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This delicious snack, consumed any time of the day and with any activity by Filipinos is now taken across the world – thanks to Bahaghari Global Foods Inc.
Who knew that the export market was craving and needing something just like Oriental Mindoro’s banana chips? This healthy alternative to traditional snacks made by Bahaghari Global Foods Inc, a family-owned enterprise in the small town of Pinamalayan, Oriental Mindoro has now reached Canada, Japan, Korea, New Zealand, Australia, Hongkong, Chile, and Maldives
Bahaghari Global Food, Inc. owner Ms, Elisa Paylago saw an opportunity in the production of banana chips in 2015 since “saba” banana is abundant in the province, of which, 50% are supplied by local farmers in Pinamalayan. Banana chips is considered as one of best pasalubong products from Oriental Mindoro and the current demand for it is significantly increasing. With the knowledge gained from being employed in one of the biggest restaurant chains in the Philippines for 17 years, Mrs. Paylago ventured into the banana chips business— and went big and targeted export markets.
Learning to Export
Starting with a GMP-compliant processing facility and a furnace operated and maintained by five (5) workers, Bahaghari Global Foods Inc. saw an average production capacity of 5,000 pieces of fresh banana per day. It later upgraded its production facility, acquiring more equipment including banana slicers, impulse sealers, furnaces, and generators and subsequently increased production capacity to 15,500 pieces of saba banana per day.
To keep pace with the industry standards, Bahaghari Global Foods Inc. sought certifications including Current Good Manufacturing Practice (cGMP), Hazard Analysis Critical Control Point (HACCP), organic, and Halal. DOST-MIMAROPA eagerly assisted the firm with series of trainings and seminars on CGMP, HACCP, and energy audit. In turn, all certifications were granted along with the US-FDA license. Now, about 75% of the total volume of banana chips are sold in various countries in North and South America, Australia, and South and East Asia and numerous markets in the Philippines including Pasalubong Centers and SM Stores.
The Cloudy Days
With the increasing demand for their banana chips, Bahaghari Global Foods Inc. encountered issues in its production process, particularly in the peeling of saba banana and packaging of the banana chips, which were done manually by workers. With its limited workforce and each worker tasked to perform a specific role during operation, an absence of a worker could derail the production, compromise product quality, and delay shipment of products.
Ms. Paylago only thought of one solution to address the firm’s problem— it is to acquire a vertical form-fill-seal machine that will automate the process of packing the banana chips. She thought that not only the technology will be able to help hasten the process of packing but will also contribute to ensuring food safety and improved product quality and appeal. However, the technology requires high capital investment which at the time the firm could not afford. This prompted Ms. Paylago to search for other possible options.
The rainbow in the cloudy sky
Like a rainbow appearing in the cloudy sky, DOST gave hope to Ms. Paylago. Through the DOST’s Small Enterprise Technology Upgrading Program (SETUP), she was able to acquire the vertical form-fill-seal machine. True enough, the firm was able to continue packaging process and keep operations on schedule despite crucial workers being absent. Packaging time was cut from three days to a day and from 10 people doing the packing of the chips per production, only five (5) people are required to man the automatic packaging helping the firm reduce its labor expenses.
Since manual packing of the chips was eliminated, breakage of the chips and food contamination was avoided reducing product rejects from 15% to 10%. The technology also enabled the firm to achieve uniform product weight per pack. With no delays in the delivery of products, productivity and sales increased to as much as 30%.
“In a fiercely competitive marketplace, where the Goliath lorded it over, BAHAGHARI GLOBAL FOOD, INC. was a David, but not for long. Amazingly, BGFI found its way, made its own space and created a brand that became highly-esteemed and widely-accepted.” – Ms. Eliza Paylago.
Now, the firm continues to seek for additional local and export markets. They also purchase bananas from local farmers, who were happy to have a steady buyer for their products.
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