashley explains brings benefits beyond just speed.
“While the palletizing process itself isn’t necessarily faster, the real advantages come in other areas,” she said. “It significantly reduces labor requirements and, more importantly, eliminates repetitive motions that can lead to workplace injuries. Every pallet pattern is pre-programmed, ensuring consistency and streamlining plant transportation.”
Another game-changing feature is the massive blend tanks, which enable larger batch sizes than ever before. “Capacity was previously a limiting factor,” Ashley said. “Now we can more efficiently pack products for our highest-demand customers in the high-acid beverage market.”
Environmental Responsibility
Sustainability was a key consideration in the facility’s design. The wastewater treatment system was built to handle eight production lines, though it is currently operating with just three. “This means we’ll never face capacity issues, and all waste will be properly treated with minimal environmental impact,” Ashley said.
The facility is also moving toward paperless operations, maintaining regulatory documents, pick lists, and testing documents in digital format.
Smart Manufacturing with Red Zone
One of the most innovative aspects is the implementation of Red Zone, a sophisticated SaaS production management system. “Red Zone enables seamless inter-department communication across our vast facility,” Ashley said. “It’s a tool that provides real-time production data and allows us to monitor line operations remotely.”
Ashley said it’s much more than that. “It really goes beyond monitoring though,” she said. “It’s a platform that gives operators a voice and helps our teams stay motivated and coordinated. It saves time by preventing unnecessary motion. And we have the space, structure, and tools we need to expand exponentially.”
Building a Culture of Excellence
Perhaps most impressive is the culture developing within our midwest facility. “Everyone here takes immense pride in both the facility and the products we produce,” Ashley said. “There’s a shared commitment to excellence that shows in everything we do.” This pride has not gone unnoticed—customer trials and visits have consistently received exceptional feedback, with visitors calling their experiences “among the best they’ve ever had.”
As a subject matter expert for Red Zone, Ashley spends considerable time on-site ensuring smooth operations. “It’s not something you can master in an hour-long class,” she said. “It’s a continuous improvement tool that requires ongoing support and training.” Her presence on-site multiple times per week helps ensure that operators are using the system effectively and getting the most out of its capabilities.
The midwest facility represents more than just a new manufacturing location—it’s a testament to our commitment to innovation, efficiency, and excellence in beverage manufacturing. With its state-of-the-art equipment, sustainable practices, and growing culture of pride and teamwork, we are truly setting new standards in the industry.
At Leahy-IFP, we are committed to making a more fruitful life for everyone. This is far more than a slogan or catchphrase, it’s a serious pledge to take the steps that are necessary to ensure our products are the best they can be and live up to the high standards we set, and our customers expect.
If you’re interested in learning more about the latest beverage trends, just let us know, we’d be happy to discuss with you and your team. We hope to hear from you soon.