In the trendy segment of sensitive beverages, owner Yahya Abbas of Ya Ya Foods in Toronto relies entirely on the aseptic expertise of KHS machines.
21 August 2020
When it comes to sensitive beverages, owner Yahya Abbas of Ya Ya Foods relies entirely on the aseptic expertise of KHS. (Image: KHS Group)
Ya YA Foods in Toronto processes a huge range of products and packaging as a contract bottler for the world's major beverage brands. In the trendy segment of sensitive beverages, owner Yahya Abbas relies entirely on the aseptic expertise of KHS.
Yahya Abbas once graduated as a civil engineer in the UK. It is therefore hardly surprising that the 59-year-old President and CEO of Ya YA Foods in Toronto still sees himself more as a technician than an office worker.
Yahya Abbas, President and CEO of Ya YA Foods (Image: KHS Group)
„I am a Enabler. I invest and create capacity, the customers then come of their own accord.“ Yahya Abbas, President and CEO of Ya YA Foods in Toronto
And in fact, almost all major beverage brands are bottled here today: „Our customers include the Top ten beverage brands in the world“, Abbas states proudly. „Some of them have been our customers for 30 years.“
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History of a family business
Abbas was 25 years old when he emigrated to Canada with his parents. Two years later, the family turned to beverages for the first time: „In 1987, my father met someone from the industry,“ he recalls. „He wanted to sell his small bottling company. We quickly came to an agreement, bought the business and then turned it into the Number one contract bottler for all of North America made.“
In just a few years, Yahya Abbas has turned a small business into the number one contract bottler for the whole of North America. (Image: KHS Group)
Unlike many of its competitors, Ya YA Foods does not offer its own brands. This is also part of the philosophy in that, as Abbas explains, his business is „feels like a partner, not a competitor.“ The family business sells 90 per cent of its production in Canada and the United States, where the market is around ten times as large as the domestic market.
The Canadians generate almost two thirds of their total sales from their big neighbour. „We benefit from our geographical location in the immediate vicinity of the US border,“ emphasises Abbas. „From this location we reach around 93 million people within one day."
In addition to traditional dairy products, Ya YA Foods also fills plant-based milk drinks, for example based on peas, soya or cashew. (Image: KHS Group)
Right on trend
Initially, highly acidic products such as juices, smoothies and tea were bottled. Currently, maple water is even being bottled in Toronto as a typical Canadian product. The Quality requirements for aseptic processing of sensitive products.
„Our maxim is not only to fulfil the regulatory requirements of the FDA or GMP, for example, but to exceed them.“ Yahya Abbas, President and CEO of Ya YA Foods in Toronto
In return, he relies on his 250 highly qualified employees. In addition to investing in the training and development of its staff, the company also utilises modern measuring systems and production technology. Thanks to its highly automated systems, Ya YA Foods only employs around 65 machine operators in production, who are responsible for a daily output of around 1.5 million units.
The products that Ya YA Foods bottles for the world's largest beverage brands include energy drinks as well as dairy products and juices. (Image: KHS Group)
Hygiene and flexibility
The bottler acquired its very first German machine back in 1992 - at that time still from KHS' predecessor company Holstein & Kappert. In 2010 Abbas once again invested in high-tech from the Dortmund systems supplier - he purchased his first aseptic filler from the American KHS subsidiary, a Innosept Asbofill ABF 71 TWIN with a capacity of up to 24,000 1-litre bottles per hour.
Overall, it was not only the reliable fulfilment of the highest hygiene requirements that impressed, but above all the flexibility of the machines. „The Format changes in the filler area work quickly and smoothly“ says Abbas with satisfaction. „KHS offered us the best option back in 2010, and nothing has changed since then.“
Fast and smooth format changeovers provide the flexibility required for Ya YA Foods' wide range of products. (Image: KHS Group)
On course for growth
Since June 2018, the company has had a further KHS aseptic line for up to 12,000 1-litre bottles per hour, which is also used to produce smaller batches and supports the acquisition of new customers. According to the company, around 13.3 million euros have already been invested in KHS technology.
In September of this year, another aseptic line from KHS was installed and put into operation, with „a lot of new technology and even more efficient than the previous ones“, as Abbas is pleased to report. He still has big plans with KHS. The next joint project is expected in 2020.
