The current Di Leo plant covers a surface area of 18,000 sq. m. out of a total area of 100,000 sq. m. Inside there are five different fully automated production lines with an annual production capacity of 18,000 tons.
The production cycle begins with storage of raw materials in insulated stainless steel silos. The powders are first transported to a sieving and metal detection station, then onward to the individual mixers where they are blended with liquid stored in interior silos.
The kneading system is traditional, with spiral mixers and computer-controlled recipe management. All of the production lines are equipped with a metal detector both in input for the raw materials and in output for the finished product.
It is cooked in cyclothermic continuous conveyor belt ovens that ensure constant and uniform cooking of the product.
The packaging system, which uses classic ICA machines, produces a packet with a square bottom and a perfectly shaped fold. The materials used are both coextrusion/paper and transparent dual coextrusion with four welded corners that give greater strength to the package. Each packager is equipped with scales for weight control and a metal detector with automatic ejection of any packets contaminated with metal parts.
The automatic packaging system also handles boxing and palletizing.