Reser's 2025 Corporate Sustainability Report - Flipbook - Page 20
Don Pancho
Expansion
In September 2025, Don Pancho opened a new 300,000-square-foot manufacturing
facility in Salem, Oregon. Designed to support the next two decades of growth for Don
Pancho's authentic Mexican foods, the new facility triples the size of the previous site
and significantly increases production capacity and the ability to produce millions more
tortillas a year. This significant increase in capacity sets the stage for future growth.
The transition to the new location was driven by the need to centralize operations,
introduce additional equipment, and create space for future expansion. Consolidating
multiple processes under one roof improves workflow efficiency, supports collaboration
across teams, and reduces unnecessary movement of materials and equipment. Much
of the existing equipment was relocated to the new site, helping minimize waste while
modernizing operations.
The facility incorporates several major upgrades that reduce energy use and
environmental impact. Upgrades include energy-efficient LED lighting, automated
lighting and HVAC controls, and a modern refrigeration system that uses CO2, a natural
refrigerant with a much lower climate impact than the previous system that used
traditional refrigerant.
The expanded layout also enhances employee comfort, airflow, and safety. A new
Clean-in-Place system reduces manual equipment handling, lowering the risk of injury.
Increased automation - including automated palletizers, mixing equipment, and modern
baggers - reduces physically demanding tasks and improves efficiency.
Together, these upgrades strengthen Don Pancho’s ability to grow sustainably while
supporting a safer, more efficient workplace for employees.
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